Mercury BRAVO Service Manual

90-863160 MAY 2000 Page v
REMOVAL, INSTALLATION AND ADJUSTMENT
Section 2A - All Models
Torque Specifications 2A-2. . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 2A-2. . . . . . .
Tools 2A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transom Specifications 2A-3. . . . . . . . . . . . . . . .
Checking Transom Thickness 2A-3. . . . . . . .
Special Information 2A-4. . . . . . . . . . . . . . . . . . . .
Bravo Three Notice:
Trim-In Limit Insert 2A-4. . . . . . . . . . . . . . . . .
Sterndrive Unit Removal 2A-6. . . . . . . . . . . . . . .
Transom Assembly Removal 2A-8. . . . . . . . . . . .
Transom Assembly Installation 2A-12. . . . . . . . .
Sterndrive Unit Installation 2A-22. . . . . . . . . . . . .
Shift Cable Installation
and Adjustment 2A-29. . . . . . . . . . . . . . . . . . .
Troubleshooting Shift Problems 2A-33. . . . . .
STERNDRIVE UNIT
Section 3A - Drive Shaft Housing
Specifications 3A-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3A-2. . . . . . . . . . . . . . .
Tools 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Preloads 3A-3. . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 3A-3. . . . .
Drive Shaft Housing Exploded View 3A-4. . . . . .
Complete Housing 3A-4. . . . . . . . . . . . . . . . . .
Exploded Parts View (Clutch) 3A-6. . . . . . . . . . .
Exploded Parts View (Shifter) 3A-7. . . . . . . . . . .
Standard Bravo U-joint Assembly 3A-8. . . . .
Bravo X, XZ, XR and Diesel
Bravo U–joint Assembly 3A-9. . . . . . . . . . . . .
Drive Shaft Housing and Gear
Case Separation 3A-10. . . . . . . . . . . . . . . . . . . . .
Drive Unit Gear Ratio Identification 3A-10. . .
Bravo One 3A-10. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Two 3A-10. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three 3A-11. . . . . . . . . . . . . . . . . . . . . .
Bravo XZ 3A-11. . . . . . . . . . . . . . . . . . . . . . . . .
Bravo XR 3A-12. . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Bravo One X 3A-12. . . . . . . . . . . . . . . .
Diesel Bravo Two X 3A-12. . . . . . . . . . . . . . . .
Diesel Bravo Three X 3A-13. . . . . . . . . . . . . .
Separate Housings 3A-14. . . . . . . . . . . . . . . .
Drive Shaft Housing Disassembly 3A-17. . . . . .
Shifter Repair 3A-22. . . . . . . . . . . . . . . . . . . . . . . .
Shifter Inspection 3A-25. . . . . . . . . . . . . . . . . . . . .
Shifter Reassembly 3A-26. . . . . . . . . . . . . . . . . . .
U-Joint and Pinion Gear 3A-30. . . . . . . . . . . . . . .
Inspection 3A-30. . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-30. . . . . . . . . . . . . . . . . . . . . .
Reassembly 3A-34. . . . . . . . . . . . . . . . . . . . . .
Gear Disassembly,
Inspection and Reassembly 3A-42. . . . . . . . . . .
Disassembly 3A-42. . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-44. . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 3A-44. . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Housing and Top Cover -
Bearings and Bearing Sleeves 3A-47. . . . . . . . .
Inspection 3A-47. . . . . . . . . . . . . . . . . . . . . . . .
Bearing Sleeve Removal (Top Cover) 3A-47
Bearing Sleeve Removal
(Drive Shaft Housing) 3A-48. . . . . . . . . . . . . .
Roller Bearing Removal 3A-49. . . . . . . . . . . .
Steel Bearing Adaptor Removal 3A-51. . . . .
Steel Bearing Adaptor Installation 3A-52. . . .
Bearing Sleeve Installation 3A-53. . . . . . . . . .
Roller Bearing Installation 3A-54. . . . . . . . . . .
Drive Shaft Housing Reassembly 3A-55. . . . . . .
Install Gear Housing To Drive
Shaft Housing 3A-66. . . . . . . . . . . . . . . . . . . . .

Mercury BRAVO Specifications

General

Brand	Mercury
Model	BRAVO
Category	Engine
Language	English