Mercury 40 FourStroke - Page 467

6
B
BIGFOOT GEAR HOUSING
90-857046R1 NOVEMBER 2001 Page 6B-1
LOWER UNIT
Section 6B - Bigfoot Gear Housing
Table of Contents
Specifications 6B-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Drive Shaft - 2.31:1) 6B-6. . . . . . .
Gear Housing (Prop Shaft - 2.31:1) 6B-8. . . . . . . .
General Service Recommendations 6B-10. . . . . . .
Bearings 6B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals 6B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Lubricant 6B-11. . . .
Removal 6B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6B-13. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft 6B-16. . . . .
Pinion Gear, Drive Shaft,
and Forward Gear 6B-21. . . . . . . . . . . . . . . . . . . .
Upper Drive Shaft Bearing 6B-24. . . . . . . . . . . . .
Oil Sleeve 6B-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Drive Shaft Bearing Race 6B-26. . . . . . . .
Shift Shaft 6B-27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6B-29. . . . . . . . . . .
Reassembly/Installation 6B-30. . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6B-30. . . . . . . . . . .
Shift Shaft 6B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier 6B-33. . . . . . . . . . . . . . . . . . . . . . .
Forward Gear 6B-37. . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 6B-39. . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Wear Sleeve 6B-40. . . . . . . . . . . . . .
Drive Shaft Lower Bearing Race 6B-42. . . . . . . .
Oil Sleeve 6B-43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Upper Bearing 6B-43. . . . . . . . . . . . .
Forward Gear, Drive Shaft Lower Bearing
Pinion Gear, and Drive Shaft 6B-45. . . . . . . . . . .
Pinion Gear Depth and
Forward Gear Backlash 6B-46. . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft 6B-51. . . . .
Water Pump 6B-53. . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Pressure Test 6B-57. . . . . . . . . . .
Filling Gear Housing With Lubricant 6B-58. . . . . . .
Gearcase Installation 6B-59. . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment and Replacement 6B-64. .
Specifications
GEAR HOUSING
BIGFOOT
(2.31:1)
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Pinion Gear Locating Tool
Flat Number
Disc Number
Forward Gear Backlash
Backlash Indicating Tool
Mark Number
Water Pressure
@ 800 rpm
@ 6000 rpm (WOT)
Leak Test Pressure
2.31:1
24.0 fl oz (710 mL)
Premium Blend Gear Lube
30 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
91-12349A2
#8
#3
0.012 - 0.019 in. (0.30 - 0.48 mm)
91-78473
#4
2-6 psi (14-41 kPa)
12-25 psi (83-172 kPa)
10-12 psi (69-83 kPa)
for 5 Minutes