Gear Housing Pressure Test; Gear Housing Installation; Filling Gear Housing With Lubricant - Mercury 40 Service Manual

Gear Housing Pressure Test

1. Remove vent plug and install pressure test
gauge. Tighten securely.
2. Pressurize housing to 10-12 PSI (69-83 kPa) and
observe gauge for 5 minutes.
3. Rotate drive shaft, prop shaft and move shift rod
while housing is pressurized to check for leaks.
4. If pressure drop is noted immerse housing in wa-
ter.
5. Re-pressurize to 10-12 PSI (69-83 kPa) and
check for air bubbles.
6. Replace leaking seals as necessary. Retest
housing.
NOTE: It should hold 10-12 PSI (69-83 kPa) for 5
minutes.
7. Remove tester from housing and install vent
plug.
90-852572R1 JANUARY 1998

Gear Housing Installation

Filling Gear Housing with Lubricant

NOTE: Gear housing lubricant capacity is approxi-
mately 14.9 fl. oz. (440 ml).
WARNING
If gear housing is installed on outboard, discon-
nect (and isolate) spark plug leads from spark
plugs before working near the propeller.
CAUTION
Do not use automotive grease in the gear hous-
ing. Use only Quicksilver Gear Lube.
1. Remove any gasket material from "Fill" and
"Vent" plugs and gear housing. Install new gas-
kets on "Fill" and "Vent" plugs.
IMPORTANT: Never add lubricant without remov-
ing "Vent" plug. Gear housing cannot be filled
because of trapped air. Fill gear housing when
driveshaft is in a vertical position.
2. Remove "Fill" plug and gasket.
3. Insert lubricant tube in "Fill" hole, then remove
"Vent" plug and gasket.
4. Fill until excess lubricant flows out of "Vent" hole.
5. Replace this "Vent" plug and gasket.
6. Install "Fill" plug and gasket.
a - "Vent" Plug
7. Torque "Fill" and "Vent" screws to 55 lb. in. (6.2
N·m).
a
LOWER UNIT - 6A-27