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COX CXO300 Manual
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COX CXO300 Manual

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WATER PUMP
REPLACEMENT GUIDE
(VESSEL)
–––
CXO300 – designed
for purpose
coxmarine.com

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Summary of Contents for COX CXO300

  • Page 1 WATER PUMP REPLACEMENT GUIDE (VESSEL) ––– CXO300 – designed for purpose coxmarine.com...
  • Page 2 - Trim PTT Up Trim PTT up Action Description Raise PTT angle, high enough for the transmission assembly to clear.
  • Page 3 - Remove Propeller Assembly Remove propeller assembly. Action Description Un-screw the propeller securing fastener. Remove and Discard the single use nut. Remove the propeller and hub assembly. Store the hub assembly safely, for future assembly. Tool Tool Type Tool Category Tool Code Tool Description Hand tools...
  • Page 4 WT 3269 - Remove propeller sacrificial anode Action Description Inspect anode for degradation and wear. Record the orientation of the anode if needed. Un-screw the bolt, reacting the anode within the transmission housing. Remove anode, fastener and washer. Store anode, fastener and washer safely for future assembly. Tool Tool Type Tool Category...
  • Page 5 WT 3266 - Remove transmission (Including transfer pipes) Action Description Un-screw 3 retaining bolts/nuts and washers. Tip if removing a 30" or 35" Transmission, the studs can be reacted using the appropriate size open ended spanner across the flats. Tool Tool Type Tool Category Tool Code...
  • Page 6 Action Description Un-screw 2 retaining bolts/nuts and washers using a thin wall socket for access. WARNING ensure the transmission is supported before removing the final fastener. Tool Tool Type Tool Category Tool Code Tool Description Hand tools Standard Tools 3/8" Ratchet Hand tools Sockets and Extensions 3/8"...
  • Page 7 Action Description WARNING Heavy - 2 person manual lift or use of specialist lifting equipment. WARNING Spacer (30" and 35" only) may drop down, when transmission is being removed. Info dowel pins locate the Transmission and the Spacer (If applicable) and can inhibit removal as they are slight interference fit.

  • Page 8: Remove Water Pump

    - Remove water pump Disconnect PTFE drain hose Action Description Disconnect the small plastic pipe from the FESTO fitting on the water pump gearbox. Tip to release the FESTO fitting, push the pipe into the union, press down the union collar and keep depressed, and simultaneously pull out the plastic pipe.
  • Page 9 Remove water pump fasteners Action Description Un-screw the 3 M6 fasteners (Fig 1). Un-screw the 2 dowel fasteners (Fig 2). Store the fasteners safely, ready for future assembly. Tool Tool Type Tool Category Tool Code Tool Description Hand tools Standard Tools 3/8"...
  • Page 10 Remove water pump from transmission Action Description Navigate the PTFE hose through the water pump body grommet. Remove the water pump assembly, sliding up and off the transmission drive shaft.
  • Page 11 - Install new water pump Offer new water pump into place Action Description Check that the small plastic pipe is fully home in the FESTO fitting, under the water pump. Assemble the water pump sliding over, and down the transmission drive shaft.
  • Page 12 Connect PTFE oil drain pipe Action Description Navigate the small plastic pipe through the water pump and into the FESTO fitting on the water pump gearbox. Push the pipe securely into the FESTO collar and into the tighter resistance sealing position. Tip the small plastic pipe should engage into the FESTO fitting by 15mm.
  • Page 13 Torque water pump fasteners Action Description Tighten by hand the 2 dowel bolts (Fig1). Tighten by hand the 3 M6 fasteners (Fig2). Torque the 2 dowel bolts to 7Nm. Torque the 3 M6 fasteners to 7Nm. Tool Tool Type Tool Category Tool Code Tool Description Hand tools...
  • Page 14 WT 6267 - Install transmission spacer (30" and 35" variants only) Check for dowels and pip seal Action Description Check 2x dowels are located correctly and present. If not in the spacer, installed in the midsection. Check the pip seal is in place for exhaust seal on the top face of the transmission spacer.
  • Page 15 Install transmission spacer Action Description Ensure spacer correct orientation, with water pump cut out towards transmission. Assemble transmission spacer over studs onto midsection.
  • Page 16 WT 6258 - Install intermediate shift shaft Install intermediate shift shaft Action Description Assemble Intermediate shift shaft through midsection and PTT swivel bracket bore. Align the shaft onto the splines of the GSA arm in adapter plate. Ensure the retaining clip (Cir Clip) is not pushed up into the adapter pate.
  • Page 17 WT 6270 - Install input shaft sleeve to midsection Install input shaft sleeve Action Description Ensure correct length input shaft sleeve (25",30" or 35"). Lubricate the O-rings inside the midsection, with a small amount of marine grease. Insert input shaft sleeve into mid section ensuring it engages correctly through the O-rings. Check the input shaft sleeve installed is the new flexible version and not the rigid aluminium tube.
  • Page 18 WT 6271 - Install water transfer tube to transmission Install water transfer tube Action Description Lubricate the O-rings inside the water pump, with a small amount of marine grease. Insert water transfer tube into water pump. Check the water transfer tube is engaged correctly and pushed past the O-ring.
  • Page 19 WT 6312 - Install transmission Make sure exhaust seal is present Action Description Check gasket is in place for exhaust seal on the top face of the transmission...
  • Page 20 Install transmission Action Description Adjust transmission into gear. WARNING Heavy - 2 person manual lift or the use of specialist lifting equipment is required. Lift transmission and install to the outboard, making sure water transfer pipe (water pump) and input shaft sleeve (Midsection) are aligned with the corresponding locations.
  • Page 21 Assemble right hand transmission fasteners Action Description Assemble 3x fasteners with washers to left hand side of transmission. Tool Tool Type Tool Category Tool Code Tool Description Hand tools Sockets and Extensions 16mm spanner Assemble right hand transmission fasteners Action Description Assemble 3x fasteners with washer to right hand side of transmission.
  • Page 22 Torque all fasteners Action Description Assemble 2x fasteners with washers to the rear transmission mounting locations. Torque all fasteners initially, to 20Nm, making sure the transmission is correctly seated to midsection. Torque all fasteners to a final 32Nm. Tip if using the torque adapter ring extension, make sure the length offset is applied to the torque wrench settings. Tool Tool Type Tool Category...
  • Page 23 WT 9276 - Pressure test transmission Install pressure test adapter Action Description Remove vent plug from transmission. Assemble pressure test adapter with a sealing washer into plug thread. Torque to 15Nm. Tool Tool Type Tool Category Tool Code Tool Description Hand tools Sockets and Extensions 1/4"...
  • Page 24 Carry out transmission pressure test Action Description Connect pressure test pump to the adapter. Test transmission sealing by increasing pressure to 10 PSI. Wait for a period of 3 minutes. Accept if there is no drop in pressure. Record an image of the gauge at 10PSI after the test is complete into the evidence sheet. Decline if the pressure drops - remove transmission and check midsection O-rings.
  • Page 25 Hand tools Standard Tools 1/4" Digital torque wrench 1.5 - 27Nm Hand tools Sockets and Extensions 1/4" 5mm hex socket Hand tools Sockets and Extensions 1/4" 14mm deep socket...
  • Page 26 WT 6269 - Install propeller sacrificial anode Install prop anode Action Description Assemble anode to transmission with the 3/8" fastener and washer. Torque fastener to 30Nm. Tool Tool Type Tool Category Tool Code Tool Description Hand tools Standard Tools 3/8" Digital torque wrench 6-130Nm Hand tools Standard Tools 3/8"...
  • Page 27 - Propeller check and install Inspect propeller hub Action Description Visual Check that the propeller is in good working order with minimal cavitation or corrosion. Check that the propeller, damper hub has minimal free play and wear. Replace if worn. Install propeller Action Description...
  • Page 28 - Trim PTT Down Trim PTT down Action Description Lower PTT angle back to closed position.
  • Page 29 COX POWERTRAIN LIMITED The Cecil Pashley Building Unit 8, Cecil Pashley Way Brighton City Airport Lancing, West Sussex BN43 5FF United Kingdom +44 (0) 1273 454 424 info@coxpowertrain.com www.coxmarine.com TCD002705/A AUG_2023...