Mercury 45 Service Manual

6
A
NON-BIGFOOT GEAR HOUSING
Page 6A-190-828631R3 MARCH 1999
LOWER UNIT
Section 6A - Non-Bigfoot Gear Housing
Table of Contents
Specifications 6A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricants and Service Aids 6A-5. . . . . .
Gear Housing (Driveshaft)
(1.83:1 Gear Ratio) 6A-6. . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Prop Shaft)
(1.83:1 Gear Ratio) 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. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Seals 6A-22. . . . . . . . . . . . . . . . . . . . .
Inspection 6A-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Drive Shaft Bearing 6A-24. . . . . . . . . . . . . .
Pinion Gear Bearing 6A-25. . . . . . . . . . . . . . . . . . .
Pinion Gear 6A-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear 6A-25. . . . . . . . . . . . . . . . . . . . . . . . .
Shift Shaft 6A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Disassembly 6A-29. . . . . . . . . . . .
Propeller Shaft and Carrier Inspection 6A-30. . . . . .
Clutch 6A-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Follower 6A-30. . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear 6A-30. . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear Bearing 6A-31. . . . . . . . . . . . . . . . .
Bearing Carrier 6A-32. . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Reassembly 6A-36. . . . . . . . . . . . . . . .
Shift Shaft Assembly 6A-36. . . . . . . . . . . . . . . . . . .
Pinion Bearing Race 6A-37. . . . . . . . . . . . . . . . . . .
Forward Gear 6A-38. . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear/Drive Shaft Assembly 6A-39. . . . . . .
Propeller Shaft 6A-40. . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier 6A-42. . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6A-43. . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Pressure Test 6A-46. . . . . . . . . . . . . . .
Gear Housing Installation 6A-47. . . . . . . . . . . . . . . . . .
2-Stroke Models 6A-48. . . . . . . . . . . . . . . . . . . . . . .
4-Stroke Models 6A-48. . . . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment and Replacement 6A-49. . . . .
Filling Gear Housing with Lubricant 6A-51. . . . . .
Specifications
1995/1996
GEAR HOUSING
(2.00:1)
45/50 1995/1996 models
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Forward Gear Backlash
Water Pressure
@ 750 rpm (Idle)
@ 6000 rpm (WOT)
2.00:1
14.9 fl oz (440 mL)
Quicksilver Gear Lube-Premium Blend
26 Spiral/Bevel
13 Spiral/Bevel
No Adjustment
2-4 psi (14-28 kPa)
12-17 psi (69-103 kPa)
1997 AND NEWER
GEAR HOUSING
(1.83:1)
45/50 1997 and Newer models
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Forward Gear Backlash
Water Pressure
@ 750 rpm (Idle)
@ 6000 rpm (WOT)
1.83:1
14.9 fl oz (440 mL)
Quicksilver Gear Lube-Premium Blend
22 Spiral/Bevel
12 Spiral/Bevel
No Adjustment
2-4 psi (14-28 kPa)
12-17 psi (69-103 kPa)

Mercury 45 Specifications

General

Horsepower	45 HP
Cylinders	3
Starting	Electric
Full Throttle RPM Range	5000-6000 RPM
Steering	Remote
Exhaust	Through Prop
Shaft Length	20 in