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 water intake screens.
- Water intake screen
Remove the upper shift rod connector screw.
- Shift rod connector screw
Remove the six gearcase retaining screws or nuts (25 inch models).
- Gearcase retaining screws
Remove the gearcase assembly from the exhaust housing, being careful not to bend the shift rod.
Gearcase 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.
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.
Slide the gearcase into place, making sure that:
- Driveshaft engages the crankshaft
- Water tube enters grommet on water pump
- Upper shift rod enters the shift rod connector.
Apply Gasket Sealing Compound to threads of the gearcase retaining screws. Install and tighten the screws to a torque of 128 to 146 in. lbs. (14.5 to 16.5 N•m).
- Gearcase retaining screws
For 25 inch models, apply Triple-Guard grease to threads of the studs. Install washers and gearcase retaining nuts. Tighten nuts to a torque of 128 to 146 in. lbs. (14.5 to 16.5 N•m).
- Gearcase retaining nuts
Align the groove in the upper shift rod with the screw hole in the connector. Apply Gasket Sealing Compound to threads of the shift rod connector screw. Tighten screw, with washer, to a torque of 60 to 84 in. lbs. (7 to 9.5 N•m).
Install the port and starboard water intake screens with water intake holes positioned at the rear of gearcase. Tighten screws to a torque of 10 to 14 in. lbs. (1.1 to 1.6 N•m).
- Water intake screen
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.
