Service Manual 75-90 HP E-TEC Gearcase [Gearcase Removal And Installation]

Gearcase Removal

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.

1. Shift rod screw

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.

1. Index mark
2. Trim tab
3. Trim tab retaining screw

Remove the forward screw with washer and recessed retaining screw.

1. Forward screw
2. Recessed screw

Remove the four gearcase retaining screws.

1. Gearcase retaining screws

Remove the gearcase assembly from the exhaust housing, being careful not to bend the shift rod or damage the water tube. The lower inner exhaust housing may come out with the gearcase.

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.

IMPORTANT: Before installing gearcase, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 266.

Coat the driveshaft splines with Moly Lube. DO NOT coat top surface of the driveshaft because lubricant may prevent seating of the driveshaft in the crankshaft.

Apply Adhesive 847 to the lower exhaust housing seals’ inner surfaces. Place two new seals on the housing. Apply Triple-Guard grease to the seals’ outer surfaces and place the housing on the gear case.

TYPICAL

1. Lower exhaust seals

Apply Gel-Seal II to gearcase mating surface pads on exhaust housing. Slide the gearcase into place, making sure:

• Driveshaft engages the crankshaft.
• Water tube enters the water pump.
• Lower inner exhaust housing installs correctly.
• Shift rod does not turn and is positioned properly in shift shaft connection area.

Apply Gasket Sealing Compound to threads of the gearcase retaining screws. Tighten the screws to a torque of:

• 3/8 in. screws – 26 to 28 ft. lbs. (35 to 38 N•m)
• 7/16 in. screws – 40 to 50 ft. lbs. (54 to 68 N•m)

1. 3/8 in. screws

1. 7/16 in. screw
2. 3/8 in screw

Apply Gasket Sealing Compound to threads of the trim tab screw. Install and align the trim tab with the index marks noted prior to disassembly. Tighten the trim tab screw to a torque of 35 to 40 ft. lbs. (47 to 54 N•m). For adjustment, refer to Trim Tab Adjustment on p. 62.

1. Trim tab screw
2. Index mark

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).

1. Shift rod screw

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

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

Disassembly

Rotate the driveshaft counterclockwise to unlock the impeller cam. Remove the four impeller housing screws.

1. Screws

Slide the water pump off the driveshaft. Remove the impeller drive cam, O-ring, impeller plate, and gasket. Discard the gasket.

1. O-ring
2. Impeller plate

Remove all the parts from the housing.

Inspection

Check impeller for overheating, hub separation, and other wear or damage.

Check liner and wear plate for scoring, distortion, and impeller material transfer.

Inspect the housing for cracks or melting.