Mercury BRAVO Service Manual

90-863160 MAY 2000 Page vii
Section 3D - Gear Housing - Bravo Three
Table of Contents 3D-1. . . . . . . . . . . . . . . . . . . . .
Specifications 3D-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3D-2. . . . . . . . . . . . . . .
Bearing Preloads 3D-2. . . . . . . . . . . . . . . . . . .
Gear Ratio - Teeth per Gear
(Gear Housing) 3D-2. . . . . . . . . . . . . . . . . . . .
Torque Conversion Chart For
Bearing Carrier 3D-3. . . . . . . . . . . . . . . . . . . .
Torque Conversion Chart For
Bearing Retainer Nut 3D-3. . . . . . . . . . . . . . .
Torquing Outer Prop Shaft Bearing
Retainer and Bearing Carrier 3D-4. . . . . . . .
Lubricants/Sealants/Adhesives 3D-4. . . . . . . . . .
Tools 3D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Gear Housing
Exploded View 3D-6. . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft and Propeller Shaft
Components 3D-6. . . . . . . . . . . . . . . . . . . . . . .
Pre-Disassembly Inspection 3D-8. . . . . . . . . . . .
Gear Housing Disassembly 3D-9. . . . . . . . . . . . .
Driveshaft And Pinion Bearing 3D-16. . . . . . . . .
Inspection and Cleaning 3D-16. . . . . . . . . . . .
Drive Shaft Disassembly 3D-17. . . . . . . . . . . .
Drive Shaft Reassembly 3D-17. . . . . . . . . . . .
Pinion Bearing 3D-18. . . . . . . . . . . . . . . . . . . . . . .
Removal 3D-18. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3D-19. . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 3D-19. . . . . . . . . . . . . . . . . . . . . . .
Inspection 3D-19. . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3D-20. . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Spline Lash Check 3D-21. . .
Outer Propeller Shaft Servicing 3D-23. . . . . .
Front Driven Gear And Bearing 3D-24. . . . . . . .
Inspection 3D-24. . . . . . . . . . . . . . . . . . . . . . . .
Bearing Removal 3D-24. . . . . . . . . . . . . . . . . .
Bearing Installation 3D-24. . . . . . . . . . . . . . . .
Bearing Cup Removal 3D-25. . . . . . . . . . . . . .
Bearing Cup Installation 3D-25. . . . . . . . . . . .
Bearing Carrier Seal And Bearing 3D-26. . . . . .
Inspection 3D-26. . . . . . . . . . . . . . . . . . . . . . . .
Removal 3D-26. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3D-26. . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Water Passage 3D-27. . . . . . . . . .
Inspection and Cleaning 3D-27. . . . . . . . . . . .
Seal Removal 3D-28. . . . . . . . . . . . . . . . . . . . .
Seal Installation 3D-28. . . . . . . . . . . . . . . . . . .
Gear Housing Reassembly and
Shimming 3D-29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Backlash 3D-36. . . . . . . . . . . . . . . .
Installing Gear Housing On Drive
Shaft Housing 3D-42. . . . . . . . . . . . . . . . . . . .
Propeller Installation 3D-43. . . . . . . . . . . . . . . . . .
TRANSOM ASSEMBLY
Section 4A - Service Procedures Requiring Minor Disassembly
Bravo Transom Assembly Specifications 4A-2.
Torque Specifications 4A-2. . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 4A-2. . . . .
Tools 4A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Transom Assembly
Exploded Views 4A-4. . . . . . . . . . . . . . . . . . . . . .
Inner Transom Plate Components 4A-4. . . .
Bell Housing Components 4A-5. . . . . . . . . . .
Gimbal Ring Components 4A-6. . . . . . . . . . . .
Gimbal Housing Components 4A-8. . . . . . . .
Special Information 4A-10. . . . . . . . . . . . . . . . . . .
Trim Limit Switch 4A-10. . . . . . . . . . . . . . . . . .
Trim Position Sender 4A-10. . . . . . . . . . . . . . .
Removal 4A-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-12. . . . . . . . . . . . . . . . . . . . . . . .
Trim Position Sender Adjustment 4A-16. . . .
Trim Limit Switch Adjustment 4A-16. . . . . . . .
High Performance Transom
Assembly - Without Electrical
Trim Sender and Trim Limit Switch 4A-18. .
Gimbal Bearing 4A-19. . . . . . . . . . . . . . . . . . . . . .
Inspection 4A-19. . . . . . . . . . . . . . . . . . . . . . . .
Removal 4A-19. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-20. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable 4A-22. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4A-22. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 4A-23. . . . . . . . . . . . . .
Exhaust Bellows (If Equipped) 4A-27. . . . . . . . .
Removal 4A-27. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-27. . . . . . . . . . . .
Installation 4A-28. . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Tube (If Equipped) 4A-30. . . . . . . . . . . .
Removal 4A-30. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-30. . . . . . . . . . . .
Installation 4A-31. . . . . . . . . . . . . . . . . . . . . . . .
Water Hose and Water Fitting 4A-32. . . . . . . . . .
Removal 4A-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-33. . . . . . . . . . . . . . . . . . . . . . . .
Crimp Clamp Tool 4A-35. . . . . . . . . . . . . . . . . . . .

Mercury BRAVO Specifications

General

Brand	Mercury
Model	BRAVO
Category	Engine
Language	English