Mercury 40 Service Manual page 502

Gear Housing Installation
Disconnect (and isolate) spark plug leads before installing gear housing onto drive
shaft housing.
1. Position shift lever in NEUTRAL gear position.
2. Tilt engine to full "Up" position. Engage tilt lock lever.
3. Shift gear housing into NEUTRAL. Propeller shaft will rotate freely in either direction.
IMPORTANT: Liberally apply 2-4-C Marine Lubricant w/Teflon to drive shaft splines.
4. Position drive shaft into drive shaft housing. Move gear housing upwards in drive shaft
housing while aligning both shift shafts, water tube seal and drive shaft splines.
NOTE: If the drive shaft splines will not align with the crankshaft splines, rotate flywheel
slightly while pushing gear housing into drive shaft housing.
5. Install 4 bolts and washers, (two each side). Torque bolts to specified torque.
a -
90-828631R3 MARCH 1999
Bolt and Washers (2 each side)
Gear Housing Bolt Torque
40 lb-ft (54.2 Nm)
WARNING
a
52836
NON-BIGFOOT GEAR HOUSING
Page 6A-47