Pre-Disassembly Inspection
Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).
IMPORTANT: Clean and inspect all parts during disassembly. Replace any damaged parts, seals, O-rings, and gaskets.
Remove the propeller and mounting hardware.
Drain and inspect oil as described in Gearcase Lubricant on p. 79.
Remove gearcase as described in GEARCASE REMOVAL AND INSTALLATION on p. 301.
Remove water pump as described in WATER PUMP SERVICE on p. 304.
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 damage, 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 – “S2”, “O”, “L” and “M” Type
IMPORTANT: Identify gearcase type before dis assembly. For counter rotation gearcases, refer to GEARCASE DISASSEMBLY on p. 338.
Remove the two screws, washers, and retainers holding the propeller shaft bearing housing.
- Retainer tab screws
Remove wedge, screw, and washer.
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.
- Bearing housing – slides in or out
Remove the thrust washer, thrust bearing, and reverse gear from gearcase.
Propeller Shaft Bearing Housing Removal – “L2” and “M2” Type
IMPORTANT: Identify gearcase type before dis assembly. For counter rotation gearcases, refer to GEARCASE DISASSEMBLY on p. 338.
The propeller shaft bearing housing on “L2” and “M2” models is PRESSED into gearcase housing.
“L2” TYPE GEARCASES
Remove the two screws, washers, and retainers holding the propeller shaft bearing housing.
- Retainer tab screws
“M2” TYPE GEARCASES
Remove the two screws holding the propeller shaft bearing housing.
- Retainer screws
Remove the propeller shaft bearing housing from the gearcase using:
- Propeller Shaft Bearing Housing Puller Kit, P/N 354060.
DO NOT use tools designed to push on the propeller shaft. Pushing force against the propeller shaft could damage the forward gear thrust bearing or thrust washer.
IMPORTANT: The L2 type gearcase uses the adaptor ring included with puller kit.
Install the threaded adaptor from the puller kit on to the propeller shaft until seated.
Assemble puller kit components. Hold adaptor with wrench and turn nut clockwise to pull bearing housing.
Pull propeller shaft and bearing housing far enough to loosen the PRESSED bearing housing from the gearcase housing.
“L2” Type Gearcase
“M2” Type Gearcase
Remove the bearing housing, thrust washer, thrust bearing, and reverse gear from gearcase.
Pinion Gear and Driveshaft Removal – “S2” Type
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 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 driveshaft.
Refer to Propeller Shaft Bearing Housing Removal – “S2”, “O”, “L” and “M” Type on p. 308. 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 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.
Pinion Gear and Driveshaft Removal – “O”, “L”, “L2”, “M” and “M2” Type
Adjust the shift rod to move the clutch dog as far forward as possible. This will help ease removal of the pinion nut.
Use Driveshaft Holding Socket, P/N 311875, Pin ion Nut Holder, P/N 334455, and Wrench Retainer, P/N 341438 to loosen the pinion nut from the bottom of the driveshaft. Pad handle of holder to prevent damage to gearcase.
- Holding socket
- Pinion holder
- Retainer
Remove the four driveshaft bearing housing
- Driveshaft bearing housing screws
Remove driveshaft from the gearcase. The bearing housing, shims, thrust bearing, and thrust
- Bearing housing
- Shims
- Thrust bearing
- Thrust washer
If driveshaft cannot be removed, refer to Locked Driveshaft Removal on p. 314.
Remove the pinion gear and pinion nut from the gearcase.
Locked Driveshaft Removal
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
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. Unscrew the shift rod from the detent lever. Remove screws, cover, and shift rod 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
