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

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 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 to the rear.

Shift Rod Height:
• (L) Models: 21.38 in. (543 mm) ± One-Half Turn
• (Y) Models: 23.88 in. (607 mm) ± One-Half Turn

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. 265.

Remove gearcase as described in Gearcase REMOVAL AND INSTALLATION on p. 267.

Remove water pump as described in WATER PUMP on p. 269.

Pre-Disassembly Inspection
Before disassembling the gearcase, examine the following:
• Gearcase Housing — Check for visible damage 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.

1. Hydrostatic seal grooves

• Gearcase Anodes — If anodes have eroded to two-thirds their original size, they must be replaced.

1. 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

Remove the four screws with O-rings holding the propeller shaft bearing housing using a 5/16 in. thin wall socket.

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 8 in. screws, P/N 316982, from Universal Puller Set, P/N 378103.

Assemble components and pull the bearing housing from the gearcase.

Remove the two retaining rings using Retaining Ring Pliers, P/N 331045.

IMPORTANT: Retaining rings are under extreme pressure during removal and installation. To prevent personal injury, wear safety glasses and proceed with care to avoid unsnapping the ring from the pliers. After the retaining rings are removed far enough from the gearcase to clear the housing, release the tension on the pliers while retaining ring is still around the propeller shaft.

Retaining ring

Remove the retainer plate from the gearcase.

1. Retainer plate

Remove the larger thrust washer, thrust bearing, and reverse gear from the gearcase. Remove the smaller thrust washer located in front of the gear.

1. Larger thrust washer
2. Thrust bearing
3. Reverse gear

Pinion Gear and Driveshaft Removal
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 by using Driveshaft Holding Socket, P/N 334995, and an 11/16 in. open-end wrench. Pad handle of the wrench to prevent damage to gearcase.

1. Holding socket
2. 11/16 Wrench

Remove the four driveshaft bearing housing screws.

1. Driveshaft bearing housing screws

Remove pinion nut and driveshaft from the gearcase. If driveshaft cannot be removed, refer to next procedure, (Special) Driveshaft Removal Procedures.

The bearing housing, shims, thrust bearing, and thrust washer will come out with the driveshaft.

1. Bearing housing
2. Shims
3. Thrust bearing
4. Thrust washer

(Special) Driveshaft Removal Procedures
The driveshaft to pinion taper is a locking taper. If necessary, use Puller, P/N 387206, and Backing Plate, P/N 325867, to break the lock. Install the tools as shown by clamping them around the driveshaft with the tool’s setscrew aligned with the impeller drive cam slot. Tighten the setscrew into the slot. 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.

1. Drive shaft
2. Puller
3. Backing plate

Reach inside the gearcase and remove the pinion gear.

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 four screws, shift rod, and cover from the gearcase.

Discard the cover gasket. Remove and discard the shift rod O-ring from inside of cover.

Remove the fill/drain plug and then remove propeller shaft assembly from gearcase.

Shift Housing

Wear safety glasses to avoid injury.

IMPORTANT: The shift housing and forward gear bearing are serviced as an assembly. If either are worn or damaged, replace the complete assembly.

Disassembly
Insert a suitable tool under one end of the clutch dog spring and remove it from its groove by unwrapping it from around the clutch dog. Discard the spring.

1. Clutch dog spring

Push the pin out of the clutch dog. Remove all components.

1. Pin