SHIFT ROD ADJUSTMENT
Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.
With the shift rod and detent lever in NEUTRAL, rotate the shift rod up or down as necessary for correct adjustment. Once correct height is achieved, rotate rod one half turn or less to face offset forward.
IMPORTANT: The NEUTRAL detent is a two step design. Make sure the NEUTRAL detent ball is in the center step before checking shift rod height.
Shift Rod Heights
| Model | Type | Height |
|---|---|---|
| 20 in. (L) | “S2” (V4)“O” (V6)“L” (V6) | 20 15/16 in.(20.945 in./ 532 mm)± 1/2 Half Turn |
| 25 in. (X) | “O” (V4)“M” (V6) | 25 15/16 in.(25.945 in./659 mm)± 1/2 Turn |
DISASSEMBLY
Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).
IMPORTANT: Clean and inspect all components during disassembly. Replace any damaged components, seals, O-rings, and gaskets upon assembly.
Remove the propeller and mounting hardware.
Drain and inspect oil as described in LUBRICANT on p. 307.
Remove gearcase as described in REMOVAL AND INSTALLATION on p. 308.
Remove water pump as described in WATER PUMP on p. 311.
Pre-Disassembly Inspection
Before disassembling the gearcase, examine the following:
Gearcase Housing — Check for visible dam age to skeg, strut, anti-ventilation plate, bullet, and mating surface. Check seal areas for visible signs of lubricant leakage.
Propeller Shaft — Check for bent or damaged shaft. Check for twisted splines and damaged threads.
Shift Rod — Check for misadjusted, bent, or binding rod. A misadjusted shift rod height can cause shift difficulty, loss of boat and outboard control, and gearcase damage.
Hydrostatic Seal Grooves — Must be in good condition to help prevent propeller ventilation.
- Hydrostatic seal grooves
- Gearcase Anodes — If anodes have eroded to two-thirds their original size, they must be replaced.
- Gearcase anode
Drive Shaft — Check splines for visible dam age, twisting and wear. Severe spline wear indicates the exhaust housing or gearcase has been distorted, possibly by impact damage.
Water Intake Screens — Check for damage and blockage. If screens cannot be cleaned, they must be replaced. Different screens are available and should not be mixed. Refer to correct model parts manual for listing and description.
Propeller Shaft Bearing Housing Removal
IMPORTANT: This procedure is for standard rotation gearcases only. For counter rotation gear cases, refer to COUNTER ROTATION on p. 341. Remove the two screws, washers, and retainers holding the propeller shaft bearing housing.
- Retainer tab screws
Remove wedge, screw, and washer (except “S2” type).
Remove the propeller shaft bearing housing from the gearcase using the following:
- Puller body, screw, and handle from Universal Puller Set, P/N 378103.
- Two 5/16-18 x 11 in. (279 mm) threaded rods, two large 5/16 in. I.D. flat washers, and two 5/16-18 nuts (obtain locally).
Assemble components and pull the bearing housing from the gearcase. Remove the thrust washer, thrust bearing, and reverse gear from gearcase.
Pinion Gear and Driveshaft Removal
“S2” TYPE GEARCASE
Remove upper driveshaft. Refer to Driveshaft Service on p. 320 for upper driveshaft removal and installation. Remove propeller shaft bearing housing and reverse gear, thrust bearing and thrust washer.
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 assist in the removal of the pinion gear.
- Propeller shaft
Use the required tools to remove the pinion screw and gear from the lower driveshaft.
- Lower Driveshaft Spline Tool, P/N 5007052
- Lower driveshaft Wrench, P/N 352877
- Pinion gear and screw
- Lower driveshaft
With driveshaft bearing housing and screws in place, insert Lower Driveshaft Spline Tool, P/N 5007052, into lower driveshaft.
- 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 pin ion screw.
- 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 lower Driveshaft Spline Tool and a 1/2” drive wrench to turn the Lower Driveshaft Wrench in a counterclockwise direction. Loosen screw completely
Remove the four driveshaft bearing housing screws with washers and then the bearing housing.
- Driveshaft bearing housing
Remove shims, thrust washer, and thrust bearing with the lower driveshaft.
- Shims
- Thrust bearing
- Thrust washer
Remove pinion gear from gearcase housing.
“O,” “L,” AND “M” TYPE GEARCASES
Position the shift rod to move the clutch dog as far forward as possible. This will assist in the removal of the pinion nut.
Loosen the pinion nut from the bottom of the driveshaft using Driveshaft Holding Socket, P/N 311875, Pinion Nut Holder, P/N 334455, and Wrench Retainer, P/N 341438. Pad the handle of holder to prevent damage to gearcase.
- Holding socket
- Pinion holder
- Retainer
Remove the four driveshaft bearing housing screws with washers.
- Driveshaft bearing housing screws
The bearing housing, shims, thrust bearing, and thrust washer will come out with the driveshaft.
- Bearing housing
- Shims
- Thrust bearing
- Thrust washer
Reach inside the gearcase and remove the pinion gear and pinion nut.
If driveshaft cannot be removed, refer to (Special) Driveshaft Removal Procedures on p. 319.
(Special) Driveshaft Removal Procedures
“O,” “L,” AND “M” TYPE GEARCASES
The driveshaft to pinion taper is a locking taper. If necessary, use Driveshaft Puller, P/N 390706, and Backing Plate, P/N 325867, to break the lock. Install the tools as shown by clamping them around the driveshaft. Alternately tighten the two vertical screws against the backing plate inserted between the puller and the gearcase until the driveshaft pops loose from the pinion.
- Drive shaft
- Puller
- Backing plate
If upper driveshaft becomes separated from lower driveshaft, use Lower Driveshaft Puller, P/N 342681, to remove. Install puller into lower driveshaft and turn 90° to position hook under pin in driveshaft. Thread Slide Hammer, P/N 391008, into puller and remove driveshaft.
Driveshaft Service
“S2” TYPE GEARCASE
Removal
IMPORTANT: To separate the upper driveshaft from the lower driveshaft, the upper retainer must be removed and upper driveshaft must slide down into lower driveshaft.
Remove the four driveshaft bearing housing screws with washers and bearing housing.
- Driveshaft bearing housing screws
Remove upper retainer.
- Retainer
Force upper driveshaft into lower driveshaft. This moves lower retainer on stepped groove of lower driveshaft. Refer to diagram below.
Upper Driveshaft Removal
Lift and remove upper driveshaft from lower drive shaft.
Installation
To install upper driveshaft into lower driveshaft, position new retainers (circlip type) on upper driveshaft as shown.
- Retainer(s)
Hold lower retainer in place and align upper drive shaft with lower driveshaft. Force upper driveshaft down until seated. Make sure upper driveshaft is locked in place.
Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing on p. 326. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the
- Seal protector
Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 N•m).
- Driveshaft bearing housing screws
“O,” “L,” AND “M” TYPE GEARCASES
Refer to DISASSEMBLY on p. 314 for driveshaft removal.
To separate the upper driveshaft (if needed) from the lower driveshaft, remove the roll pin. Replace the damaged component.
To assemble the driveshaft, install new driveshaft retainer into the groove of the upper driveshaft.
Install the upper driveshaft into the lower drive shaft, aligning the holes in the driveshaft retainer and the lower driveshaft.
Install the roll pin to the specified dimension.
- Roll pin
Shift Housing, Gear and Propeller Shaft Removal
Push down on the shift rod. This will move the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out. Unthread the shift rod from the detent lever. Remove the six screws, shift rod, and cover from the gearcase.
Discard the cover gasket. Remove and discard the shift rod O-ring from inside of cover.
- Cover gasket
Remove propeller shaft assembly from gearcase.
Water Intake Screens
Remove and clean water intake screens. Replace if damaged.
- Water intake screen
GEARCASE HOUSING INSPECTION
Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection. Inspect pinion bearing and forward thrust surface of gearcase housing.
Use Gearcase Alignment Gauge Kit, P/N 5006349 to check the condition of gearcase housing prior to reassembly. Refer to instructions provided with kit. Use Gauging Head, P/N 352879, for “S” Type gearcase housings.
IMPORTANT: DO NOT force gauging shaft into alignment hole. Shaft MUST slide easily into hole of gauging head. If shaft does not slide into hole, gearcase housing is damaged and must be replaced.
