Mercury 40 FourStroke User Manual

6
A
NON-BIGFOOT GEAR HOUSING
Page 6A-190-857046R1 NOVEMBER 2001
LOWER UNIT
Section 6A - Non-Bigfoot Gear Housing
Table of Contents
Specifications 6A-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6A-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Driveshaft - 2:1) 6A-6. . . . . . . . . . .
Gear Housing (Prop Shaft - 2:1) 6A-8. . . . . . . . . . .
General Service Recommendations 6A-10. . . . . . .
Bearings 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals 6A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Lubricant 6A-11. . . .
Gear Housing Removal 6A-12. . . . . . . . . . . . . . . . . .
2-Stroke Models 6A-12. . . . . . . . . . . . . . . . . . . . . .
4-Stroke Models 6A-13. . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6A-15. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft 6A-17. . . . .
Pinion Gear, Drive Shaft,
and Forward Gear 6A-18. . . . . . . . . . . . . . . . . . . .
Water Pump Seals 6A-21. . . . . . . . . . . . . . . . . . . .
Inspection 6A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Upper Bearing 6A-23. . . . . . . . . . . . .
Pinion Gear Bearing 6A-24. . . . . . . . . . . . . . . . . .
Pinion Gear 6A-24. . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear 6A-24. . . . . . . . . . . . . . . . . . . . . . . .
Shift Shaft 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Disassembly 6A-28. . . . . . . . . . .
Propeller Shaft and Carrier Inspection 6A-29. . . . .
Clutch 6A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Follower 6A-29. . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear 6A-29. . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear Bearing 6A-30. . . . . . . . . . . . . . . .
Bearing Carrier 6A-31. . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Reassembly 6A-35. . . . . . . . . . . . . . .
Shift Shaft Assembly 6A-35. . . . . . . . . . . . . . . . . .
Pinion Bearing Race 6A-36. . . . . . . . . . . . . . . . . .
Forward Gear 6A-37. . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear/Drive Shaft Assembly 6A-38. . . . . .
Propeller Shaft 6A-39. . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier 6A-41. . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6A-42. . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Pressure Test 6A-45. . . . . . . . . . . . . .
Gear Housing Installation 6A-46. . . . . . . . . . . . . . . . .
2-Stroke Models 6A-47. . . . . . . . . . . . . . . . . . . . . .
4-Stroke Models 6A-47. . . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment and Replacement 6A-49. . . .
Filling Gear Housing with Lubricant 6A-50. . . . .
Specifications
GEAR HOUSING
(2.00:1)
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Forward Gear Backlash
Water Pressure (Warm Engine)
@ 800 rpm
@ 6000 rpm (WOT)
Leak Test Pressure
2.00:1
14.9 fl oz (440 mL)
Quicksilver Gear Lube-Premium Blend
26 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
No Adjustment
2–4 psi (14-28 kPa)
12-17 psi (69-103 kPa)
10-12 psi (68-83 kPa)
for 5 Minutes

Mercury 40 FourStroke Specifications

General

Brand	Mercury
Model	40 FourStroke
Category	Outboard Motor
Language	English