315
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
12
Gearcase Installation
Before installing gearcase, shift rod
adjustment MUST be checked. Refer to SHIFT
ROD ADJUSTMENT on p. 319.
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.
Apply Adhesive 847 to the lower exhaust housing
seals’ inner surfaces. Place two new seals on the
housing. Apply Triple-Guard grease to the seals’
outer surfaces and place the housing on the
gearcase.
Slide the gearcase into place, making sure:
• Driveshaft engages the crankshaft.
• Water tube enters the water pump.
• Lower inner exhaust housing installs correctly.
• Shift rod does not turn and is positioned prop-
erly in the shift rod lever below the crankcase.
IMPORTANT: New gearcase screws are treated
with a thread-locking material. Apply Triple-Guard
grease to threads to ensure that the correct
clamping force is achieved when tightening—If a
previously installed screw is re-used, use a wire
brush to remove any old thread-locking material or
corrosion and lubricate threads with Triple-Guard
grease.
Install screws and washers and tighten to a torque
of:
• 3/8 in. screws – 26 to 28 ft. lbs. (35 to 38 N·m)
• 7/16 in. screws – 45 to 50 ft. lbs. (61 to 68 N·m)
A WARNING
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.
30385
1. Lower exhaust seals 32002
1. 3/8 in. screws 001990
1. 3/8 in screw
2. 7/16 in. screw
COA3139
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