Service Manual Evinrude E-TEC 40-60 HP Gearcase [Assembly]

Push shifter detent into farthest downward position. Tip the rear of the gearcase slightly downward to assist in the installation of the shaft assembly. Be sure the thrust bearing and the thrust washer are properly positioned. Insert the shaft assembly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing.

1. Pin

Lubricate a new shift rod cover O-ring with Triple-Guard grease. Install the O-ring into the shift rod cover.

Apply Triple-Guard grease to the threaded end of the shift rod and insert it through the cover. Turn the shift rod while pushing it through the cover to avoid damaging the O-ring.

ASSEMBLY Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket. Position the gasket on the gearcase. Thread the shift rod into the shifter detent about four turns.

1. Cover gasket

Move shift rod from side to side while pushing on the propeller shaft to ensure proper alignment of the bearing housing locator pin into the locator pin hole in the gearcase.

Apply Gasket Sealing Compound to the threads of the shift rod cover screws. Install the screws. Torque the screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

Place the cover seal on the shift rod cover.

1. Cover seal

Refer to DRIVESHAFT SHIMMING on p. 283 before proceeding.

Position the driveshaft thrust bearing, thrust washer, and shim(s) (selected earlier) on the driveshaft, exactly in order shown.

1. Thrust bearing
2. Thrust washer
3. Shim(s)

Lightly apply Gasket Sealing Compound to the gearcase area that contacts mounting flange of the bearing housing. Do not coat inside bearing housing bore surface of the gearcase.

Using Driveshaft Seal Protector, P/N 312403, slide the driveshaft bearing housing onto the driveshaft.

1. Seal protector

Move shift rod to position clutch dog as far forward as possible. Be sure excess grease is removed from the pinion bearing.

IMPORTANT: The inside taper of the pinion gear and the driveshaft taper MUST be completely free of grease. Clean the tapers with Cleaning Solvent. Use a shop towel free of grease and lint.

Lightly coat the threads of a new pinion nut with outboard lubricant and install on the driveshaft using Pinion Nut Starting Tool, P/N 320675. Turn the driveshaft by hand to engage the nut. Hand tighten pinion nut and remove the pinion nut starting tool. Proceed to next step and then torque procedure.

Align the embossed word “FRONT” toward the shift rod and push the driveshaft bearing housing into position. Apply Gasket Sealing Compound to the threads of the screws. Install screws a little at a time to draw the bearing housing down evenly. Torque screws to 96 to 120 in. lbs. (11 to 14 N·m).

1. Driveshaft bearing housing screws

Use Driveshaft Holding Socket, P/N 334995, and an 11/16 in. open-end wrench, to torque the pinion nut to 40 to 45 ft. lbs. (54 to 60 N·m). Pad handle of the wrench to prevent damage to gearcase.

1. Holding socket
2. 11/16 Wrench

Place the small thrust washer in recess of the reverse gear.

1. Small thrust washer

Oil and install thrust bearing and larger thrust washer on hub of reverse gear. Slide the gear assembly onto the propeller shaft until it engages the pinion gear.

1. Thrust bearing
2. Thrust washer

Slide the bearing housing retainer plate into position over the propeller shaft.

1. Retaining ring

Using Retaining Ring Pliers, P/N 331045, install the two retaining rings.

IMPORTANT: Retaining rings are under extreme pressure during installation. Wear safety glasses and proceed with care to avoid unsnap ping the ring from the pliers.

Look inside the gearcase and make sure that the retaining rings are seated in the grooves in the gearcase.

1. Retaining ring

Thread two Guide Pins, P/N 383175, into the retainer plate to align holes in the plate with holes in the propeller shaft bearing housing. Do not thread guide pins more than two turns into the retainer plate.

1. Guide pin

Install O-ring in groove in the bearing housing. Lightly apply Gasket Sealing Compound to the O-ring flange and aft support flange of the bearing housing. Do not allow sealer to contact either forward thrust surface or bearings in the housing.

Align the bearing housing on the guide pins with the word “UP” toward the top. Place the housing into gearcase and tap the housing with a soft face mallet to seat the O-ring.

Apply Gasket Sealing Compound to the threads and seals of the four propeller housing retaining screws. Install two of the screws into the bearing housing finger tight. Remove the guide pins and install the remaining two screws. Tighten all four screws to 120 to 140 in. lbs. (14 to 16 N·m).

To complete gearcase assembly, refer to:
• LEAK TEST on p. 266
• WATER PUMP on p. 269
• SHIFT ROD ADJUSTMENT on p. 272
• REMOVAL AND INSTALLATION on p. 267
• LUBRICANT on p. 265
• Propeller Hardware Installation on p. 67
• Trim Tab Adjustment on p. 69.

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