Service Manual Evinrude E-TEC 40-60 HP Gearcase [Removal And Installation]

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 screw from shift 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 reinstalled in the same position. Remove the trim tab retaining screw and trim tab from the gearcase.

1. Trim tab
2. Trim tab retaining screw

Remove the forward screw with the washer and remove middle screw.

1. Forward screw
2. Middle 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.

Installation

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 installation of gearcase on motor, shift rod adjustment must be checked. Refer to SHIFT ROD ADJUSTMENT on p. 272.

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

Apply Adhesive 847 to the inner exhaust housing seal’s inner surface. Position seal on the exhaust housing. Apply Triple-Guard grease to the seal’s outer surfaces.

Slide the gearcase into place, making sure:

• Driveshaft engages the crankshaft.
• Water tube enters the water pump.
• 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. Torque the screws:
• 3/8 in. screws – 18 to 20 ft. lbs. (24 to 27 N·m)
• 7/16 in. screws – 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)

1. 3/8 in. screws

1. 7/16 in. screw
2. 5/16 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. Torque the trim tab screw to 18 to 20 ft. lbs. (24 to 27 N·m). For adjustment, refer to Trim Tab Adjustment on p. 69

1. Trim tab screw

Position the shift rod in the connector.

Install and torque shift rod screw to 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

Remove the four impeller housing screws.

1. Impeller housing screws

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

1. Impeller plate
2. Drive cam

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.