Mariner Mercury 135 JET User Manual

6C-0 - LOWER UNIT 90-824052R3 JUNE 2002
Table of Contents
Page
Gear Housing Specifications (1.78:1 Ratio) 6C-1. .
Special Tools 6C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Driveshaft) - XR6/Magnum III -
1.78:1 Ratio 6C-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Prop Shaft) - XR6/Magnum III -
1.78:1 Ratio 6C-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service Recommendations 6C-8. . . . . . . .
Removal, Disassembly, Cleaning and
Inspection 6C-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Gear Housing from
Driveshaft Housing 6C-9. . . . . . . . . . . . . . . .
Draining Lubricant from Gear Housing 6C-10. . .
Water Pump 6C-11. . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly 6C-11. . . . . . . . . .
Cleaning and Inspection 6C-12. . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft
Removal 6C-12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier Cleaning and
Inspection 6C-13. . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier Disassembly 6C-13. . . . . . . .
Propeller Shaft Cleaning and
Inspection 6C-14. . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Disassembly 6C-15. . . . . . . . .
Pinion Gear and Driveshaft 6C-15. . . . . . . . . . . .
Removal 6C-15. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 6C-16. . . . . . . . . . . .
Forward Gear and Bearings 6C-17. . . . . . . . . . . .
Removal and Disassembly 6C-17. . . . . . . . . .
Cleaning and Inspection 6C-17. . . . . . . . . . . .
Shift Shaft, Bushing and Cam 6C-18. . . . . . . . . .
Shift Shaft Removal 6C-18. . . . . . . . . . . . . . . .
Shift Shaft, Bushing, CamCleaning and
Inspection 6C-18. . . . . . . . . . . . . . . . . . . . . . .
Shift Shaft and Bushing Disassembly 6C-18.
Gear Housing 6C-18. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 6C-18. . . . . . . . . . . .
Driveshaft Needle Bearing 6C-19. . . . . . . . . . . . .
Removal of Driveshaft Needle Bearing -
Early Model 6C-19. . . . . . . . . . . . . . . . . . . . .
Removal of Driveshaft Needle Bearing -
Late Model 6C-20. . . . . . . . . . . . . . . . . . . . . .
Page
Reassembly and Installation 6C-20. . . . . . . . . . . . . .
Driveshaft Needle Bearing 6C-20. . . . . . . . . . . . .
Installation - Early Model 6C-20. . . . . . . . . . . .
Driveshaft Needle Bearing 6C-21. . . . . . . . . . . . .
Installation - Late ModeL 6C-21. . . . . . . . . . . .
Late Model 6C-21. . . . . . . . . . . . . . . . . . . . . . . .
Lower Shift Shaft and Bushing 6C-22. . . . . . . . .
Reassembly and Installation 6C-22. . . . . . . . .
Bearing Carrier 6C-22. . . . . . . . . . . . . . . . . . . . . . .
Reassembly 6C-22. . . . . . . . . . . . . . . . . . . . . . .
Forward Gear and Race 6C-23. . . . . . . . . . . . . . .
Reassembly 6C-23. . . . . . . . . . . . . . . . . . . . . . .
Driveshaft and Pinion Gear 6C-25. . . . . . . . . . . .
Reassembly/Installation 6C-25. . . . . . . . . . . . .
Determining Pinion Gear Depth 6C-26. . . . . . . . .
Propeller Shaft 6C-27. . . . . . . . . . . . . . . . . . . . . . .
Reassembly 6C-27. . . . . . . . . . . . . . . . . . . . . . .
Installation 6C-28. . . . . . . . . . . . . . . . . . . . . . . .
Determining Forward Gear Backlash 6C-28. . . .
Water Pump 6C-30. . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly/Installation 6C-30. . . . . . . . . . . . .
Filling Gear Housing With Lubricant 6C-31. . . . .
Installing Gear Housing to Drive
Shaft Housing 6C-31. . . . . . . . . . . . . . . . . . . . . .
Propeller Installation 6C-33. . . . . . . . . . . . . . . . . .

Mariner Mercury 135 JET Specifications

General

Brand	Mariner Mercury
Model	135 JET
Category	Engine
Language	English