How Repair Lower Unint On 40hp 4 Stroke Mercury

DOWNLOAD MERCURY-MARINER REPAIR MANUALS

LOWER Unit of measurement REMOVAL & DISASSEMBLY Always disconnect the battery cable, earlier removing lower unit. 1. Shift to "NEUTRAL" position. 2. Remove bolt and trim tab 1. 3. Remove 7 (7) bolts 2 and dissever gearcase 3 from driveshaft housing. 4. Remove clutch rod from clutch shaft (if necessary). v. Place a drain pan under oil drain plug. Remove oil drain plug 6 first then oil level plug 5 and let gear oil to drain. Inspect oil for water, contaminates or metal. Clutch rod Notation: Earlier gearcase is removed completely, disconnect speedometer pick up tube 4 from gearcase. 6. Remove cotter pin 7 from propeller nut and remove pro peller nut 8. 7. Remove washer 9, spacer 0, propeller A, stopper B and spacer C from propeller shaft. 􀀣 To prevent injury from propeller blades, wear gloves and identify a block of wood betwixt the anti-cavitation plate and the propeller blade tips to lock the propeller in place. nine. Keep impeller key half-dozen for reuse and discard plate gasket. x. Remove three (3) bolts ane and shift rod guide housing assembly 2. 11. Remove two bolts 1 securing propeller shaft bearing housing to gearcase. 12. Using special tools, depict out propeller shaft begetting housing. Remove propeller shaft and bearing housing assembly. 􀁜 09930-30104 : Sliding hammer A 09930-30161 : Propeller shaft remover B thirteen. Hold pinion nut securely, then fit special tool to the driveshaft and loosen pinion nut. 􀁜 09921-29410 : Driveshaft holder xiv. Remove four bolts ane securing driveshaft oil seal housing 2, then remove oil seal housing and pinion shim iii. 15. Elevator out driveshaft associates 4. Remove driveshaft collar v, washer half dozen, wave washer 7, washer (with tab) eight and washer 9 from driveshaft. Disassembly of propeller shaft components 1. Slide propeller shaft abroad from contrary gear 3 and bearing housing assembly 1. Account for contrary gear dorsum-up shim ii and reverse gear thrust washer 4. INSPECTION NOTE: If excessive ware, cracks, lacking or other damage is found on any component, supercede component. Annotation: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. 􀀣 Habiliment safe grasses when using compressed air. PROPELLER • Inspect propeller for bent, chipped or broken blades. Replace or repair if necessary. • Inspect propeller bushing splines for wear or other damage. Replace if necessary. • Audit propeller bushing for deterioration or slipping. Supplant if necessary. GEARCASE • Inspect gearcase for cracks or other damage. Supervene upon if necessary. • Inspect pinion bearing for pitting, rough or other damage. Supersede if necessary. NOTE: If removal and replacement are required, see "PINION BEARING" section on page 9-vii. LOWER Unit of measurement GEARS • Inspect forwards, reverse and pinion gear teeth and engaging dogs for excessive vesture or other damage. Supercede if necessary. • Inspect frontward gear bearing for pitting, crude or other impairment. Supplant if necessary. PROPELLER SHAFT COMPONENTS • Inspect horizontal slider and connector pin for excessive article of clothing or other damage. Supplant if necessary. • Inspect clutch dog shifter for excessive habiliment, flake or other damage. Replace if necessary. • Inspect dog pin for bent or other impairment. Replace if necessary. • Inspect propeller shaft / splines for vesture, twist or other damage. Supersede if necessary. PROPELLER SHAFT BEARING HOUSING • Inspect housing for cracks or other damage. Supercede if necessary. • Inspect propeller shaft bearings and reverse gear bearing for pitting, rough or other impairment. Supersede if necessary. • Inspect oil seals and O-ring for cuts, nicks or tears. Replacing propeller shaft oil seal 1. Remove retaining ring ane and washer two. ii. Excerpt oil seals 3 using oil seal remover. 􀁜 09913-50121 : Oil seal remover 􀀃 Do not re-use oil seal in one case removed. Ever apply a new oil seal. 3. Apply Water Resistant Grease to inner circumference of housing. four. Using an oil seal installer, bulldoze two oil seals (one at a time) into housing. The lipped portion of seal should face towards propeller. Use Water Resistant Grease to seal lips. 􀁎 99000-25161 : Water Resistant Grease five. Install washer and retaining ring.

SHIFT ROD GUIDE HOUSING COMPONENTS • Inspect shift rod guide housing for cracks or other damage. Supersede if necessary. • Inspect shifter yoke for excessive wear or other damage. Replace if necessary. • Inspect oil seal and O-ring for vesture, cuts, nicks or tears. • Inspect shift rod / splines for excessive clothing, twist or other impairment. Replace if necessary. • Inspect detent brawl for wear, crude or other damage. Replace if necessary. WATER PUMP AND RELATED ITEMS • Inspect impeller vanes for cuts, cracks, tears or excessive wear. Supplant if necessary. • Inspect pump case and under console for cracks, baloney or corrosion. Supervene upon if necessary. DRIVESHAFT OIL SEAL HOUSING • Inspect housing for cracks or other damage. Replace if necessary. • Inspect oil seals and O-ring for wearable, cuts, nicks or tears. Replacing driveshaft oil seal ane. Excerpt oil seals using oil seal remover. 􀁜 09913-50121 : Oil seal remover 2. Employ Water Resistant Grease to inner circumference of housing. 􀁎 99000-25161 : Water Resistant Grease 3. Using an oil seal installer, drive ii oil seals (one at a time) into housing. The lipped portion of seal should face towards water pump case. Grease inner lips of seal. 1 Dust seal 2 Shift rod guide housing iii Bolt 4 Ball 5 Spring vi 7 O-ring 8 Washer ix Circlip 0 E-ring A Shift rod B Shifter yoke C Pivot D Horizontal slider E Magneto F Grommet G H2o pump example H Pin I Bolt J Key K Water pump impeller 50 Pump case under console G Gasket N Frazzle seal O Frazzle seal plate P Wedlock Q Hose R Nipple S Gearcase T Bolt U Bolt V Pin Westward Anode X Washer Y Bolt Z Trim tab [ Bolt \ Screw ] Water filter PORT ^ Water filter STBD WATER PUMP ane. Place dowel pins 1, under panel gasket two and under panel 3 into position. ii. Insert key 4 in driveshaft and slide impeller five onto driveshaft, ensuring that key and keyway are aligned. 3. Install pump case 6 while rotating driveshaft clockwise to flex impeller vanes in right direction. 4. Tighten iv pump example bolts to specified torque. 􀀢 Pump case commodities : 20 N.g (ii.0 kg-m, 14.v lb.-ft.) PROPELLER INSTALLATION 1. Install spacer 1 and propeller stopper 2 onto propeller shaft, then slide on propeller three. two. Fit spacer 4, washer 5 and nut 6, and so tighten nut to specified torque. 􀀢 Propeller nut : 55 N.m (5.five kg-m, twoscore.0 lb.-ft.) iii. Push cotter pin 7 through nut and shaft, then bend to secure. LOWER UNIT INSTALLATION one. Apply clutch rod splines with H2o Resistant Grease, so install clutch rod i by aligning clutch rod splines with splines in clutch shaft. two. Ensure that shift rod 2 is at neutral position. NOTE: Earlier install lower unit of measurement assembly, bring shift to neutral position by turning shift rod. 3. Insert two dowel pins 3. iv. Apply driveshaft splines and shift rod splines with Water Resistant Grease. v. Apply Mercury Silicone Seal lightly to mating surfaces of gearcase and driveshaft housing. vi. Set clutch control lever 4 at neutral position, then slide lower unit v into place, ensuring that acme of driveshaft engages properly with countershaft and that h2o tube locates in water pump instance outlet. NOTE: In order for shift rod splines and clutch rod splines to be aligned correctly, clutch rod may need to be turned slightly right or left. 7. Apply Silicone Seal to 7 gearcase bolts half-dozen and tighten them to specified torque. 􀀢 Gearcase bolt : 55 N . m (5.five kg-k, 40.0 lb.-ft.) 􀁎 99000-25161 : H2o Resistant Grease 􀁍 99000-31120 : Mercury-Mariner Silicone Seal eight. Motion clutch control lever 4 to forward and reverse positions from neutral position to check proper gear engagement. GEAR OIL Fill gearcase with specified gear oil. (See "PERIODIC MAINTENANCE / GEAR OIL" section on folio two-6) 􀁌 99000-22540 : Mercury-Mariner Outboard Motor Gear Oil.

1965-1989 Service Manual Application: 2 hp To 40hp 2 Stroke 1 & 2 cylinder engines.

1965-1989 Mercury Service Manual Application: 45 HP, four CYL, 1965 1966 1967 1968 1969 1970, 50 HP, three CYL, 1986 1987 1988 1989, 500/l HP, 4 CYL, 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985, 60 HP, 3 CYL, 1984 1985 1986 1987 1988 1989, 650/65 HP, three CYL, 1972 1973 1974 1975 1976, 650/65 HP, 4 CYL, 1965 1966 1967 1968 1969 1970 1971, 650,700/70 HP, 3 CYL, 1976 1977 1978 1979 1980 1981 1982 1983, lxx HP, 3 CYL, 1986 1987 1988 1989, 75 HP, 4 CYL, 1984 1985 1986, eighty HP, iii CYL, 1987 1988 1989, 800/lxxx HP, 4 CYL, 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983, 800/85 HP, 4 CYL, 1973 1974 1975 1976 1977, ninety HP, 3 CYL, 1987 1988 1989, 850XS/90 HP, four CYL, 1976, 100 HP, iv CYL, 1988 1989, 115 HP, four CYL, 1988 1989.

1956-1989 xc-300 HP Mercury Outboard motors repair transmission Application: Covers all Mercury Motors from 1965 to 1989 90-300 hp Inline half-dozen and V6, 2 stroke models fuel injection and MR Drive: 90 95 100 115 125 135 140 150 150XR2/150 HP 155 HP 175 HP 200 HP 220XRi/200 HP 225 HP 275 HP 300 HP 850XS/90 HP, 4cyl 900/90hp, 6cyl 950/95hp, 6cyl 1000/100hp, 6cyl 1100/100hp, 6cyl 1150/115hp, 6cyl 1250/125hp, 6 cyl 1350/135hp, 6cyl 1400/140hp 1400/140hp, 6cyl 1500/150hp, 6cyl 1500XS/155hp, 6 cyl 1750/175hp, V6 2000/200hp, V6.

1990-2000 Mercury Mariner 2.5 / 275 HP Workshop Service Manual Repair

1990-2000 Mercury/Mariner Workshop Service Manual Repair Application: Manual covers 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 & 2000 Mercury Outboard 2-Stroke models, exact models listed: xc, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 2.5hp, 3hp, 3.3hp, 4hp, 5hp, 6hp, 8hp, 9.9hp, 10hp, 15hp, 20hp, 25hp, 30hp, 40hp, 50hp, 60hp, 75hp, 90hp, 100hp, 115hp, 125hp, 135hp, 150hp, 175hp, 200hp, 225hp, 250hp, 275hp.

1986-1990 Service Transmission Awarding: 6/viii/nine.9/15HP Motors 1986 and upward With Serial Numbers OA1972112 and Higher up.

1995-2000 Mercury - Mariner 40hp · 45hp · 50hp Four Stroke (4-Stroke) Non-Big Human foot and Bigfoot Engines With Starting Serial Numbers: 0G231123, 1995 & to a higher place with Serial Numbers 0G231123 & above. Mercury-Mainer twoscore (4-Stroke) 4 cylinder 1998, 1999 & 2000 Not-Bigfoot, Mercury-Mainer 45 (4-Stroke) 4 cylinder 1998, 1999 & 2000 Non-Bigfoot and Big Foot, Mercury-Mainer 50 (four-Stroke) 4 cylinder 1995, 1996, 1997 & 1998.

1997-2000 Service Manual Model Application: 97-00 Mercury - Mariner 40-50-55-60 HP Two-Stroke Models with serial numbers OG531301 and to a higher place.

1997-1998 Service manual application: 1997-1998 Mercury 200HP ( 200 HP) & 225HP (225 HP) DFI (Direct Fuel Injection) outboard engine. V6 Cylinder, Ii Cycle. Models covered are  200 & 225 OPTIMAX DIRECT FUEL INJECTION With Series Numbers 0G386496 and In a higher place.

1998-1999 Mercury/Mariner Outboard motor service manual awarding: 98-99 Mercury-Mariner ix.9hp (9.ix hp), 15hp (15 hp) Bigfoot and Non-Big Foot 4-Stroke Outboard Engine. Models Covered are Mercury - Mariner nine.9/15 (4-Stroke) (323 cc) & 9.9/15 Bigfoot (4-Stroke) (323 cc) with Serial Numbers 0G590000 and Above.

1998-1999 Service manual application: 98-99 Mercury 135HP (135 HP) & 150HP (150 HP) DFI (Direct Fuel Injection) outboard engine. V-6 Cylinder, Two Cycle, Straight Injected. Models covered are 135 & 150 OPTIMAX DIRECT FUEL INJECTION With Series Numbers OG590000 and Above.

1999-2002 Service transmission application: Mercury Outboard 30HP, 40HP (four-Stroke) - Non-Bigfoot & Bigfoot Engine-Motor (Four-Stroke) starting with serial number 0G760300 and above.

1999-2000 Mercury Service Manual Application: 99-00 Mercury 4 HP - 5 HP & 6 HP Four Stroke Engines.

2000-2001 Service Repair Manual Year Application: 2000 & 2001 Mercury 75hp (75 hp) 90hp (90 hp) 4-Stroke (4-Stroke-FourStroke) Outboard boat motor engine. Starting model year 2000 & starting Serial Number 0G960500 and above.

2000-2001 Mercury OptiMax Outboard motor service manual awarding: 2000-2001 Mercury 115hp (115 hp) 135hp (135 hp) 150hp (150 hp) 175hp (175 hp) DFI (Direct Fuel Injection) outboard motor. Starting Model Year 2000  & Starting Series Number OG960500 & above.

2001 Service Repair Transmission Application: 2001 (01) Mercury-Mariner models fifty HP (50HP) & 60 HP (60HP) 4-Stroke (Four Stroke) Outboard Engines With Series Numbers 0T178500 and Higher up. Covers Bigfoot (Big Foot) and Not-Bigfoot models.

2001-2002 Mercury 115 HP Service manual application: Mercury Outboard motor 01-02 Mercury 115 HP (115HP) EFI (Electronic Fuel Injection) outboard engine. 4 Cylinder InLine, 4 Stroke DOHC, 16 Valves. Starting Serial Number 0T178500.

2002-2004 Mercury/Mariner Outboard motor service manual application: 2002-2004 Mercury-Mariner 40HP EFI 4-Stroke (4-Stroke), 2002-2004 Mercury-Mariner 60HP EFI iv-Stroke (Iv-Stroke), 2002-2004 Mercury-Mariner l HP EFI 4-Stroke (Four-Stroke), 2002-2004 Mercury-Mariner forty HP EFI four-Stroke (FourStroke) Bigfoot, 2002-2004 Mercury-Mariner threescore HP EFI iv-Stroke (FourStroke) Bigfoot.

Mercury Marine Outboard Service Transmission, Mariner Outboard Repair Manual, Owner's Store Manual, Workshop Manual, Handbook, Volume, 2004, 2003, 2002, 2001, 2000, 1999, 1998, 1997, 1996, 1995, 1994, 1993, 1992, 1991, 1990, 1989, 1988, 1987, 1986, 1985, 1984, 1983, 1982,1981, 1980, 1979, 1978, 1977, 1976, 1975, 1974, 1973, 1972, 1971, 1970, 1969, 1968, 1967, 1966, 1965 Exploded Views, Exploded Diagrams, Repair Guide, Engine Repair Guide, How To Fix, How Practise you Repair and Set, Parts Locations Diagrams, 13.nine HP (three.9HP), 6HP (6-HP), 9.8HP (9.8 HP), 20 HP (twenty-HP), 35 HP (35HP), iv.0 HP (4.0HP), 7.5 HP (7.5HP), twoscore HP (40HP)  4.5 HP (four.5HP) 3.6 HP 18HP, (18 HP), 20 HP, 25HP, 2.2 HP (two.2HP) vi.0 (half dozen.0HP), 8.0 (8.0HP), 9.9 (nine.9HP), 20 HP (20HP), 25 HP,35 (35-HP), 15 HP (15HP, 45, l, 55, lx, 65, seventy, 90 Horsepower Engines

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