Transmission Installation - Mercury MerCruiser Service Manual

ZF/45C, 45IV, 63A, 65IV Transmissions
a. Disconnect the shift cable from the transmission.
b. Disconnect the wires from the neutral start switch.
IMPORTANT: Make note of how the transmission harness is routed and connected for future reference.
5. On DTS transmissions, disconnect the transmission harness from the shift solenoids and pressure transducers.
6. Disconnect the wires from the transmission fluid temperature switch.
7. Loosen the trunnion clamping fasteners on the engine mounts (port and starboard).
8. Remove the nuts and bolts from the coupling, and separate the propeller shaft coupler from the transmission output flange.
9. Remove the four rear‑engine‑mount‑to‑engine‑bed fasteners and hardware.
10. Support the rear of the engine using a suitable hoist, or put wooden blocks under the flywheel housing.
11. Support the transmission with a hoist or other suitable means through the lifting eye on the transmission case.
12. Remove the port and starboard rear mount brackets (with base and trunnion) from the transmission.
The weight of an unsupported transmission can bend the transmission input shaft or damage the engine coupler. Do not
permit the splines of the input shaft or coupler to support the weight of the transmission. Completely support the transmission
during removal, and until the attaching hardware is secured during installation.
13. Remove all hardware attaching the transmission to the flywheel housing.
14. Pull the transmission straight back and away from the engine to completely disengage the splines on the input shaft.
15. Carefully lift out the transmission.

Transmission Installation

1. Check the transmission output shaft rolling torque. Refer to the manufacturer's service manual for procedures,
specifications, and corrective actions.
2. Apply Engine Coupler Spline Grease to the transmission input shaft splines and the engine drive plate splines.
Tube Ref No.
Engine Coupler Spline
91
Grease
3. Using a suitable hoist, position the transmission in the boat and align the transmission splines with the drive plate splines.
4. Push the transmission into place and secure it to the flywheel housing. Tighten the fasteners to the specified torque.
Description
Transmission‑to‑flywheel‑housing fasteners
5. Disconnect the hoist.
6. Attach the rear mount brackets to the transmission. Tighten the fasteners and hardware to the specified torque.
Description
Rear mount bracket fasteners
7. Using a hoist, raise the engine and transmission to remove blocks, if employed.
8. Lower the assembly to the engine bed.
9. Relieve hoist tension.
10. Securely tighten the four rear‑engine‑mount‑to‑bed fasteners and hardware.
11. Install the transmission fluid cooler hoses. Tighten the hose fittings at the transmission housing to the specified torque.
Description
Transmission fluid cooler hose fitting
12. For non‑DTS transmissions:
a. Connect the neutral start switch and fluid temperature switch wiring connectors.
Page 9A-14
Description
Transmission input shaft splines and engine drive plate
© 2016 Mercury Marine
NOTICE
Where Used
splines
Nm lb‑in.
61 –
Nm lb‑in.
61 –
Nm lb‑in.
34 –
90-8M0099748 eng DECEMBER 2015
Part No.
8M0071842
lb‑ft
45
lb‑ft
45
lb‑ft
25