Lower Unit - TOHATSU MFS25 Service Manual

1 Special Tools
.................................... 6-2
2 Parts Layout .................................
Gear Case ............................................. 6-4
Drive System & Water Pump ..................... 6-5
Shift ...................................................... 6-7
3 Inspection Items
........................... 6-8
1) Draining Gear Oil ................................. 6-8
2) Removing Propeller .............................. 6-8
3) Removing Lower Unit ........................... 6-9
4) Disassembly of Water Pump .................. 6-9
5) Inspection of Water Pump ..................... 6-10
6) Removing Propeller Shaft Housing Ass'y ... 6-10
7) Disassembly of Propeller Shaft Ass'y ...... 6-11
8) Inspection of Propeller Shaft .................. 6-11
9) Assembly of Propeller Shaft Ass'y ......... 6-11
10) Disassembly of Propeller Shaft Housing ... 6-12
11) Inspection of Propeller Shaft Housing ...... 6-13
12) Assembly of Propeller Shaft Housing ...... 6-14
13) Removing Pump Case (Lower) ............... 6-15
14) Disassembly of Pump Case (Lower)......... 6-15
15) Assembly of Pump Case (Lower) ............ 6-15
16) Removing Clutch Cam and Cam Rod ...... 6-15
6

Lower Unit

17) Disassembly of Clutch Cam and Cam Rod ... 6-15
18) Inspection of Cam Rod and Clutch Cam ... 6-16
6-4
19) Assembly of Cam Rod and Clutch Cam... 6-16
20) Removing Drive Shaft ..................... 6-16
21) Disassembly of Drive Shaft ............... 6-16
22) Inspection of Drive Shaft .................. 6-17
23) Disassembly of Forward Gear (A Gear)... 6-17
24) Inspection of Pinion Gear (B Gear)
and Forward Gear (A Gear) ............... 6-17
25) Assembly of Forward Gear (A Gear) ... 6-17
26) Assembly of Drive Shaft .................. 6-18
27) Disassembly of Gear Case ............... 6-18
28) Inspection of Gear Case .................. 6-19
29) Assembly of Lower Unit..................... 6-19
30) Installation of Pinion Gear (B Gear) ... 6-20
31) Settling Pinion Gear (B Gear) Height ... 6-21
32) Settling Forward Gear (A Gear) Backlash ... 6-24
33) Reassembly of Pinion Gear Nut (B Gear Nut) ... 6-27
34) Assembly of Propeller Shaft Housing ... 6-27
35) Reassembly of Pump Case (Lower) ... 6-28
36) Assembly of Water Pump .................. 6-28
37) Installation of Lower Unit .................. 6-30
6