168
GEARCASE
REMOVAL AND INSTALLATION
Installation
IMPORTANT: On models with a gearcase
extension kit, make sure the driveshaft tube
extension, water tube extension, and gearcase
exhaust seals are in place.
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.
Pull up on the shift rod and engage REVERSE
gear. Move the shift lever on the outboard to
REVERSE position.
Lightly apply Triple-Guard grease to lower outside
diameter of the water tube.
Install the gearcase onto the exhaust housing.
Guide the water tube into the water tube grommet
and see that the driveshaft engages the crank-
shaft. Rotate the flywheel, if necessary.
Make sure the upper shift rod enters the shift rod
connector.
Align the groove in the lower shift rod with the
screw hole in the connector. Apply Gasket Sealing
Compound to shift rod connector screw. Install
and tighten the screw with washer to a torque of
60 to 84 in. lbs. (7 to 9 N·m).
Apply Nut Lock to the threads of the gearcase
(and extension) retaining screws. Install and
tighten the screws to a torque of 96 to 120 in. lbs.
(11 to 14 N·m).
IMPORTANT: When installing a gearcase to a
gearcase extension, do not tighten the retaining
screws until the gearcase and the extension have
been placed in proper position with the exhaust
housing and powerhead assembly.
Install propeller and check proper shift control
operation. Refer to Propeller Hardware Installa-
tion on p. 47.
1. Driveshaft splines 32568
1
1. Screws 32566
32397
1
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