TOHATSU 40 Service Manual page 155

SECTION 6
22. Align the clutch push rod with the clutch cam and slide
40
the propeller shaft and housing into the gearcase opening.
Push forward and rotate the propeller shaft as needed until bevel
gears have engaged. Ensure the propeller shaft housing bolts are
completely clean and apply Loctite 242 to the bolt threads. Install
and torque the bolts evenly to prevent improper seating of the
housing.
23. Move the cam rod to each position and rotate the
41
driveshaft to test gearcase function in all gears. Check the
propeller shaft for looseness in the forward and reverse directions.
If looseness exceeds 0.016 in [0.40 mm], replace bevel gear C
washer (28) with one of correct thickness.
Refer to current Parts Catalog for washer availability.
24. Before adding gear oil, pressure test and vacuum test
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the gearcase as follows:
• Remove the oil level plug and install gearcase pressure tester.
• Pump pressure tester until gauge indicates 3 - 6 psi [21 - 42 kPa
/ 0.2 - 0.4 kg/cm ]. If pressure loss occurs, determine source of
2
leakage by submerging gearcase in water. Make necessary
repairs to correct the problem and retest.
• Remove the pressure tester and install gearcase vacuum tester.
6-18
T1400
T1401
NOTE
T1402
3-/ 4-Cylinder