Service Manual 5008736_55 MFE Gearcase [Gearcase Removal And Installation]

Drain lubricant before testing.

Use Gearcase Pressure Tester, P/N 507977. Install lubricant drain/fill plug and seal, thread pressure test gauge fitting and seal in lubricant level hole.

Pressurize 3 to 6 psi (21 to 42 kPa).

If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leak. If the gauge does not indicate leakage, increase pressure to 16 to 18 psi (110 to 124 kPa). Check for leaks.

Make necessary repairs and repeat test.

Install Gearcase Vacuum T ester, P/N 507982. Apply 3 to 5 in. of vacuum (76 to 127 mm) Hg. with pump.

If vacuum gauge indicates leakage, apply oil around suspected seal. If leak stop s or oil is drawn in, seal is defective.

Repeat test, gearcase must h old minimum of 15 in. vacuum (381 mm) Hg.

27022

To prevent accidental starting while servicing, twist and remove all spark plug leads.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

Remove pin and washer from shift rod lever to release the lower shift rod.

002171

1. Shift rod screw

MRL MODELS

Note where the index mark on the gearcase aligns with the index number of the adjustable trim tab so the trim tab can be installed in the same position. Remove the trim tab retaining screw and trim tab from the gearcase.

001996

1. Trim tab
2. Trim tab retaining screw

Remove the forward screw with washer and recessed retaining screw.

001995

1. Forward screw
2. Recessed screw

MJRL MODELS

Remove the impeller housing and impeller assembly. Refer to IMPELLER SERVICE, MJRL MODELS on p. 236.

Remove the recessed retaining screw from the gearcase.

006653

1. Screw

Remove nut and washer.

006652

1. Nut

ALL MODELS

Remove the four gearcase retaining screws.

001994

1. Gearcase retaining screws

Remove the gearcase assembly from the exhaust housing, being careful not to bend the shift rod.

During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

Before installing gearcase, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 244.

Coat the driveshaft splines with Moly Lube. DO NOT co at top surface of the driveshaft be cause lubricant may prevent seating of the driveshaft in the crankshaft.

30385

Apply Adhesive 847 to the exhaust housing seal’s outer surface. Place the seal in the gearcase exhaust cavity. Apply Triple-Guard grease to the seal’s inner surfaces.

008354

1. Exhaust housing seal

Slide the gearcase into place, making sure:

• Driveshaft engages the crankshaft—rotate flywheel if necessary
• Inner exhaust housing installs correctly
• Shift rod does not turn and is positioned properly in shift shaft connection area.

Apply Triple-Guard grease to threads of the gearcase retaining screws. Tighten the screws to a torque of:

• 3/8 in. screws – 18 to 20 ft. lbs. (24 to 27 N·m)
• 7/16 in. screw – 28 to 30 ft. lbs. (38 to 40 N·m)
• 5/16 in. screw – 10 to 12 ft. lbs. (13.5 to 16 N·m)

001994

1. 3/8 in. screws

001995

1. 7/16 in. screw
2. 5/16 in screw

MRL MODELS

Apply Triple-Guard grease to threads o f the trim tab screw. In stall and align the trim t ab with the index marks noted prior to disassembly. Tighten the trim t ab screw to a torque of 35 to 40 f t. lbs. (47 to 54 N·m). For adjustment, refer to Trim Tab Adjustment (MRL) on p. 44.

001996

1. Trim tab screw

MJRL MODELS

Install nut and washer. Tighten to a torque of 28 to 30 ft. lbs. (38 to 40 N·m).

006652

1. Nut

Install recessed retaining screw. Tighten to a torque of 10 to 12 ft. lbs. (13.5 to 16 N·m).

006653

1. Exhaust pipe
2. Retaining screw

Install the impeller assembly an d impeller housing. Refer to IMPELLER SERVICE, MJRL MODELS on p. 236.

ALL MODELS

Place the shift rod in the shift rod lever. Install the retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

002171

1. Shift rod screw

To prevent loss of operator control, check for proper shifting operation and adjust, if necessary.

IMPORTANT: During break-in pe riod of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.