Gearcase Installation - Mercury 45 Jet 50-55 Service Manual

Gearcase Installation

WARNING
Disconnect (and isolate) spark plug leads from
spark plugs before installing gear housing onto
drive shaft housing. Failure to follow this warning
could result in accidental engine starting and
possible injury.
1. Position shift block in forward gear position,
as shown.
a
a - Shift Block; Front of Block MUST Extend 1/8I (3.2mm) Past
Front of Rail.
b - Rail
2. Tilt engine to full up position and engage tilt lock
lever.
3. Shift gear housing into neutral position. Propeller
shaft will rotate freely in either direction.
4. Install water tube seal; lube I.D. of seal with Quick-
silver 2-4-C w/Teflon (92-825407A12).
5. Apply a bead of RTV Sealer as shown.
a
b
a - Water Tube Seal
b - RTV Sealer
90-817643R1 DECEMBER 1996
Do not use lubricant on top of drive shaft. Excess
lubricant, that is trapped in clearance space, will
not allow drive shaft to fully engage with
crankshaft. Subsequently, tightening the gear
housing fasteners (while lubricant is on top of
drive shaft) will load the drive shaft/crankshaft
and damage either or both the power head and
gear housing. Top of drive shaft is to be wiped free
of lubricant.
6. Apply a light coat of Quicksilver 2-4-C w/Teflon
b
onto drive shaft splines.
7. Apply a light coat of Quicksilver 2-4-C w/Teflon on
gear case shift shaft splines and upper shift shaft
splines. Do not use lubricant on ends of shift
shafts.
8. Install components as shown in appropriate
photo.
19879
a - Nylon Spacer
b - Shift Shaft Coupler; Used on Models Equipped with Power
Trim
53938
CAUTION
b
LOWER UNIT - 6B-33
a
53968