Pinion Shaft Removal - Mercury 200 OptiMax Jet Drive Service Manual

Pump Unit
Gear Housing Pressure
Without gear lubricant for five minutes without leakage
NOTE: When draining the gearcase for the first time, the lubricant may appear cream colored due to the mixing of assembly
lubricant and gear lubricant. This is not an indication of water intrusion. If, during the subsequent draining of the gearcase,
the lubricant appears cream colored or milky, water may be present. Gearcase should be disassembled and all gaskets,
seals, and O‑rings replaced. Inspect all components for water damage.
NOTE: Gear lubricant drained from a recently run gearcase will be a light chocolate brown in color due to agitation/aeration.
Oil which is stabilized will be a clear yellow brown in color.
Filling the Drive Housing
IMPORTANT: The drive housing must be level and upright to obtain the correct fluid level.
1. Remove the fill/drain plugs.
2. Slowly fill the drive housing through the fill hole with High Performance Gear Lubricant until lubricant flows out of the vent hole
and no air bubbles are visible.
3. Install the vent screw into the vent hole.
IMPORTANT: Do not lose more than 30 cc (1 fl oz) of gear lubricant while installing the fill screw.
4. Remove the fill hose and fitting from the fill hole and quickly install the fill screw into the fill hole. Tighten the fill and vent screws
to the specified torque.
Tube Ref No.
High Performance Gear
87
Lubricant
Description
Fill and vent screws

Pinion Shaft Removal

1. Remove the four screws securing the pinion shaft housing to the drive housing. Remove the pinion shaft assembly.
NOTE: Take care not to damage or misplace the shims.
Page 5A-30
Description
69–83 kPa (10–12 psi)
Where Used
Drive housing
Nm
7
45265
90-8M0050731 MAY 2011
Part No.
92-858064K01
lb‑in. lb‑ft
62