Mercury 40 FourStroke - Page 487

BIGFOOT GEAR HOUSING
90-857046R1 NOVEMBER 2001 Page 6B-21
Pinion Gear, Drive Shaft, and Forward Gear
1. Hold drive shaft using Drive Shaft Holding Tool. Remove (and discard) pinion nut.
Model Drive Shaft Holding Tool
40/50 Bigfoot (4-Stroke, 747cc/935cc) 91-56775
40/50/60 Bigfoot (4-Stroke, 995cc) 91-877840A1
75/90/115 EFI (4-Stroke) 91-804776A1
60 Bigfoot (2-Stroke) 91-56775
75/90/100/115/125 (2-Stroke) 91-56775
2. Remove drive shaft, pinion gear, pinion bearing and forward gear.
3. Replace pinion gear if it is chipped or worn.
4. Replace pinion bearing and race if either are rusted, pitted or damaged; or if bearing
does not roll freely. To remove race, refer to “Lower Drive Shaft Bearing Race,” following.
5. Replace forward gear if gear teeth or clutch teeth are chipped or worn.
19175
a
b
c
d
e
f
a- Drive Shaft Holding Tool
b- Pinion Nut
c- Drive Shaft
d- Pinion Gear
e- Pinion Bearing
f- Forward Gear