Mercury 40 Service Manual page 491

NON-BIGFOOT GEAR HOUSING
Gear Housing Reassembly
IMPORTANT: This gear case assembly does not have have any shims for the gear as-
semblies. Backlash cannot be adjusted. The mechanic must verify that all bearing
races are firmly seated in the gear case during reassembly and that all gear case com-
ponents are in serviceable condition. Prior to installing the seal carrier and water
pump assembly on the drive shaft, the FORWARD gear should be held stationary
(with a screw driver or similar tool). While pulling up on the drive shaft, lightly turn
the shaft back and forth. A light "clicking" sound should be heard indicating the pres-
ence of backlash between FORWARD and PINION gears. If this backlash is not pres-
ent, the pinion gear race and/or forward gear race are not fully seated. Races should
be removed and inspected for debris. Reinstall races and check backlash. If backlash
is still not present, replace gear housing.
Shift Shaft Assembly
1. Apply 2-4-C w/Teflon to new O-rings and install O-rings on shift shaft and carrier.
2. Install carrier on shift shaft.
IMPORTANT: When installing shift shaft assembly into gear housing, DO NOT BOT-
TOM OUT SHAFT IN HOUSING. Pull up on shift shaft until shift boot is not deformed.
If shaft is bottomed out, cross pin in clutch dog will be bent by cam follower when
tightening carrier bolts.
3. Install shift shaft/carrier assembly into gear housing.
4. Secure boot to carrier with sta-strap.
5. Position shift shaft so ramp faces towards propeller shaft.
a -
b -
c -
d -
e -
Page 6A-36
e
95
2-4-C w/Teflon (92-850736A1)
O-rings
Carrier
Boot
Sta-strap
Ramp
d
c
a
95
b
52841
90-828631R3 MARCH 1999