90-824052R3 JUNE 2002 LOWER UNIT - 6E-45
Gear Lubricant Filling Instructions
1. Remove any gasket material from “Fill” and
“Vent” screws and gear housing.
2. Install new gaskets on “Fill” and “Vent” screws.
IMPORTANT: Never apply lubricant to gear
housing without first removing “Vent” screw, or
gear housing cannot be filled because of trapped
air. Fill gear housing ONLY when housing is in a
vertical position.
3. Slowly fill housing thru “Fill” hole with Quicksilver
Super Duty Lower Unit Lubricant until lubricant
flows out of “Vent” hole and no air bubbles are
visible.
4. Install “Vent” screw into “Vent” hole.
IMPORTANT: DO NOT lose more than one fluid
ounce (30cc) of gear lubricant while reinstalling
“Fill” screw.
5. Remove grease tube (or hose) from “Fill” hole
and quickly install “Fill” screw into “Fill” hole.
Installing Gear Housing to Driveshaft
Housing
WARNING
Disconnect high tension leads from spark plugs
and remove spark plugs from engine before
installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt
lock lever.
2. Apply a light coat of Quicksilver 2-4-C w/Teflon
Marine Lubricant onto driveshaft splines.
CAUTION
DO NOT allow lubricant on top of driveshaft.
Excess lubricant, that is trapped in clearance
space, will not allow driveshaft to fully engage
with crankshaft. Subsequently, tightening the
gear housing nuts (while excess lubricant is on
top of driveshaft) will load the driveshaft/
crankshaft and damage either or both the
powerhead and gear housing. Top of driveshaft
is to be wiped free of lubricant.
3. Apply a light coat of Quicksilver 2-4-C w/Teflon
Marine Lubricant onto shift shaft splines. (DO
NOT allow lubricant on top of shift shaft.)
4. Apply a thin bead of G.E. Silicone Sealer
(92-90113--2) against the top of divider block.
5. Insert trim tab bolt into hole in rear of gear hous-
ing to driveshaft housing machined surface.
6. Shift gear housing into forward gear and place
guide block anchor pin into forward gear position.
51900
a
a - Guide Block Anchor Pin
7. Position gear housing so that the driveshaft is
protruding into driveshaft housing.
NOTE: If, while performing Step 8, the driveshaft
splines will not align with crankshaft splines, place a
propeller onto propeller shaft and turn it
counterclockwise as the gear housing is being
pushed toward driveshaft housing.
8. Move gear housing up toward driveshaft housing
while aligning shift shaft splines and water tube
with water tube guide (in water pump cover).
9. Place flat washers onto studs (located on either
side of driveshaft housing). Start a nut on these
studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab
recess. DO NOT tighten bolt at this time.
11. Recheck shift shaft spline engagement and
correct if necessary.
IMPORTANT: Do not force gear case up into place
with attaching nuts.
12. Evenly tighten 2 nuts which were started in Step
9. Torque to listing in “Torque Specifications,”
preceding.
13. After 2 nuts (located on either side of driveshaft
housing) are tightened, check shift operation as
follows:
a. Place guide block anchor pin into forward
gear position while turning prop shaft. Rotate
flywheel clockwise (viewed from top);
propeller shaft should rotate clockwise.
b. Place guide block anchor pin into NEUTRAL
position. Propeller shaft should rotate freely
clockwise/counterclockwise.
c. Place guide block anchor pin into REVERSE
gear position. Rotate flywheel clockwise
(viewed from top); propeller shaft should
rotate counterclockwise.
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