Assembly; Disassembly; Pre-Disassembly Inspection - BRP Johnson J30TEL4SUA 2007 Service Manual

Assembly

Install a new gasket and the plate on top of the
gearcase.
Insert the impeller key in the driveshaft, then slide
the impeller onto the driveshaft. Make sure that
the key and keyway on the impeller are aligned.
2
1
1. Impeller housing plate
2. Impeller
3. Impeller key
Install the impeller housing while rotating the
driveshaft clockwise to flex the impeller vanes in
the correct direction.
Install and tighten four (4) nuts to a torque of 71 in.
lbs. (8 N·m).
1
2
1. Impeller housing
2. Nuts (4)

DISASSEMBLY

IMPORTANT:
during disassembly. Replace all damaged compo-
nents, seals, O-rings, and gaskets upon assem-
bly.

Pre-Disassembly Inspection

Before disassembling the gearcase, examine the
following:
•
Gearcase housing — All gasket surfaces must
be free of gasket material. All threaded holes
must be free of corrosion and sealer. Make sure
that the inside of the gearcase is clean and free
3
of debris.
•
Gearcase anode — If the anode has been
reduced to two-thirds of its original size, it must
be replaced.
001890
•
Driveshaft — Check the splines for chips, wear,
and cracks. Bearing and gear surfaces must not
show signs of metal transfer, corrosion, or dis-
coloration. Severe spline wear might indicate a
exhaust housing or gearcase that has been dis-
torted by impact damage.
•
Propeller Shaft — Check for bent or damaged
shaft. Check for twisted splines and damaged
threads.
•
Shift Rod — Check for misadjusted, bent, or
binding rod. A misadjusted shift rod height can
cause shift difficulty, loss of boat and outboard
control, and gearcase damage.
•
Water intake screen — The screen must be
clear. If the screen cannot be adequately
cleaned, replace it. Different screens are avail-
able and should not be mixed. Refer to the cor-
rect parts manual for listing and description.
•
Water pump — Check impeller for wear, crum-
bling, and hub bonding. Check impeller cup and
plate for scoring and distortion.
001891
GEARCASE
DISASSEMBLY
Clean and inspect all components
9
205