LOWER UNIT Setion 6A Right Hnd Non-Rtheting Tle of Contents RIGHT HAND NON-RATCHETING Ger Housing Speifitions (Stndrd Rottion). 6A-1 Speil Tools................................ 6A-2 Ger Housing (Drive Shft)(Stndrd Rottion).. 6A-6 Ger Housing (Prop Shft)(Stndrd Rottion)... 6A-8 Generl Servie Reommendtions........... 6A-10 Removl, Disssemly, Clening nd Inspetion Stndrd Rottion......................... 6A-11 Removl................................ 6A-11 Drining nd Inspeting Ger Housing Lurint................................ 6A-13 Wter Pump............................. 6A-14 Oil Sel Crrier Assemly................. 6A-16 Bering Crrier nd Propeller Shft Removl 6A-18 Drive Shft Assemly..................... 6A-27 Propeller Shft Assemly nd Forwrd Ger Bering Cup............................. 6A-32 Forwrd Ger Assemly................... 6A-35 Shift Spool Assemly..................... 6A-38 Propeller Shft Assemly.................. 6A-40 Shift Shft Assemly...................... 6A-41 Pinion Bering........................... 6A-44 Ger Housing Ressemly................... 6A-45 Ger Housing Inspetion.................. 6A-45 Pinion Bering........................... 6A-46 Forwrd Ger Bering Cup................ 6A-47 Shift Shft Assemly...................... 6A-48 Propeller Shft Assemly.................. 6A-50 Drive Shft nd Pinion Ger............... 6A-51 Ger Lotion/Bklshes/Cheking nd Adjustment................................. 6A-54 Drive Shft - Bering Prelod Tool.......... 6A-54 Pinion Ger Lotion..................... 6A-55 Bering Crrier Assemly................. 6A-58 Forwrd Ger Bklsh................... 6A-60 Reverse Ger Bklsh................... 6A-61 Drive Shft - Bering Prelod Tool.......... 6A-63 Bering Crrier Assemly.................... 6A-64 Finl Instlltion.......................... 6A-64 Oil Sel Crrier Assemly.................... 6A-67 Instlltion............................... 6A-67 Wter Pump Assemly....................... 6A-67 Instlltion............................... 6A-67 Ger Lurint Filling Instrutions.......... 6A-70 Instlling Ger Housing to Driveshft Housing 6A-70 Propeller Instlltion...................... 6A-71 Speedometer Tue Instlltion............. 6A-73 6 A Ger Housing Speifitions (Stndrd Rottion) Rtio 1.75:1 1.87:1 Pinion Depth 0.025 in. (0.635 mm) With Tool 91-12349A2 using Dis #2 nd Flt #4 Forwrd Ger Bklsh 0.017 in. to 0.028 in. (0.431 mm to 0.711 mm) Pointer on line mrk #1 Reverse Ger Bklsh 0.030 in. to 0.050 in. (0.762 mm to 1.27 mm) Gerse Lurint Cpity All Rtios 27.0 fl. oz. (798.0 ml) Gerse Pressure Chek Gerse without Oil Gerse should hold 15 psi for 5 minutes without lekge Ger Rtio Teeth on Pinion Ger Teeth on Forwrd nd Reverse Ger 1.75:1 12 21 1.87:1 15 28 90-859769R1 DECEMBER 2000 Pge 6A-1
Speil Tools 1. Ger Housing Cover Nut Tool 91-61069 2. Bering Crrier Removl Tool 91-46086A1 nd Puller Bolt 91-85716 3. Slide Hmmer Puller 91-34569A1 4. Bering Removl nd Instlltion Kit 91-31229A5. This kit ontins the following tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plte 91-29310; Mndrel 91-38628; nd Driver Rod 91-37323. 5. Pilot 91-36571 6. Puller Rod 91-31229 nd Nut 91-24156 Pge 6A-2 90-859769R1 DECEMBER 2000
7. Puller Plte 91-29310 RIGHT HAND NON-RATCHETING 8. Mndrel 91-38628 9. Driver Rod 91-37323 10. Universl Puller Plte 91-37241 11. Driveshft Holding Tool 91-56775 12. Oil Sel Driver 91-31108 13. Forwrd Ger Bering Tool 91-877321A1 14. Bering Driver Cup 91-31106 15. Pinion Loting Ger Tool 91-12349A2 or 91-74776 90-859769R1 DECEMBER 2000 Pge 6A-3
16. Bklsh Inditor Rod 91-53459 for (1.75:1 rtio) nd 91-78473 for (1.87:1 rtio) 17. Dil Inditor 91-58222A1 18. Bering Retiner Tool 91-43506 19. Bering Prelod Tool 91-14311A2 1 -Plte (44307) 2 -Adptor (N.S.S.) 3 -Bering (N.S.S.) 4 -Wsher (N.S.S.) 5 -Spring (24-14111) 20. Mndrel 91-92788 6 -Bolt (10-12580) 7 -Nut (11-13953) 8 -Set Srew (10-12575) 9 -Sleeve (23-13946) 21. Mndrel 91-15755 22. Dil Inditor Holder 91-89897 Pge 6A-4 90-859769R1 DECEMBER 2000
23. Lekge Tester FT8950 RIGHT HAND NON-RATCHETING 24. Oil Sel Driver 91-817569 25. Wter Pump Alignment Pins 91-821571A1 26. Bering Adptor Instlltion Tool 91-18605A2 90-859769R1 DECEMBER 2000 Pge 6A-5
Ger Housing (Drive Shft)(Stndrd Rottion) 4.75 IN/120.65MM TORPEDO DIA. 7 Lotite 271 (92-809820) 92 Lotite 7649 Primer (92-809824) 95 2-4-C With Teflon (92-825407A12) 33 34 35 36 32 31 95 95 95 37 44 46 45 38 43 25 30 29 26 27 95 95 95 95 42 24 23 40 28 22 19 12 13 21 95 41 39 6 10 11 3 14 15 20 9 1 95 7 5 9 11 10 4 95 8 16 5 7 92 7 17 18 2 Pge 6A-6 90-859769R1 DECEMBER 2000
Ger Housing (Drive Shft)(Stndrd Rottion) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 GEAR HOUSING (BASIC) 2 1 PIN 3 1 FILLER BLOCK 4 1 PITOT TUBE 5 2 ANODE 6 1 SCREW 60 7 7 1 NUT 8 1 ROLLER BEARING 9 2 DOWEL PIN 10 2 SCREW ASSEMBLY 60 7 11 2 SEALING WASHER 1 HOSE(LONG - 7 IN) 12 1 HOSE (X-LONG - 12 IN) 1 HOSE(XX-LONG - 17 IN) 13 1 CONNECTOR 14 1 COVER 15 1 GASKET 16 1 PINION GEAR (1.75:1-12/21) (Prt of 43-859321A3) 17 1 WASHER 18 1 NUT 70 95 19 1 OIL SEAL 20 1 O RING 21 2 SCREW (M6 x 16) 60 7 22 1 RUBBER WASHER 23 1 SHIFT SHAFT (LOWER) 1 DRIVE SHAFT (LONG) 24 1 DRIVE SHAFT (X-LONG) 1 DRIVE SHAFT (XX-LONG) 25 AR SHIM SET 26 1 TAPERED ROLLER BEARING 27 1 CUP 28 1 KEY 29 AR SHIM SET 30 1 TAPERED ROLLER BEARING 31 1 CUP 32 1 RETAINER 100 135 33 1 CARRIER ASSEMBLY 34 1 O RING 35 1 OIL SEAL 36 1 OIL SEAL 37 1 WATER PUMP ASSEMBLY 38 1 SEAL 39 1 GASKET 40 1 GASKET 41 1 FACE PLATE 42 1 IMPELLER 43 4 SCREW (M6 x 16) 60 7 44 1 COUPLING ASSEMBLY 45 1 O RING 46 1 O RING 90-859769R1 DECEMBER 2000 Pge 6A-7
Ger Housing (Prop Shft)(Stndrd Rottion) 4.75 IN/120.65MM TORPEDO DIA. 76 1 47 75 95 87 49 52 50 51 48 94 53 61 55 57 62 58 68 87 59 63 64 60 69 67 87 56 54 66 87 65 73 70 95 72 71 95 74 95 95 95 95 87 Quiksilver Ger Lurint (92-19007A24) 94 Anti-Corrosion Grese (92-78376-A6) 95 2-4-C With Teflon (92-825407A12) Pge 6A-8 90-859769R1 DECEMBER 2000
Ger Housing (Prop Shft)(Stndrd Rottion) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 GEAR HOUSING (BASIC) 47 1 PLUG 48 1 SHIFT CRANK 49 1 SHAFT 50 1 SHIFT SPOOL 51 1 COTTER PIN 52 1 SLEEVE 53 1 FORWARD/PINION GEAR SET (1.75:1-12/21) 54 AR SHIM SET 55 1 TAPERED ROLLER BEARING 56 1 CUP 57 1 RETAINING RING 58 1 ROLLER BEARING 59 1 SPRING 60 1 SLIDING CLUTCH 61 1 DETENT PIN 62 1 CROSS PIN 63 1 PROPELLER SHAFT 64 1 REVERSE GEAR (1.75:1-12/21) 65 1 THRUST SPACER 66 1 THRUST RING 67 1 BALL BEARING 68 1 O RING 69 1 BEARING CARRIER 70 1 ROLLER BEARING 71 1 OIL SEAL (INSIDE) 72 1 OIL SEAL (OUTSIDE) 73 1 TAB WASHER 74 1 COVER 210 285 75 1 ANODIC PLATE 76 1 SCREW 40 54 90-859769R1 DECEMBER 2000 Pge 6A-9
Generl Servie Reommendtions BEARINGS SHIMS SEALS There my e more thn one wy to disssemle or ressemle prtiulr prt(s), therefore, it is reommended tht the entire proedure e red prior to repir. IMPORTANT: Red the following efore ttempting ny repirs. In mny ses, disssemly of su-ssemly my not e neessry until lening nd inspetion revels tht disssemly is required for replement of one or more omponents. Servie proedure order in this setion is norml disssemly-ressemly sequene. It is suggested tht the sequene e followed without devition to ssure proper repirs. When performing prtil repirs, follow the instrutions to the point where the desired omponent n e repled, then proeed to ressemly nd instlltion of tht omponent in the ressemly prt of this setion. Use the Tle of Contents (on k of setion divider) to find orret pge numer. Threded prts re right hnd (RH), unless otherwise indited. When holding, pressing or driving is required, use soft metl vise jw protetors or wood for protetion of prts. Use suitle mndrel (one tht will ontt only the ering re) when pressing or driving erings. Whenever ompressed ir is used to dry prt, e sure tht no wter is present in ir line. Upon disssemly of ger housing, ll erings must e lened nd inspeted. Clen erings with solvent nd dry with ompressed ir. Air should e direted t the ering so tht it psses thru the ering. DO NOT spin ering with ompressed ir, s this my use ering to sore from lk of lurition. After lening, lurite erings with Quiksilver Ger Lurint. DO NOT lurite tpered ering ups until fter inspetion. Inspet ll erings for roughness, thes nd ering re side wer. Work inner ering re in-nd-out, while holding outer re, to hek for side wer. When inspeting tpered erings, determine ondition of rollers nd inner ering re y inspeting ering up for pitting, soring, grooves, uneven wer, imedded prtiles nd/or disolortion from overheting. Alwys reple tpered ering nd re s set. Roller ering ondition is determined y inspeting the ering surfe of the shft tht the roller ering supports. Chek shft surfe for pitting, soring, grooving, imedded prtiles, uneven wer nd/or disolortion from overheting. The shft nd ering must e repled, if the onditions desried re found. Keep reord of ll shim mounts nd lotion during disssemly to id in ressemly. Be sure to follow shimming instrutions during ressemly, s gers must e instlled to orret depth nd hve the orret mount of klsh to void noisy opertion nd premture ger filure. As norml proedure, ll O-rings nd oil sels SHOULD BE REPLACED without regrd to pperne. To prevent lekge round oil sels, pply Lotite 271 to outer dimeter of ll metl se oil sels. When using Lotite on sels or threds, surfes must e len nd dry. To ese instlltion, pply Quiksilver 2-4-C w/teflon Mrine Lurint on ll O-rings. To prevent wer, pply Quiksilver 2-4-C w/teflon Mrine Lurint on l.d. of oil sels. Pge 6A-10 90-859769R1 DECEMBER 2000
To prevent orrosion dmge fter ressemly, pply Quiksilver 2-4-C w/teflon Mrine Lurint to externl surfes of ering rrier nd over nut threds prior to instlltion. Removl, Disssemly, Clening nd Inspetion Stndrd Rottion Removl WARNING Disonnet high tension leds from sprk plugs nd remove sprk plugs from engine efore removing ger housing from driveshft housing. 1. Disonnet high tension leds from sprk plugs nd remove sprk plugs from engine. 2. Shift engine into NEUTRAL position. 3. Tilt engine to full up position nd engge tilt lok lever. 4. Bend ts of propeller t wsher wy from thrust hu (rer), then remove propeller loknut, t wsher, thrust hu (rer), propeller nd thrust hu (forwrd) from propeller shft. 5. Mrk ger housing nd trim t so tht trim t n e reinstlled in the sme position. Remove plsti p t rer edge of driveshft housing. Remove olt tht seures trim t nd remove t from ger housing. 6. One trim t is removed, remove olt from inside of trim t vity. d f h g i e 51916 51912 -T Wsher -Propeller Nut -Rer Thrust Hu d-continuity Wsher (if equipped) e -Propeller Shft 52375 f -Thrust Hu (forwrd) g-bolt (seures trim t) h-bolt (inside trim t vity) i -Ris Align Crefully with Trim T while Seuring T 90-859769R1 DECEMBER 2000 Pge 6A-11
7. While pressing in on speedometer hose juntion, pull out on hose to disonnet. -Press in on Juntion -Pull out on Hose 57735 8. Loosen the side mounting loknuts. (Do not ttempt to remove one nut efore opposite side is loosened suffiiently, or ger housing ould e dmged.) -Side Mounting Loknuts (2 eh side) 52374 9. Pull ger housing wy from driveshft housing s fr s the loosened nuts (in Step 8) will llow, then remove loosened nuts. (DO NOT llow ger housing to fll, s it now is free.) 10. Pull ger housing from driveshft housing. Pge 6A-12 90-859769R1 DECEMBER 2000
Drining nd Inspeting Ger Housing Lurint RIGHT HAND NON-RATCHETING 1. Ple ger housing in suitle holding fixture or vise with the driveshft in vertil position. NOTE: Drin nd Fill srews my e loted on the strord side of gerse on lter models. 2. Position len drin pn under ger housing nd remove Fill nd Vent srews from ger housing. - Fill Srew - Vent Srew 3. Inspet ger lurint for metl prtiles. Presene of smll mount of fine metl prtiles (resemling powder) indites norml wer. Presene of lrger prtiles (or lrge quntity of fine prtiles) indites need for ger housing disssemly, nd omponent inspetion. 4. Note the olor of ger lurint. White or rem olor indites presene of wter in lurint. Chek drin pn for wter seprtion from lurint. Presene of wter in ger lurint indites the need for disssemly, nd inspetion of oil sels, sel surfes, O-rings nd ger housing omponents. NOTE: Ger lurint drined from reently run ger se will e light hoolte rown in olor due to gittion/ertion. Oil whih is stilized will e ler yellow rown in olor. 90-859769R1 DECEMBER 2000 Pge 6A-13
Wter Pump REMOVAL AND DISASSEMBLY 1. Remove the wter sel, wter tue oupling ssemly, nd the wter pump srews. 57944 -Wter Sel -Wter Tue Coupling -Wter Pump Srews (4) 2. Crefully slide the wter pump stright up off of the drive shft. It my e neessry to enourge the wter pump up y gently prying up on its mounting flnges with ouple of srewdrivers. 70487 -Wter Pump Body -Srewdrivers Pge 6A-14 90-859769R1 DECEMBER 2000
3. Remove the impeller, impeller key, the fe plte nd gskets, (disrd the gskets). d -Impeller -Impeller Key 70605 -Wter Pump Fe Plte d-gsket (1 eh side of fe plte) CLEANING AND INSPECTION 1. Inspet the wter tue oupling ssemly for wer or dmge. If neessry reple the worn or dmged omponents espeilly the two O-rings on the inside, one t the top nd one t the ottom. -Wter Tue Adptor -O-rings (2) 70613 IMPORTANT: The irulr groove formed y the impeller seling ed should e disregrded when inspeting over nd plte. The depth of the groove will not ffet wter pump output. 2. Inspet fe plte nd wter pump over for grooves nd/or rough surfes. 3. Reple over nd /or fe plte if grooves (other thn seling grooves) re more thn 0.030 in. (0.762 mm) deep. 90-859769R1 DECEMBER 2000 Pge 6A-15
4. Inspet impeller side sel surfes nd ends of impeller ldes for rks, ters nd wer. Reple impeller if ny of these onditions re found. 5. Inspet impeller onding to impeller hu. 6. Inspet impeller for glzed or melted pperne (used y opertion without suffiient wter supply). Reple impeller if ny of these onditions exist. -Impeller -Hu 70500 Oil Sel Crrier Assemly REMOVAL IMPORTANT: When ompleting ger housing repirs, tht require removl of wter pump impeller, it is reommended tht the impeller e repled. If it is neessry, however, to re-use impeller, DO NOT instll in reverse to originl rottion, or premture impeller filure will our. IMPORTANT: It is reommended tht ll sels nd gskets e repled (s norml repir proedure) to ssure effetive repir. 1. Remove the oil sel rrier from the ger housing. It my e neessry to gently pry up on it with two srewdrivers. -Oil Sel Crrier -Srewdrivers 57940 Pge 6A-16 90-859769R1 DECEMBER 2000
OIL SEAL CARRIER ASSEMBLY - COMPONENT DISASSEMBLY RIGHT HAND NON-RATCHETING NOTE: Complete the instrutions in this setion only if the ssemly omponents hve een found to e defetive nd re in need of repir or replement. 1. Remove the o-ring. -O-ring -Oil Sels (2) 70501 2. Remove oil sels. -Oil Sel Crrier -Oil Sels -Srewdriver 70610 90-859769R1 DECEMBER 2000 Pge 6A-17
OIL SEAL CARRIER ASSEMBLY COMPONENT REASSEMBLY The oil sels in the rrier ssemly re the sme dimeter. The ottom (first) sel lip fes down; the top (seond) sel lip fes up. Apply 2-4-C w/teflon Mrine Lurint to sel lips nd etween sels. Press sel into rrier with suitle mndrel. Seond sel should e pressed in flush with rrier surfe. 95 95 2-4-C With Teflon (92-825407A12) -Bottom Sel (lip fes down) -Top Sel (lip fes up) Bering Crrier nd Propeller Shft Removl 1. Strighten the t on the t wsher. -T on T Wsher 70490 Pge 6A-18 90-859769R1 DECEMBER 2000
2. Remove the ering rrier retiner following step or s follows: CAUTION RIGHT HAND NON-RATCHETING DO NOT drill into the ger housing retiner threds when using the following proedure for removing the retiner. If the retiner is orroded in ple, drill 4 holes in the retiner nd frture the retiner with hisel. Pry the remining segments out. -Drilled Holes 23356. Remove the ering rrier retiner using the Bering Crrier Retiner Wrenh (91-61069). -Bering Crrier Retiner Wrenh 70491 90-859769R1 DECEMBER 2000 Pge 6A-19
3. Pull the ering rrier from the ger housing y pulling on the outer ring of the ering rrier. POSITION PULLER JAWS CLOSE TO BOSSES IN CARRIER. NOTE: If the ering rrier is seized in the ger housing, it my e neessry to use het to loosen the rrier. -Puller Jws (91-46086A1) -Puller Bolt (91-85716) CLEANING/INSPECTION - BEARING CARRIER 70492 IMPORTANT: It is reommended tht ll sels nd O-rings e repled (s norml repir proedure) to ssure effetive repir. 1. Clen ering rrier with solvent nd dry with ompressed ir. 2. Inspet the ering rrier for signs of exessive orrosion espeilly in the re where the ering rrier touhes the ger housing. If exessive orrosion is evident reple the rrier. 50314 -Bering Crrier -Inspet for Corrosion CAUTION DO NOT spin erings dry with ompressed ir, s this ould use ering to sore. 3. Bering rrier propeller shft needle ering ondition is determined y propeller shft ering surfe ondition. (See Propeller Shft Inspetion. ) Pge 6A-20 90-859769R1 DECEMBER 2000
4. Inspet reverse ger to pinion ger wer pttern (should e even nd smooth). If not, reple reverse ger nd pinion ger. 5. Chek luth jws on reverse ger for dmge. Reple reverse ger, if dmge is found on luth jws. 6. Apply light oil to reverse ger ering. Rotte reverse ger ering while heking ering for rough spots nd/or thes. Push in nd pull out on reverse ger to hek for ering side wer. Reple ering if ny of the listed onditions exist. DISASSEMBLY - BEARING CARRIER 1. Remove nd disrd O-ring from etween ering rrier nd thrust wsher. 2. If inspetion of reverse ger or reverse ger ering determines tht replement of ger or ering is required, remove ger nd ering s follows: CAUTION Clmp onto the reinforing ri of the ering rrier ONLY, or dmge to the rrier my result. 3. Ple the ering rrier in vise, lmping on the reinforing ri. 4. Remove the reverse ger, thrust ring, nd ering s n ssemly, using slide hmmer puller d e f -Bering Crrier Reinforing Ri -Bering Crrier -Slide Hmmer Puller (91-34569A1) d-reverse Ger e -Thrust Hu f -Bering (not seen) - Loted in the Crrier 90-859769R1 DECEMBER 2000 Pge 6A-21
IMPORTANT: The ering MUST BE repled if removed from ger. 5. Ple the universl puller plte etween the thrust wsher nd ering s shown nd press on the plte until it ottoms. -Universl Puller Plte (91-37241) -Thrust Wsher -Bering 23351 6. Using suitle mndrel nd the universl puller plte to support the ering, press the ering from the reverse ger s shown. d -Universl Puller Plte (91-37241) -Bering -Ger d-mndrel 23351. Disrd the ering.. Inspet the ger, nd thrust wsher for exessive wer, rks, or dmge. Reple the pproprite omponents if ny of these onditions re found. Pge 6A-22 90-859769R1 DECEMBER 2000
NOTE: Inspetion of the ering surfes on the propeller shft where the needles of the ering rrier needle ering rolls, gives n indition of the ondition of the needle ering inside the ering rrier. Reple needle ering in the ering rrier if the prop shft is pitted, grooved, sored, worn unevenly, disolored from overheting, or hs emedded prtiles. 7. Perform the following step. or. s neessry.. If Repling the Needle Bering nd Sels: Remove the needle ering nd sels with the tools s shown. d -Bering Driver Rod (91-37323) -Needle Bering -Driver Hed (91-36569) d-oil Sels 23140 (1.) Disrd the needle ering nd oth sels.. If Repling the Sel Only: Remove the oil sels with suitle pry r, eing reful not to dmge the ore of the ering rrier. -Oil Sels -Pry Br 23140 (1.) Disrd oth of the sels. 90-859769R1 DECEMBER 2000 Pge 6A-23
BEARING CARRIER ASSEMBLY Component Ressemly NOTE: Complete the instrutions in this setion only if the ssemly omponents hve een disssemled nd repired or repled. 1. Clen ll of the omponents with suitle solvent nd dry the prts thoroughly using ompressed ir. Be reful not to spin the ering. 2. Lurite the ore tht the needle ering is pressed into with Quiksilver Ger Lurint (92-13783A24). 3. Assemle the needle ering (with the numered end of the ering towrds the driver shoulder), onto the driver. 4. Press the needle ering into the ering rrier until the driver ottoms out on the ering rrier. Ensure tht the numered side of the needle ering fes the sel end (ft end) of the rrier. 87 87 Quiksilver Ger Lurint (92-19007A24) 50315 -Needle Bering Driver (P/N 91-15755) -Needle Bering -Bering Crrier Pge 6A-24 90-859769R1 DECEMBER 2000
5. Thoroughly len the ore in whih the first sel is to e pressed. 6. Assemle the first sel (with the lips of the sel fing wy from the driver shoulder) onto the long end of the oil sel driver. 7. Press on the oil sel driver until the driver ottoms on the ering rrier. 50315 -Oil Sel Driver -Oil Sel (91-31108) -Bering Crrier 8. Apply thin film of Lotite 271 (92-809820) to the outer dimeter of the seond sel. 9. Assemle the seond sel (with the lips of the sel fing the driver shoulder) onto the short end of the driver. 10. Press the oil sel with the driver until the driver ottoms out on the ering rrier. 7 95 7 Lotite 271 (92-809820) 95 2-4-C With Teflon (92-825407A12) 50315 -Driver (short end) -Oil Sel (lips towrd driver shoulder) -Bering Crrier 11. Wipe up ll of the exess Lotite. Do not llow ny of the exess Lotite to spred to other prts of the ssemly. 12. Lurite the sel lips nd fill the re etween the sels with 2-4-C w/teflon (92-825407A12). 90-859769R1 DECEMBER 2000 Pge 6A-25
13. Instll the thrust wsher nd new ll ering onto the reverse ger. Press on the inner re of the ll ering using the pilot wsher until the ering ottoms out on the ger. d -Pilot Wsher (P/N 91-36571) -Bll Bering -Thrust Hu d-reverse Ger 23346 14. Lurite the ore tht the ering is pressed into with Quiksilver Ger Lurint (92-13783A24). 15. Press the ering rrier onto the reverse ger nd ering until the ering ottoms out in ering rrier, using the pilot wsher to press ginst the rrier. 87 87 Quiksilver Ger Lurint (92-19007A24) 23349 -Pilot Wsher (91-36571) -Bering Crrier -Reverse Ger nd Bering Assemly Pge 6A-26 90-859769R1 DECEMBER 2000
16. Lurite the O-ring with 2-4-C w/teflon nd instll the O-ring onto the ering rrier. 95 95 2-4-C With Teflon (92-825407A12) 23354 Drive Shft Assemly REMOVAL -O-ring -Bering Crrier 1. Remove the drive shft pinion nut s follows:. Ple the drive shft nut wrenh onto the drive shft. Do not loosen the retiner t this time.. Insert the pinion nut dpter with the MR slot fing the pinion ger into the ger housing. It my e neessry to slightly lift nd rotte the drive shft to lign the pinion ger nut into the pinion nut dpter slot.. Instll the ering rrier into the ger housing kwrds to support the prop shft nd to keep the pinion nut dpter ligned. d. Ple the drive shft nut wrenh over the drive shft splines nd loosen, (ut do not fully unsrew), the pinion nut y rotting the drive shft ounterlokwise. -Drive Shft Nut Wrenh (91-56775) -Drive Shft Bering Retiner Wrenh (91-43506) -Pinion Nut dpter (MR Slot) (91-61067A2) 70887 90-859769R1 DECEMBER 2000 Pge 6A-27
e. If the drive shft is roken, ple propeller shft nut wrenh onto the propeller shft splines, hold shift shft in forwrd ger nd loosen, (ut do not fully unsrew), the pinion nut y rotting prop shft ounterlokwise to turn gers, thus loosening the pinion nut. NOTE: The propeller shft nut wrenh is inluded with the pinion nut dpter kit -Pinion Nut Adptor (MR slot) (91-61067A2) -Propeller Shft Nut Wrenh (91-61067) -Shift Shft (Turn Clokwise) (Protet shft splines with soft mteril) 70607 f. Completely unsrew the drive shft ering retiner. g. Completely unsrew the pinion nut y rotting the drive shft (or the propeller shft) in ounterlokwise diretion. h. Remove ll tools. IMPORTANT: The pinion ering rollers re free to fll out of the pinion ering one the drive shft is removed. Be reful not to loose the (18) rollers. 2. Remove the drive shft nd ll omponents y pulling the drive shft stright out of the ger housing s shown. -Drive Shft -Drive Shft Retiner, Bering Cup, Bering, nd Shims 70608 3. Move the prop shft downwrd nd to the PORT side of the ger se. 4. Retrieve the pinion ger, the wsher nd the nut from the inside of the ger housing. Pge 6A-28 90-859769R1 DECEMBER 2000
NOTE: If pinion ger is seized onto the driveshft, ple gerse in vise using soft jw vise overs. Ple lok of wood on ger housing mting surfe. Use mllet nd refully tp ger housing wy from drive shft. CAUTION Do not strike ger housing hrd with mllet or llow ger housing to fll. -Wood Blok -Drive Shft in Soft Jw Vise 57951 5. Remove lower drive shft ering up nd shims using slide hmmer puller (34569A1) (retin shims for re-instlltion). -Slide Hmmer Puller (91-34569A1) -Lower Drive Shft Bering Cup 90-859769R1 DECEMBER 2000 Pge 6A-29
DISASSEMBLY 1. Both upper nd lower tpered roller erings n e removed from the drive shft in one opertion. Using the ottom ering up removed from the gerse, ple the up on top of vise leving the vise jws open enough to llow the drive shft to slide through. 2. Ple the driveshft through the up nd vise until the ottom ering is resting in the up. While holding the driveshft, tp on the top of the shft with led hmmer until the erings re free. Do not drop the shft when performing this opertion. -Lower Bering Cup Removed from Ger Cse -Drive Shft With Both Upper nd Lower Berings DRIVE SHAFT ASSEMBLY - Inspetion 1. Clen ll prts with suitle solvent nd dry the prts thoroughly using ompressed ir, eing reful not to spin the erings. 2. The ondition of the drive shft ering up is n indition of the ondition of the tpered roller ering on the drive shft. Reple the ering nd ering up if the up is pitted, grooved, sored, worn unevenly, disolored from overheting, or hs emedded prtiles. 3. Inspet the ering surfe on the drive shft where the needles of the lower pinion ering roll. Reple the drive shft if it is pitted, grooved, sored, worn unevenly, disolored from overheting, or hs emedded prtiles. 4. Inspet the splines t oth ends of the drive shft for worn or twisted ondition. Reple the drive shft if either ondition exists. 5. Inspet the ger for pitting, hipped or roken teeth, hirline frtures, nd exessive or uneven wer. Reple the pinion ger nd the forwrd ger s set if ny defets re found. 6. Inspet driveshft for groove(s) where wter pump se oil sels ontt shft. Reple driveshft if groove(s) re found. Pge 6A-30 90-859769R1 DECEMBER 2000
REASSEMBLY RIGHT HAND NON-RATCHETING NOTE: Complete the instrutions in this setion only if the omponents hve een disssemled 1. Apply light ot of Quiksilver Hevy Duty Ger Lurint on l.d. of drive shft tpered ering. Apply High Pressure Grese (suh s Chigo Mnufturing nd Distriuting Lue #3) to the O.D. of oth erings. 2. Assemle new tpered roller ering to the drive shft with the lrge O.D. of the ering fing the pinion ger end of the drive shft. 3. Thred used pinion nut onto end of drive shft. Leve pproximtely 1/16 (2mm) of nut threds exposed. Drive shft threds MUST NOT extend eyond nut or thred dmge ould result while pressing. 4. Press the tpered roller ering onto the drive shft using the universl puller plte nd suitle mndrel, (n old tpered roller ering inner re). d e -Used Pinion Nut -Drive Shft -Tpered Bering(s) d-old Bering Inner Re e -Universl Puller Plte 90-859769R1 DECEMBER 2000 Pge 6A-31
Propeller Shft Assemly nd Forwrd Ger Bering Cup REMOVAL 1. Tilt the propeller shft to the port side of the ger housing nd remove the shft y pulling it stright up nd out. d -Propeller Shft Assemly -Shift Spool -Shift Crnk d-thrust Wsher (Reverse Ger) 58016 2. Remove the forwrd ger ering up nd shims. Mesure nd mke note of the shim thikness. If the shims re not dmged, they my e reused. d e f g h -Puller Shft (91-31229) -Nut (11-24156) -Wsher (91-34961) d-guide Plte (91-816243) e -Puller Hed (from Slide Hmmer Puller Kit 91-34569A1) f -Jws (from Slide Hmmer Puller Kit) g-bering Cup h-shims 50780 Pge 6A-32 90-859769R1 DECEMBER 2000
PROPELLER SHAFT ASSEMBLY - Component Disssemly NOTE: When omplishing the next step, ll of the prts re free to ome prt. Work losely over work enh to ensure tht the prts re not dropped or dmged nd to void personl injury 1. Remove the spring round the luth eing reful not to over-streth it during removl. If the spring does not oil k to its norml position one it hs een removed, it must e repled. 2. Remove detent pin. 3. Remove the ross pin tht goes through the luth. 4. Remove the reminder of the omponents e d f -Spring -Cross Pin -Shift Spool Assemly d-forwrd Ger Assemly e -Sliding Cluth f -Detent Pin (hidden) PROPELLER SHAFT ASSEMBLY - Component Inspetion 1. Clen ll the prts with suitle solvent nd dry the prts thoroughly using ompressed ir, eing reful not to spin erings 2. Inspet the sliding luth jws for dmge. Jws must not e hipped or rounded off. Reple the luth if they re. 3. Inspet the ering surfes on the propeller shft where the needles of the ering rrier needle ering nd the needles of the forwrd ger needle ering roll. Reple the propeller shft if it is pitted, grooved, sored, worn unevenly, disolored from overheting, or hs emedded prtiles. 58017 -Bering Crrier Needle Bering Contt Are -Forwrd Ger Needle Bering Contt Are -Splines 23355 90-859769R1 DECEMBER 2000 Pge 6A-33
4. Inspet the propeller shft splines t oth ends for roken, worn, or twisted ondition. Reple the propeller shft if ny of these onditions exists. 5. Inspet the surfe of the propeller shft where the ering rrier sel lips ontt the shft. If the oil sels hve mde grooves, reple the propeller shft nd oil sels. -Bering Crrier Sel Contt Are -Splines 23355 6. Inspet reverse ger thrust wsher surfe for wer or tper. If surfe is worn or tpered, propeller shft must e repled. -Thrust Wsher Surfe 23355 7. Inspet the propeller shft for ent ondition.. V-Bloks nd Dil Inditor (1.) Position the propeller shft ering surfes on V-loks. (2.) Adjust the height of V-loks to level the propeller shft. (3.) Position the dil inditor tip just forwrd of the propeller shft splines. 8. Rotte the propeller shft nd oserve the dil inditor movement, If the inditor in the dil moves more thn 0.009 in. (0.23mm), reple the propeller shft. -Chek Movement with Dil Inditor (P/N 91-58222A1) Here 52727 Pge 6A-34 90-859769R1 DECEMBER 2000
9. Mesure propeller shft FORWARD to REVERSE shoulder length. If mesurement is under 2.040 in. (51.82mm), reple propeller shft. 2.040 in. (51.82mm) 23355 10. Inspet REVERSE thrust wsher for wer or tper. Mesure thikness of wsher. If thikness is LESS thn 0.240 in. (6.1mm), reple wsher 0.240 in. (6.096mm) Forwrd Ger Assemly COMPONENT INSPECTION 1. Clen the forwrd ger ssemly nd the forwrd ger ering up with suitle solvent nd dry with ompressed ir. Be reful not to spin the erings. 2. Inspet the ger for pitting, hipped or roken teeth, hirline frtures, nd exessive or uneven wer. Reple the forwrd ger nd the pinion ger s set if ny defets re found. 3. Inspet the luth jws of the ger for dmge. The surfes must not e hipped or rounded off. Reple oth the forwrd nd pinion ger s set if ny of these onditions exist. -Forwrd Ger Teeth -Cluth Jws 23351 90-859769R1 DECEMBER 2000 Pge 6A-35
4. Inspet the needle erings on the inside of the forwrd ger nd the ering surfe on the propeller shft. If either the needle ering or the ering surfe of the propeller shft is pitted, grooved, sored, worn unevenly, disolored from overheting, or hs emedded prtiles, reple the propeller shft nd remove nd reple the needle ering in the forwrd ger s outlined in the next setion. -Forwrd Ger Needle Bering Contt Are 23355 5. Inspet the tpered roller erings on the forwrd ger nd the ering surfe on the forwrd ger ering up. If either the roller erings or the ering surfe of the forwrd ger ering up is pitted, grooved, sored, worn unevenly, disolored from overheting, or hs emedded prtiles, reple the forwrd ger ering up nd remove nd reple the tpered roller erings s outlined in the next setion. FORWARD GEAR ASSEMBLY - Component Disssemly NOTE: Forwrd ger n only e removed from ger housing fter drive shft nd pinion ger hve een removed. 1. Reh into ger housing nd lift out forwrd ger. IMPORTANT: DO NOT remove tpered ering or needle erings from forwrd ger unless replement of erings is required. (Berings nnot e reused fter they hve een removed.) 2. If inspetion determines tht replement of forwrd ger tpered ering is required, seprte ger from ering s follows:. Press Universl Puller Plte (91-37241) etween forwrd ger nd tpered ering.. Ple ssemly on press nd press ger out of ering with suitle mndrel. NOTE: Tpered ering nd re MUST BE repled s set. -Forwrd Ger Bering -Universl Puller Plte (91-37241) -Mndrel 91-37241 51119 Pge 6A-36 90-859769R1 DECEMBER 2000
3. If inspetion determines tht replement of propeller shft needle erings is required, remove ering s follows:. Clmp forwrd ger in soft jw vise seurely.. Use suitle tools (srewdriver nd wl) to remove retining ring. Use punh nd hmmer to remove ering. 57905 19203 -Retining RIng -Bering FORWARD GEAR ASSEMBLY - Component Ressemly NOTE: Complete the instrutions in this setion only if the ssemly omponents hve een disssemled nd repired or repled. 1. Apply Quiksilver ger lurint to I.D. of forwrd ger. Press ering into forwrd ger using Forwrd Ger Bering Instller Tool until tool ontts ger. 87 91-877321A1 87 Super Duty Ger Lurint (92-850737A1) -Forwrd Ger Bering Instller (91-877321A1) -Needle Bering, Numered Side Towrd Instller Tool 90-859769R1 DECEMBER 2000 Pge 6A-37
2. Instll retining ring into groove of forwrd ger y strting t one end of retining ring nd working it round until seted in groove. -Retining Ring -Groove in Forwrd Ger Shift Spool Assemly INSPECTION 57905 1. Clen the ssemly with suitle solvent nd dry the prts using ompressed ir. 2. Inspet the shift spool ssemly for dmge. Smll niks nd urrs my e smoothed. If ny prts re dmged or worn exessively, it will e neessry to reple the omplete shift spool ssemly. Individul prts re not ville for the ssemly. 3. Inspet the shift spool for wer in the re where the shift rnk omes into ontt. 55694 -Contt Are -Non-Rtheting Shift Spool 4. Inspet to insure tht the spool spins freely (it my e helpful to lightly tp the stle nut end of the shift spool ginst firm surfe to lign the internl prts). 5. Inspet to insure tht the spool hs 0.002-0.010 (0.05 mm - 0.25 mm) end ply. This end ply my e hieved y turning the stle nut lokwise down until it is snug nd then king off the nut ounterlokwise to the first otter pin slot..002 (0.05mm) to.010 (0.25mm) Pge 6A-38 90-859769R1 DECEMBER 2000 55694
NOTE: If the spool spins freely nd hs the proper lerne, it will not e neessry to disssemle nd ressemle the spool. If the spool does not funtion properly, proeed with the following disssemly proedures. SHIFT SPOOL DISASSEMBLY NOTE: Disssemly of the shift spool is for lening nd inspetion of the internl prts due to n improperly funtioning shift spool ssemly or deris in the ger housing nd/or shift spool ssemly. Individul omponents for the shift spool re not ville s replement prts. If the shift spool does not funtion properly nd the following lening nd djustment proedures do not orret the prolem, it will e neessry to order new shift spool ssemly. 1. Remove nd disrd the otter pin. 2. Remove the stle nut nd spool. 3. Clmp the spool in vie eing reful not to dmge the spool. 4. Unsrew the retiner. SHIFT SPOOL REASSEMBLY 1. Ple the shift spool onto the shift spool shft. 2. Srew the stle nut down until it touhes the wsher nd slight resistne is felt. 3. Loosen the stle nut until the otter pin slot of the nut is ligned with the hole in the shft. If, when the stle nut is srewed down, the otter pin slot is lredy ligned t the hole in the shft, k the stle nut off until the next ville slot in the nut is ligned with the hole in the shft. 4. Insert new otter pin nd end ends of the otter pin in opposite diretions. 5. Verify the spool hs 0.002-0.010 in. (0.05 mm - 0.25 mm) end ply. If it does not, redjust the stle nut gin. -Shift Shft -Spool d -Cstle Nut d-cotter Pin 55694 6. If this djustment did not produe the desired results it will e neessry to disssemle, len, nd ressemle the shift spool ssemly. If the spool ssemly hs lredy een disssemled nd lened it will e neessry to reple the shift spool ssemly. 90-859769R1 DECEMBER 2000 Pge 6A-39
Propeller Shft Assemly COMPONENT REASSEMBLY 1. Instll the sliding luth on the propeller shft. Align ross pin holes in the luth with the slot in the propeller shft. 2. Assemle the forwrd ger ssemly to the propeller shft. 3. Assemle the shift spool ssemly to the propeller shft eing sure to lign the ross pin hole of the shift spool shft with the luth. 4. Assemle the ross pin through the sliding luth, through the propeller shft nd through the shift spool shft hole. 5. Instll detent pin in 3rd hole in luth. 6. Assemle the ross pin retining spring over the propeller end of the propeller shft nd wind it round the luth over the ross pin hole. Be reful not to distort the spring while ssemling it. Mke sure tht the spring is wound on so tht it does not ross over on itself nd tht it lies flt ginst the luth one it is ssemled. If it does not lie flt ginst the luth, new spring must e instlled. d f e g -Sliding Cluth -Forwrd Ger Assemly -Cross Pin (hidden) d-propeller Shft e -Spool nd Atuting Shft Assemly f -Cross Pin Retining Spring g-detent Pin (hidden) 58017 Pge 6A-40 90-859769R1 DECEMBER 2000
Shift Shft Assemly REMOVAL RIGHT HAND NON-RATCHETING NOTE: It is possile to remove nd servie the shift shft ssemly (ut not the shift rnk inside the ger se) without removing ny of the internl omponents of the ger housing. 1. Remove the shift shft ushing srews, nd remove the shift shft nd ushing y pulling oth stright out of ger housing. -Shift Shft Bushing Srews 57934 2. Remove the shift rnk from the inside of the ger housing. Clen it with suitle solvent nd dry it thoroughly. Inspet it for wer in the res tht ontt the shift spool nd inspet the splines nd the dimeter tht goes over the loting pin for dmge or wer. d 23350 -Contt Are -Shift Crnk -Splines d-dimeter for Loting Pin 90-859769R1 DECEMBER 2000 Pge 6A-41
SHIFT SHAFT ASSEMBLY - Component Disssemly nd Inspetion 1. Slide the ushing ssemly off the shift shft. Remove the oupler from the shft. e -Shift Shft Bushing Assemly -O-ring -Shift Shft d-gsket e -Ruer Wsher d 57954 2. Clen ll omponents with suitle solvent nd dry thoroughly with ompressed ir.. Inspet the shift shft ushing for rking, dmge, or exessive wer.. Inspet the oil sel inside the ushing, the sleeve, nd the O-rings on the outside of the ushing for dmge or exessive wer.. Inspet the speedometer onnetor for dmge or lokge. If ny of these onditions exist, reple the pproprite omponents. -Shift Shft Bushing -Oil Sel (Oil Sel is Replele) -Speedometer Tue Connetor 57932 Pge 6A-42 90-859769R1 DECEMBER 2000
3. Inspet the shift shft splines nd oil sel surfe for orrosion nd/or exessive wer. Reple the shift shft if either if these onditions re found. -Oil Sel Surfe -Spline 57948 SHIFT SHAFT ASSEMBLY - Component Ressemly 1. Lightly lurite the set of the O-ring dimeter on the ushing nd the lip of the oil sel with 2-4-C w/teflon (92-825407A12). 2. If the speedometer onnetor ws removed nd/or repled, lightly ot the threds of the onnetor with Quiksilver Perfet Sel (91-34277-1). Assemle the speedometer onnetor to the ushing nd torque the onnetor to 4.5 l. in. (0.5 Nm). 3. Assemle ll omponents s shown elow. h g 19 95 d 19 Perfet Sel (92-34227-1) 95 2-4-C With Teflon (92-825407A12) -Shift Shft -Speedometer Pressure Hose -Bolt (2) [Torque to 60 l. in. (7 Nm)] d-bushing e -Gsket f -O-ring g-ruer Wsher h-sel (Lip Fes Up) f e 90-859769R1 DECEMBER 2000 Pge 6A-43
Pinion Bering REMOVAL NOTE: Inspet the ering surfe on the drive shft where the needles of the lower pinion ering roll. The ondition of the drive shft t this lotion gives n indition of the ondition of the needle ering. Reple lower pinion ering (needles nd re s set) if the drive shft is pitted, grooved sored, worn unevenly, disolored from overheting, or hs emedded prtiles. IMPORTANT: All the needle erings (18) MUST BE in ple inside ering re while driving the pinion ering from the ger housing. IMPORTANT: Do not reuse the ering (re or rollers) one it hs een removed. 1. Remove nd disrd the pinion ering (re nd rollers) using tools s shown. d -Pinion Bering -Bering Driver (91-36569) -Pilot Wsher (91-36571) d-driver Rod (91-37323) 70614 Pge 6A-44 90-859769R1 DECEMBER 2000
Ger Housing Ressemly RIGHT HAND NON-RATCHETING Ger Housing Inspetion 1. Clen the ger housing thoroughly with suitle solvent nd hrd ristle rush. Dry the ger housing thoroughly using ompressed ir. Insure tht ll selnts, loking gents nd deris re removed. 2. Verify the 2 oil irultion holes in the drive shft ore nd the shift shft hole re ler nd free of deris. 3. Inspet the ger housing for exessive orrosion, impt or ny other dmge. Exessive dmge nd/or orrosion requires replement of the ger housing. 4. Inspet the ering rrier retiner threds in the ger housing for orrosion nd/or stripped threds. Dmge or orrosion to the threds requires replement of the ger housing. 5. Inspet ering re/up ontt res for evidene of ering up spinning. Chek tht ering ups re not loose in ering ores. Any one ering ore in whih the re/up is loose will require replement of the ger housing. 6. Inspet for lokge in wter inlet holes nd the speedometer hole, len s neessry. Be reful not to enlrge the speedometer hole s this ould use erroneous speedometer redings. 7. Verify tht the loting pins re in ple in the ger housing nd tht the orresponding holes in the drive shft housing re not elongted. The drive shft my rek if the housings re not ligned properly due to missing loting pins or elongted holes. 90-859769R1 DECEMBER 2000 Pge 6A-45
Pinion Bering INSTALLATION IMPORTANT: Instll only new pinion ering. Do not reinstll pinion ering tht hs een previously removed from ger housing. 1. Lurite the ore into whih the pinion ering is to e instlled with Quiksilver Ger Lurint (92-19007A24). 2. Position the new pinion ering (with the rdord shipping sleeve in ple) onto the driver hed, with the lettered nd numered side of the ering oriented upwrd. 3. Insert the driver with the ering ssemly, into position (y wy of the propeller shft ore) t the drive shft ore s shown. e d f g 87 87 Quiksilver Ger Lurint (92-19007A24) 70615 -Drive Shft Pinion Bering (With Crdord Shipping Sleeve) -Driver Hed (91-38628) -Puller Shft (91-31229) d-wsher (12-34961) e -Nut (11-24156) f -Pilot Wsher (91-36571) g-puller Plte (91-29310) 4. Instll the ering y srewing down the nut until the ering is fully seted ginst the ore shoulder. Pge 6A-46 90-859769R1 DECEMBER 2000
Forwrd Ger Bering Cup INSTALLATION RIGHT HAND NON-RATCHETING Forwrd Ger Bklsh.017 in. to.028 in. (0.43mm to 0.71mm) NOTE: If the forwrd ger, forwrd ger ering nd up, or ger housing were not repled, instll the sme quntity of shims tht were tken out when up ws removed. If the forwrd ger, forwrd ger ering/up, or ger housing were repled, instll 0.020 in. (0.51mm) of shims. NOTE: If klsh hs lredy een heked nd it ws determined tht it needs to e djusted, (see Cheking Forwrd Ger Bklsh), dding or sutrting 0.001 in. (0.03mm) shims will hnge the ger klsh y the sme mount. Exmple 1 (if klsh is too high) If Forwrd Bklsh Cheks:.040 in. (1.02 mm) (Sutrt):.018 in. (0.46 mm) Add This Quntity of Shims:.022 in. (0.56 mm) Provides Bklsh of 0.018 (0.46 mm) Exmple 2 (if klsh is too low) Bklsh Cheks: Sutrt this Quntity of Shims:.010 in..008 in. (0.25 mm) (0.30 mm) Provides Bklsh of 0.018 (0.46 mm) 1. Lurite the ore into whih the forwrd ger ering up is to e instlled with Quiksilver Ger Lurint (92-19007A24). 2. Ple the shim(s) into forwrd ore of ger housing. 90-859769R1 DECEMBER 2000 Pge 6A-47
3. Press the ering up into the ger housing using the instlltion tool s follows: IMPORTANT: Verify tht the ering up is positioned s stright s possile to void oking it in the ore while pressing it in. d 87 87 Quiksilver Ger Lurint (92-19007A24) -Hex-Hed Srew -Bering Cup Instlltion Tool (91-18605A1) -Driver Cup (91-31106) d-shims 50791 Shift Shft Assemly INSTALLATION 1. Ple the shift rnk onto the loting pin in the forwrd setion of the ger housing. Ensure tht the shift rnk fes towrds the left (port) side of the ger housing. -Shift Crnk -Loting Pin 50314 Pge 6A-48 90-859769R1 DECEMBER 2000
2. Instll the shift shft ssemly into the ger housing s shown. Engge the splined end of the shift shft with the shift rnk. Verify O-ring is positioned properly nd lurited with 2-4-C w/teflon. Seure shift shft ushing with 2 srews. Torque srews to 60 l. in. (7 Nm). -Shift Shft Assemly -Srews [Torque to 60 l. in. (7 Nm)] 57933 NOTE: If the pinion ering needle erings hve fllen out, instll 18 needles into needle ering outer re. Use 2-4-C w/teflon (92-825407A12), to help hold needles in ple. 95 95 2-4-C With Teflon (92-825407A12) 23142 -Rollers (18) -Roller Bering Outer Re 90-859769R1 DECEMBER 2000 Pge 6A-49
Propeller Shft Assemly INSTALLATION 1. To llow for the enggement of the shift spool with the shift rnk, tilt the propeller end of the propeller shft ssemly to the left (port) side of ger housing nd rotte the shift shft from reverse to neutrl while instlling shft. -Shift Atuting Spool -Shift Crnk -Propeller Shft Assemly 58016 2. Operte the shift shft to ensure tht it hs een properly instlled. The sliding luth should move forwrd when the shift shft is turned lokwise, nd should move ft when the shift shft is turned ounterlokwise. 3. Slide the ruer wsher t top end of shift shft down so tht it just touhes the oil sel in the ushing. -Ruer Wsher 57947 Pge 6A-50 90-859769R1 DECEMBER 2000
Drive Shft nd Pinion Ger INSTALLATION RIGHT HAND NON-RATCHETING NOTE: If the originl shims were not retined or if pinion ger, drive shft, drive shft upper tpered roller ering nd up, or ger housing were repled, strt off y instlling 0.038 in. (0.96 mm) shim(s), for the upper tpered roller ering. NOTE: If the originl shims were retined (or mesurement known) nd none of the ove listed prts were repled, reinstll the sme shims or sme mount of shims. 1. Ple the upper tpered ering shim(s) into the drive shft housing ore. -Shim(s) 70620 NOTE: For ese of instlltion, glue the wsher to the pinion ger, using 3M Adhesive (92-25234), or Quiksilver Bellows Adhesive (92-86166), or equivlent. NOTE: If the klsh my hve to e hnged, it is reommended tht Lotite 271 NOT e pplied to the pinion nut UNTIL the klsh setting is finlized. DO NOT reuse the old pinion nut. Instll NEW pinion nut fter klsh is finlized. NOTE: Do not instll the lower tpered ering up or shim(s) t this time. 90-859769R1 DECEMBER 2000 Pge 6A-51
2. Apply Lotite 271 (92-809820) to the threds of the pinion ger nut nd ple the pinion ger nut into the MR slot of the pinion nut dpter. NOTE: Instll the pinion ger nut with the flt side of the nut wy from the pinion ger. 3. Ple the pinion ger nd wsher into the ger housing. 4. Insert the pinion nut dpter (with the nut) into the ger housing. 5. Insert the drive shft into the ger housing drive shft ore. It my e neessry to rotte the drive shft to engge the drive shft splines into the pinion ger splines. 6. Strt the pinion nut onto the drive shft threds y rotting the drive shft until the nut is snug. -Pinion Ger (with the wsher glued to it) -Pinion Nut Adptor (91-61067A2) -Drive Shft 57952 7. Instll the upper drive shft tpered roller ering up. Apply 2-4-C w/teflon to the retiner threds nd instll the retiner. -Tpered Roller Bering Cup -Drive Shft Retiner 57953 Pge 6A-52 90-859769R1 DECEMBER 2000
8. Instll the ering rrier into the ger housing kwrds to hold the propeller shft nd the pinion nut dptor in position. 9. Torque the pinion nut to 75 l. ft. (102 Nm) y turning the drive shft using the drive shft nut wrenh nd torque wrenh. -Pinion Nut Adpter (91-61067A2) -Drive Shft Nut Wrenh (91-56775) -Bering Crrier (instlled kwrds) 10. Remove the ering rrier, pinion nut dpter nd drive shft nut wrenh. 11. Torque the retiner to 100 l. ft. (135 N m). 57950 -Drive Shft Bering Retiner Wrenh (91-43506) 57935 90-859769R1 DECEMBER 2000 Pge 6A-53
Ger Lotion/Bklshes/Cheking nd Adjustment Drive Shft - Bering Prelod Tool INSTALLATION 1. Instll the omponents from the Bering Prelod Tool Kit (91-14311A2), over the drive shft in the order shown. d e d f g -Top Nut with Threded Pipe -Nut -Spring d-thrust Wsher (2 Required) (12-18448) e -Thrust Bering f -Thrust Wsher g-plte 70496 2. Pull up on the drive shft nd tighten the two (2) llen srews in the top nut of the ering prelod tool. -Allen Srews 57936 Pge 6A-54 90-859769R1 DECEMBER 2000
3. Mesure distne () nd inrese tht distne y 1 in. (25.4mm) y turning ottom nut wy from top nut. Pinion Ger Lotion -Distne 1 in. (25.4mm) -Bottom nut [srewed down pproximtely 1 in. (25.4mm)] CHECKING AND ADJUSTING Pinion Depth 0.025 in. (0.64mm) NOTE: If the ering prelod tool hs not lredy een set up, refer to Drive Shft - Bering Prelod Tool, Instlltion setion first. NOTE: The prop shft nd forwrd ger n e instlled when heking pinion height IF Pinion Height Tool 91-56048 is used. 1. Ple the pinion ger shimming tool into the ger housing. 57937 NOTE: Tke the following mesurements t 3 lotions, rotting the drive shft 120 degrees etween eh reding (lwys rotte the drive shft in lokwise diretion). 2. Insert the thikest feeler guge tht fits snugly etween one tooth of the pinion ger nd high point of the shimming tool. 3. Rotte the drive shft 120 degrees in lokwise diretion nd tke nother reding. 4. Repet this proess until 3 redings hve een tken. 5. Add the three redings together nd divide the sum y 3 to get the verge pinion ger height. Mke note of this verge mesurement. The verge pinion ger height should e 0.025 in. (0.64mm). 90-859769R1 DECEMBER 2000 Pge 6A-55
6. If the verge pinion ger height is not orret, remove the ering prelod tool, the drive shft retiner nd the drive shft tpered roller ering up. (The up n e removed y wiggling the drive shft k nd forth or y turning ger housing nd shking it.) Add or sutrt shims eneth the up to otin the proper verge pinion ger height. Reinstll the up nd retiner. Retorque retiner to 100 l. ft. (135 Nm). Reinstll the ering prelod tool nd rotte the drive shft t lest 3 full turns in lokwise diretion. Rehek the pinion ger height s in step 5 ove. Repet this proess until the verge pinion ger height is within speifition. -Pinion Ger Shimming Tool (91-12349A2) Using Dis #2 nd Flt #4-0.025 in. (0.64mm) Feeler Guge 24643 Pge 6A-56 90-859769R1 DECEMBER 2000