Service Manual 5008738_115-200 HP 60° V Gearcase [Gearcase Assembly]

Check squareness of the pinion to the driveshaft. Hold the shim gauge bar against the bearing housing (between the screw holes) while rotating just the driveshaft and pinion assembly. Measure clearance between the gauge bar and the pinion at several locations. If variance is greater than 0.002 in. (0.050 mm) replace the pinion or driveshaft, as necessary, and repeat check.

Subtract the average clearance measurement from 0.020 in. (0.508 mm) to determine the correct shim thickness required. Select the fewest number of shims to achieve the correct thickness.

Remove the driveshaft from the tool and add the required shims between the bearing housing and the thrust washer.

IMPORTANT: Use extreme care when removing bearing housing to avoid damaging the seals. Use Driveshaft Seal Protector, P/N 318674.

Check clearance again. The measurement between the gauge bar and pinion should be 0.020 in. (0.508 mm).

005417

“S2” TYPE GEARCASE

Remove the shimming screw and pinion from the driveshaft.

IMPORTANT: Make sure shimming screw is not installed in assembled gearcase.

“O”, “L2”, AND “M2” TYPE GEARCASES

Remove the nut and pinion from the driveshaft. Discard the nut.

Water Intake Screens

Install water intake screens. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

006886

1. Water intake screen

Push shifter detent into farthest downward position. Tip the rear of the gearcase slightly downward to assist in the installation of the shaft assembly.

Be sure the thrust bearing and the thrust washer are in the proper position. Insert the shaft assembly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing.

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005427

1. Pin

Lubricate a new shift rod cover O-ring with TripleGuard grease. Install the O-ring into the shift rod cover.

IMPORTANT: Make sure O-ring is fully seated in groove.

006916

1. O-ring

Install pitot tube screw and seal in housing. (“S2” and “O”)

006841

1. Screw and seal

Install the shift rod spacer on the shift rod (25 in. models).

Place the shift rod grommet on the shift rod.

006917

1. Grommet
2. Shift rod spacer

Apply Triple-Guard grease to the threaded end of the shift rod and insert it through the cover. Turn the shift rod while pushing it through the cover to avoid damaging the O-ring.

“S2”, “O”, AND “L2” TYPE GEARCASES

Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket. Place the gasket on the gearcase.

COA3141

1. Cover gasket

“M2” TYPE GEARCASES

Apply Adhesive 847 to seal groove of shift rod cover. Place a new shift rod cover seal in groove.

006842

1. Cover seal

ALL GEARCASES

Thread the shift rod into the shifter detent about four turns.

Move shift rod from side to side while pushing on the propeller shaft to ensure proper alignment of the bearing housing locator pin into the pin hole in the gearcase.

Apply Gasket Sealing Compound to the threads of the shift rod cover screws. Tighten the screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

006919
Refer to SHIFT ROD ADJUSTMENT on p. 296.

Refer to DRIVESHAFT SHIMMING on p. 315.

Place the driveshaft thrust bearing, thrust washer, and correct shim(s) on the driveshaft as shown.

005418

1. Thrust bearing
2. Thrust washer
3. Shim(s)

Push down on shift rod to move the clutch dog to reverse position. Pull propeller shaft aft to disengage from forward gear and shift housing. Allow shaft to drop against lower gearcase housing. This will allow the installation of the pinion gear.

005405

1. Propeller shaft

IMPORTANT: Forward gear and thrust bearing and washer can become misaligned. Make sure forward thrust washer and thrust bearing and forward gear are properly aligned with shift housing before continuing gearcase assembly.

Install pinion gear in gearcase housing.

005420

Install driveshaft with thrust bearing, thrust washer, and correct shim(s) in gearcase housing. Position pinion on lower driveshaft.

005410

Position pinion screw in lower driveshaft and thread into pinion.

005421

IMPORTANT: Temporarily install bearing housing for support during pinion tightening procedure.

005426

Insert Lower Driveshaft Spline Tool, P/N 5007052, into lower driveshaft.

005407

1. Lower Driveshaft Spline Tool

Insert Lower Driveshaft Wrench, P/N 352877, through Lower Driveshaft Spline Tool and lower driveshaft. Seat hex tip of wrench in head of pinion screw.

005408

1. Wrench, hex tip

IMPORTANT: Make sure Lower Driveshaft Wrench is fully seated in head of pinion screw.

Use a long 3/4 in. combination wrench to hold Driveshaft Spline Tool and a 1/2” drive torque wrench to turn the Lower Driveshaft Wrench in a clockwise direction. Torque pinion screw to 47 to 51 ft. lbs. (64 to 69 N·m).

005409

Temporarily remove the four driveshaft bearing housing screws and bearing housing.

005421

To install upper driveshaft into lower driveshaft, position new retainers (circlip type) on upper driveshaft as shown.

005412

1. Retainer(s)

Hold lower retainer and align upper driveshaft with lower driveshaft. Force upper driveshaft down until seated. Driveshaft should lock in place.

005413

005428
Upper Driveshaft Installation

Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing Service on p. 312. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft.

COA3130

1. Seal protector

Apply Gasket Sealing Compound to the threads of the driveshaft bearing housing screws. Tighten screws in stages to a torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).

005425

1. Driveshaft bearing housing screws

Refer to DRIVESHAFT SHIMMING on p. 315.

Install new seals in driveshaft bearing housing.

Refer to Driveshaft Bearing Housing Service on p. 312.

Place the driveshaft thrust bearing, thrust washer, and correct shim(s) on the driveshaft as shown.

COA3168

1. Thrust bearing
2. Thrust washer
3. Shim(s

Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase.

COA3130

1. Seal protector

Adjust shift rod to move clutch dog as far forward as possible. Be sure excess grease is removed from the pinion bearing.

Washer must be snapped into recess of pinion gear.

006922

1. Washer

IMPORTANT: The inside taper of the pinion gear and the driveshaft taper MUST be completely free of grease. Clean the tapers with Cleaning Solvent. Use a shop towel free of grease and lint.

Place the pinion gear into the gearcase. Insert the driveshaft into the gearcase and through the pinion gear.

Lightly coat the threads of a new pinion nut with outboard lubricant. Use Pinion Nut Starting Tool, P/N 342216, to install nut on the driveshaft. Turn the driveshaft by hand to thread the nut on to shaft.

006923

Apply Gasket Sealing Compound to the threads of the driveshaft bearing housing screws. Tighten screws in stages to a torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).

COA3153

1. Driveshaft bearing housing screws

Use Driveshaft Holding Socket, P/N 311875, Pinion Nut Holder, P/N 334455, and Wrench Retainer, P/N 341438, to tighten the pinion nut to a torque of 100 to 110 ft. lbs. (136 to 149 N·m). Pad handle of holder to prevent damage to gearcase.

42229

1. Holding socket
2. Pinion holder
3. Retainer

The propeller shaft bearing housing on these models SLIDES in or out of gearcase housing.

Oil and install thrust bearing and thrust washer on hub of reverse gear. Slide the gear assembly onto the propeller shaft until it engages the pinion gear.

DSC02295

1. Thrust bearing
2. Thrust washer

Lightly apply Gasket Sealing Compound to a new bearing housing O-ring. Install O-ring in groove in the housing.

Install housing into gearcase. Align screw holes with retainer slots in gearcase.

Housing must be completely seated to install retainer tabs.

50106a
Retainer Tab Slot

Install two retainers, washers and screws. Apply Ultra Lock to threads and tighten screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m).

001989

1. Retainer tab screws

Loosen retainer screws 1/4 turn.

Install wedge, screw, and washer. Apply Ultra Lock to threads and tighten screw to a torque of 15 to 20 in. lbs. (1.7 to 2.3 N·m).

DSM02291
DSC02361

Re-tighten two retainer screws to 18 to 20 ft. lbs. (24 to 27 N·m).

Confirm that torque on the wedge screw is 15 to 20 in. lbs. (1.7 to 2.3 N·m).

IMPORTANT: The propeller shaft bearing housing on the “L2” type gearcases is PRESSED into the gearcase housing.

Oil and install thrust bearing and thrust washer on hub of reverse gear.

006905

1. Thrust bearing
2. Thrust washer

Slide the gear assembly onto the propeller shaft until it engages the pinion gear.

006843

1. Thrust bearing and thrust washer

Lightly apply Triple Guard Grease to a new bearing housing O-ring. Install O-ring in groove in the housing. Grease the machined side surfaces of bearing housing.

Install housing into gearcase. Align screw holes with retainer slots in gearcase.

006836

Use Installer Handle, P/N 345822, Propeller Shaft Bearing Housing Installer, P/N 354058, Gearcase Fixture, P/N 354059 and an appropriate floor press (10 ton or greater) to install housing into gearcase. Align and level gearcase assembly in fixture as shown. Secure fixture to floor press.

0068344

Housing must be completely seated in gearcase to install retainer tabs. Depth to retainer tab surface on bearing housing is approximately 1 in. (25.4 mm).

006845

Install two retainers, washers and screws. Apply Ultra Lock to threads and tighten screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m).

001989

1. Retainer tab screws

IMPORTANT: The propeller shaft bearing housing on the “M2” type gearcases is PRESSED into the gearcase housing.

Oil and install thrust bearing and thrust washer on hub of reverse gear. Slide the gear assembly onto the propeller shaft until it engages the pinion gear.

006925

1. Thrust bearing
2. Thrust washer

Lightly apply Triple Guard Grease to new bearing housing O-rings. Install O-rings in grooves in the housing. Grease the machined side surfaces of bearing housing.

Place bearing housing in gearcase.

006846

Align retaining holes in bearing housing with screw holes in gearcase. Thread Alignment Pins, P/N 354140, into gearcase.

006926

1. Alignment pins

Use Installer Handle, P/N 345822, Propeller Shaft Bearing Housing Installer, P/N 354057, Gearcase Fixture, P/N 354059 and an appropriate floor press (10 ton or greater) to install housing into gearcase. Align and level gearcase assembly in fixture as shown. Secure fixture to floor press.

006927

1. Gearcase fixture, P/N 354059
2. Vertical alignment screws
3. Handle P/N 345822
4. Housing installer P/N 354057

Housing must be completely seated in gearcase to install retainer screws. Bearing housing is approximately level with gearcase.

006928

Apply Ultra Lock to threads and install two retaining screws. Tighten screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m).

006835

1. Retainer screws