Mercury 40 Service Manual page 456

Section 6A - Non-Bigfoot Gear Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricants and Service Aids
Gear Housing (Driveshaft)
(1.83:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Prop Shaft)
(1.83:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . .
General Service Recommendations
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Lubricant
Gear Housing Removal . . . . . . . . . . . . . . . . . . .
2-Stroke Models . . . . . . . . . . . . . . . . . . . . . . .
4-Stroke Models . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Seals . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Drive Shaft Bearing
Pinion Gear Bearing . . . . . . . . . . . . . . . . . . .
Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications
1995/1996
GEAR HOUSING
(2.00:1)
1997 AND NEWER
GEAR HOUSING
(1.83:1)
90-828631R3 MARCH 1999
LOWER UNIT
6A-1
6A-2
. . . . . . 6A-5
6A-6
6A-8
. . . . . . . . 6A-10
6A-10
6A-10
. . . . . 6A-11
6A-12
6A-12
6A-13
6A-15
6A-15
6A-22
6A-24
. . . . . . . . . . . . . . 6A-24
6A-25
6A-25
6A-25
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)
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)
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Disassembly
Propeller Shaft and Carrier Inspection
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear Bearing
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Reassembly
Shift Shaft Assembly . . . . . . . . . . . . . . . . . . .
Pinion Bearing Race . . . . . . . . . . . . . . . . . . .
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear/Drive Shaft Assembly
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Pressure Test
Gear Housing Installation . . . . . . . . . . . . . . . . . .
2-Stroke Models . . . . . . . . . . . . . . . . . . . . . . .
4-Stroke Models . . . . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment and Replacement
Filling Gear Housing with Lubricant
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)
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)
NON-BIGFOOT GEAR HOUSING
6A-28
. . . . . . . . . . . . 6A-29
. . . . . . 6A-30
6A-30
6A-30
6A-30
. . . . . . . . . . . . . . . . . 6A-31
6A-32
. . . . . . . . . . . . . . . . 6A-36
6A-36
6A-37
6A-38
. . . . . . . 6A-39
6A-40
6A-42
6A-43
. . . . . . . . . . . . . . . 6A-46
6A-47
6A-48
6A-48
. . . . . 6A-49
. . . . . . 6A-51
2.00:1
1.83:1
Page 6A-1
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