Mercury FourStroke 3.5 - Lower Unit

Gear Housing
90-8M0065421 NOVEMBER 2012 Page 6A-1
6
A
Lower Unit
Section 6A - Gear Housing
Table of Contents
Gear Housing Specifications..............................................6A-2
Gear Housing (Driveshaft)................................................. 6A-4
Gear Housing (Propeller Shaft)..........................................6A-6
Shift Linkage Components.................................................6A-8
General Service Recommendations................................ 6A-10
Bearings....................................................................6A-10
Shims........................................................................6A-10
Seals.........................................................................6A-10
Draining and Inspecting the Gear Housing Lubricant...... 6A-10
Propeller Removal.................................................... 6A-11
Gear Housing Removal............................................ 6A-11
Gear Housing Disassembly............................................. 6A-13
Water Pump..............................................................6A-13
Bearing Carrier and Propeller Shaft..........................6A-15
Propeller Shaft Disassembly.....................................6A-17
Driveshaft, Pinion Gear, and Forward Gear............. 6A-18
Upper Driveshaft Bearing......................................... 6A-19
Lower Driveshaft Bearing/Forward Gear Bearing.....6A-20
Gear Housing Assembly.................................................. 6A-21
Propeller Shaft Assembly......................................... 6A-21
Lower Driveshaft Bearing......................................... 6A-21
Forward Gear Bearing.............................................. 6A-21
Forward Gear............................................................6A-22
Driveshaft..................................................................6A-23
Bearing Carrier Assembly.........................................6A-24
Shift Shaft................................................................. 6A-25
Forward Gear Backlash............................................ 6A-26
Propeller Shaft.......................................................... 6A-26
Bearing Carrier......................................................... 6A-26
Water Pump..............................................................6A-27
Gear Housing...................................................................6A-28
Filling the Gear Housing with Lubricant.................... 6A-28
Gear Housing Installation......................................... 6A-29
Propeller Installation................................................. 6A-31