301
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE DISASSEMBLY
12
GEARCASE
DISASSEMBLY
Pre-Disassembly Inspection
IMPORTANT: Clean and inspect all parts during
disassembly. Replace an y damaged parts, seals,
O-rings, and gaskets.
Remove the propeller and mounting hardware.
Drain a nd inspect o il as d escribed in Gearcase
Lubricant on p. 39.
Remove gearcase. Refe r to GEARCASE
REMOVAL AND INSTALLATION on p. 296.
Remove wa ter pump. Re fer to WATER PUMP
SERVICE on p. 298.
Before disassembling the gearcase, examin e the
following:
• Gearcase Housing — Check for visible da m-
age to skeg, strut, an ti-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 sp lines a nd d amaged
threads.
• Shift Rod — Check for misadjusted, bent, or
binding rod. A misadjusted shift rod height can
cause shift difficulty, loss o f boat an d outboard
control, and gearcase damage.
• Hydrostatic Seal Grooves — Must be in goo d
condition to help prevent propeller ventilation.
• Gearcase Anodes — If anodes have eroded to
two-thirds their origina l size, t hey must b e
replaced.
• Drive Shaft — Check splin es for visible dam-
age, twisting and wear. Severe spline wear indi-
cates th e exh aust h ousing or ge arcase has
been distorted, possibly by impact damage.
• Water Intake Screens — Ch eck f or damage
and blo ckage. If screens ca nnot b e cleane d,
they mu st be re placed. Dif ferent scre ens a re
available and should not be mixed. Refer to cor-
rect model parts manual for listing an d descrip-
tion.
A WARNING
Wear safety glasses to avoid personal
injury, and set compressed air pressure to
less than 25 psi (172 kPa).
1. Hydrostatic seal grooves 002217
1. Gearcase anode 002014
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