Lower Unit - TOHATSU TLDI MD 115A SERIES Service Manual

1. Special tools .............................. 6-2
2. Parts Layout .............................. 6-4
Gear Case (Drive Shaft) ..................... 6-4
Gear Case (Propeller Shaft) ............... 6-6
3. Inspection Items ........................ 6-8
1) Draining Gear Oil ........................ 6-8
2) Removing Propeller ..................... 6-8
3) Removing Lower Unit .................. 6-9
4) Removing Water Pump ............... 6-10
5) Inspection of Water Pump ............ 6-11
6) Disassembly of Water Pump Case (Lower) ... 6-12
7) Assembly of Water Pump Case (Lower) ... 6-12
8) Removing Propeller Shaft Housing Ass'y ... 6-13
9) Disassembly of Propeller Shaft Housing Ass'y ... 6-14
10) Inspection of Propeller Shaft Housing... 6-15
11) Assembly of Propeller Shaft Housing ... 6-16
12) Disassembly of Propeller Shaft Ass'y ... 6-19
13) Inspection of Propeller Shaft Ass'y ... 6-20
14) Assembly of Propeller Shaft Ass'y ... 6-20
15) Disassembly of Cam Rod ............ 6-21
16) Inspection of Clutch Cam ............ 6-22
17) Assembly of Clutch Cam Parts ...... 6-22
18) Removing Forward (A) Gear Ass'y ... 6-23
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Lower Unit

19) Disassembly of Forward Gear (A) Gear ... 6-24
20) Inspection of Forward (A) Gear ...... 6-24
21) Assembly of Forward (A) Gear Parts ... 6-25
22) Removing Drive Shaft Ass'y ......... 6-26
23) Disassembly of Drive Shaft Ass'y ... 6-27
24) Inspection of Drive Shaft............... 6-28
25) Assembly of Drive Shaft Parts ...... 6-28
26) Disassembly of Gear Case............ 6-30
27) Inspection of Forward (A) Gear and
Pinion (B) Gear........................... 6-31
28) Inspection of Gear Case ............... 6-31
29) Assembly of Gear Case Parts ...... 6-32
30) Assembly of Lower Unit Parts ...... 6-34
31) Attaching Clutch Cam Ass'y ......... 6-37
32) Installation of Lower Unit ............ 6-38
33) Measurement of Pinion (B) Gear Height
and Shim Selection ..................... 6-40
34) Measurement of Back Lash between Forward (A) and
Pinion (B) Gears and Shim Selection ......... 6-42
35) Measurement of Back Lash between Pinion (B) and
Reverse (C) Gears and Shim Selection ...... 6-45
36) Measurement of Propeller Shaft Play and
Selection of Washer Thickness ......... 6-48
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