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GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE DISASSEMBLY
GEARCASE • Hydrostatic Seal Grooves — Must be in good

condition to help prevent propeller ventilation.
DISASSEMBLY
Pre-Disassembly Inspection
1
WARNING
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,
1. Hydrostatic seal grooves 002217
O-rings, and gaskets.
Remove the propeller and mounting hardware. • Gearcase Anodes — If anodes have eroded to
two-thirds their original size, they must be
Drain and inspect oil as described in Gearcase replaced.
Lubricant on p. 39.
Remove gearcase. Refer to GEARCASE

REMOVAL AND INSTALLATION on p. 296.
Remove water pump. Refer to WATER PUMP 1

SERVICE on p. 298.
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 1. Gearcase anode 002014
signs of lubricant leakage.

• Propeller Shaft — Check for bent or damaged • Drive Shaft — Check splines for visible dam-
shaft. Check for twisted splines and damaged age, twisting and wear. Severe spline wear indi-
threads. cates the exhaust housing or gearcase has
• Shift Rod — Check for misadjusted, bent, or been distorted, possibly by impact damage.
binding rod. A misadjusted shift rod height can • Water Intake Screens — Check for damage
cause shift difficulty, loss of boat and outboard and blockage. If screens cannot be cleaned,
control, and gearcase damage. they must be replaced. Different screens are
available and should not be mixed. Refer to cor-
rect model parts manual for listing and descrip-
tion.
12
301
Propeller Shaft Bearing Housing Remove the two retaining rings using Retaining
Ring Pliers, P/N 331045.
Removal
Use a 5/16 in. thin wall socket to remove the four CAUTION
screws with O-rings holding the propeller shaft
bearing housing. Retaining rings are under extreme pres-
sure 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 pro-
peller shaft.
COA3571
Remove the propeller shaft bearing housing from 1

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.
1. Retaining ring 9438
Remove the retainer plate from the gearcase.
1
9437
1. Retainer plate COA3513
302
Remove the larger thrust washer, thrust bearing, Remove the four driveshaft bearing housing
and reverse gear from the gearcase. Remove the screws.
smaller thrust washer located in front of the gear.
1
1
1 1
2
1. Driveshaft bearing housing screws COA3671
1. Larger thrust washer COA3514 Remove the driveshaft from the gearcase. The
2. Thrust bearing
3. Reverse gear bearing housing, shims, thrust bearing, and thrust
washer will come out with the driveshaft.
Pinion Gear and Driveshaft
Removal
1
Adjust the shift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
2
Use Driveshaft Holding Socket, P/N 334995, and 4
an 11/16 in. open-end wrench to loosen and
remove the pinion nut from the bottom of the 3
driveshaft. Pad handle of the wrench to prevent
damage to gearcase. 1. Bearing housing COA3558
2. Shims
3. Thrust bearing
4. Thrust washer
1
If driveshaft cannot be removed, refer to Locked
Driveshaft Removal on p. 304.
Remove the pinion gear from the gearcase.
12
1. Holding socket COA3573T
2. 11/16 Wrench
COA3159
303
Locked Driveshaft Removal Shift Housing, Gear and

The driveshaft to pinion taper is a locking taper. If Propeller Shaft Removal
necessary, use Puller, P/N 387206, and Backing
Plate, P/N 325867, to break the lock. Install the Push down on the shift rod. This will move the
tools as shown by clamping them around the detent lever downward to clear the inside of the
driveshaft with the tool’s setscrew aligned with the gearcase when the shaft assembly is pulled out.
impeller drive key slot. Tighten the setscrew into Unscrew the shift rod from the detent lever.
the slot. Alternately tighten the two vertical screws Remove screws, cover, and shift rod from the
against the backing plate inserted between the gearcase.
puller and the gearcase until the driveshaft pops Discard the cover gasket. Remove and discard
loose from the pinion. the shift rod O-ring from inside of cover.
3
COA3666
1. Drive shaft COA3664
2. Puller IMPORTANT: Make sure oil fill/drain plug is
3. Backing plate
removed from gearcase.
Remove propeller shaft assembly from gearcase.
COA3575
304

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GEARCASE SERVICE, 40 – 65 HP MODELS

GEARCASE • Hydrostatic Seal Grooves — Must be in good

IMPORTANT: Clean and inspect all parts during

Remove gearcase. Refer to GEARCASE

Remove water pump. Refer to WATER PUMP 1

Before disassembling the gearcase, examine the

signs of lubricant leakage.

Remove the propeller shaft bearing housing from 1

1. Retaining ring 9438

Remove the retainer plate from the gearcase.

1. Retainer plate COA3513

Locked Driveshaft Removal Shift Housing, Gear and

Remove propeller shaft assembly from gearcase.

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