Gear Housing - EZ Shift

Lower Unit
Section 6A - Gear Housing - EZ Shift
Table of Contents

Gear Housing Specifications............................6A-2 Bearing Carrier Assembly.......................6A-31

Gear Housing (Driveshaft) EZ Shift Components Forward Gear Assembly.........................6A-37
.........................................................................6A-8 Clutch Actuator Rod Assembly and
Gear Housing (Propeller Shaft) EZ Shift Installation...............................................6A-38
Components...................................................6A-12 Propeller Shaft Assembly.......................6A-39
General Service Recommendations..............6A-14 Driveshaft Wear Sleeve Installation........6A-41
Bearings..................................................6A-14 Lower Driveshaft Bearing Race Installation
Shims......................................................6A-14 ................................................................6A-42
Seals.......................................................6A-15 Oil Sleeve Installation.............................6A-44
Draining and Inspecting Gear Housing Lubricant Driveshaft Upper Bearing Installation.....6A-44
.......................................................................6A-15 Pinion Gear Depth..................................6A-45
Gear Housing Removal..................................6A-15
Gear Housing Disassembly...........................6A-16
Forward Gear, Driveshaft Lower Bearing,
Pinion Gear and Driveshaft Installation 6
Water Pump Disassembly......................6A-16
Shift Shaft Disassembly..........................6A-19
................................................................6A-49
Bearing Carrier and Propeller Shaft
A
Bearing Carrier and Propeller Shaft Removal Installation...............................................6A-50
................................................................6A-20 Forward Gear Backlash..........................6A-52
Propeller Shaft Disassembly...................6A-23 Shift Shaft Assembly...............................6A-54
Propeller Shaft Inspection.......................6A-25 Water Pump Assembly and Installation
Pinion Gear, Driveshaft, and Forward Gear ................................................................6A-55
Removal..................................................6A-26 Gear Housing Pressure Test..................6A-60
Upper Driveshaft Bearing Removal........6A-28 Gearcase Installation.....................................6A-60
Oil Sleeve Removal................................6A-29 Filling Gear Housing with Lubricant...............6A-62
Lower Driveshaft Bearing Race Removal Trim Tab Adjustment and Replacement........6A-63
................................................................6A-30 Replacement...........................................6A-63
Forward Gear Bearing Race Removal....6A-30 Adjustment..............................................6A-63
Gear Housing Assembly................................6A-31
Forward Gear Bearing Race Assembly
................................................................6A-31

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Gear Housing - EZ Shift

Gear Housing Specifications

Models 75/90 (EU 80/100) Gear Housing Specifications
Gear Ratio 2.33:1
Gearcase Capacity 710 ml (24 fl. oz.)
Lubricant Type High Performance Gear Lubricant
Forward Gear ‑ Number of Teeth 28 Spiral/Bevel
Pinion Gear ‑ Number of Teeth 12 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Forward Gear Backlash 0.33 ‑ 0.48 mm (0.013 ‑ 0.019 in.)
Water Pressure @ 700 RPM (Idle) 5 ‑ 21 kPa (0.7 ‑ 3.0 psi)
Water Pressure @ 6000 RPM 175 ‑ 240 kPa (24 ‑ 35 psi)
Leak Test 69 ‑ 83 kPa (10 ‑ 12 psi) for 5 minutes

Model 115 Gear Housing Specifications

Gear Ratio 2.07:1
Gearcase Capacity 710 ml (24 fl. oz.)
Lubricant Type High Performance Gear Lubricant
Forward Gear ‑ Number of Teeth 29 Spiral/Bevel
Pinion Gear ‑ Number of Teeth 14 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Forward Gear Backlash 0.33 ‑ 0.48 mm (0.013 ‑ 0.019 in.)
Water Pressure @ 700 RPM (Idle) 5 ‑ 21 kPa (0.7 ‑ 3.0 psi)
Water Pressure @ 6000 RPM 175 ‑ 240 kPa (24 ‑ 35 psi)
Leak Test 69 ‑ 83 kPa (10 ‑ 12 psi) for 5 minutes

Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
Pinion nut, shift shaft seal outside diameter,
water pump base screws, water pump
cover screws, driveshaft ring seal
Bearing carrier stud, outside diameter of
prop shaft seals
Outside diameter of bearing carrier seal
Outside diameter of seal
Outside diameter of driveshaft rubber ring
7 Loctite 271 Threadlocker Pinion nut threads 92-809819
Outside diameter of shift shaft bushing oil
seal
Shift shaft bushing screws
Outside diameter of water pump upper seal
Outside diameter of lower water pump seal
Water pump base screw threads
Water pump cover screw threads
Threads of gear housing retaining screws

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 Gear Housing - EZ Shift

Tube Ref No. Description Where Used Part No.

Gearcase
Thrust washers
Thrust bearing
Reverse gear bearing surface
87 High Performance Gear Lubricant Inside diameter of forward gear and outside 92-802854A1
diameter of needle bearing
Forward gear roller bearing and the lower
driveshaft tapered roller bearing
Gear housing
Shift shaft O-ring, inside diameter of all
seals
Bearing carrier O-ring, inner diameter of
prop shaft seals, cam follower
Outside diameter of forward gear bearing
race
Outside diameter of needle bearing and
bearing carrier bore
O-ring and seal lips; outside diameter of
reverse gear bearing and bearing carrier
bore
Inside diameter of bearing
Actuator rod
95 2-4-C Marine Lubricant with Teflon Surface of cross pin 92-802859A1
Outside diameter of bearing race
Inside diameter of bearing sleeve and
outside diameter of upper driveshaft
bearing
Cam pocket of cam follower
O-ring, bearing carrier, and gear housing
mating surfaces
Inside diameter of shift shaft bushing oil
seal; shift shaft bushing O-ring
Lip of each seal
Inside diameter of water pump cover
Water tube seal inner diameter
Driveshaft splines and shift shaft splines
116 RTV 587 Ultra Blue Silicone Sealer Water pump exhaust dam 92-809825

117 Loctite 7649 Primer N Pinion nut threads and driveshaft threads 92-809824

Special Tools
Puller Jaws Assembly 91‑46086A1
Puller Bolt 91‑85716

Removes bearing carrier and bearing races.

9514

Slide Hammer 91‑34569A 1

Aids in the removal of various engine components. Use with
6761 puller jaws.

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Gear Housing - EZ Shift

Bearing Removal and Installation Kit 91‑31229A7

Installs and removes the bearings in all gearcases.
91‑31229A7 tool assembly includes the following components:
11‑24156 Hex Nut
12‑34961 Washer
91‑15755T Bearing Carrier
91‑29310 Plate
91‑29610 Pilot Plate
91‑30366T1 Mandrel
91‑31229 Puller Shaft
91‑32325T Driver Head
91‑32336 Driver Needle Bearing
91‑36379 Puller/Head Gear
91‑36569T Driver Head
91‑36571T Pilot Washer
91‑37292 Roller Bearing
91‑37311 Driver Head
91‑37312 ‑Driver Head
2966
91‑37323 Driver Head Rod
91‑37324 Pilot Washer
91‑38628T Puller/Driver Head
91‑52393 Driver Needle Bearing
91‑52394 Head Pull Rod

Slotted Cross Pin Tool 91‑86642‑‑1

Assists in clutch assembly/disassembly.

9895

Dial Indicator 91‑58222A1

20

30
10

40

Measures gear backlash and pinion gear location.

50
0

60
90

9479
80

70

Driveshaft Holding Tool 91‑889958T

Holds driveshaft during pinion nut removal on the Verado

models.
ob01206

Universal Puller Plate 91‑37241

Removes bearings from gears and the driveshaft.

8505

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Bearing Puller Assembly. 91‑83165T

Removes bearings, races and bearing carriers

3610

Bearing Race Driver 91‑14308T02

Removes pinion bearing race.

8879

Bearing Cup Driver 91‑31106T

06
311

Installs the driven gear bearing cup.

8882

Bearing Installation Driver 91‑13945

Installs reverse gear needle bearing into prop shaft carrier.

8877

Driver Rod 91‑37323

ob01623 Used in pinion gear and pinion bearing installation.

Oil Seal Driver 91‑31108T

Installs bearing carrier oil seals.

8883

Pilot Mandrel 91‑37350T

Presses on inner race of forward gear roller bearing.

8884

Bearing Driver 91‑856875A 1

Installs prop shaft needle bearing into 3 jaw or 6 jaw forward

gear.
8885

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Gear Housing - EZ Shift

Wear Sleeve Installation Tool 91‑14310T 1

Installs wear sleeve onto driveshaft.

8881

Bearing Installation Puller 91‑14309T02

Installs pinion bearing into gearcase.

8880

Bearing Preload Tool 91‑14311A04

Simulates a load on the driveshaft for accurate pinion height

and backlash measurements.

8756

Pinion Gear Locating Tool 91‑12349A05

Measures pinion gear height.

3608

Dial Indicator Adapter 91‑83155

Attaches the dial indicator to the gearcase when checking

backlash.

2999

Backlash Indicator 91‑19660‑‑1

Measures gear backlash.

8757

Oil Seal Driver 91‑13949

Installs oil seals into water pump base.

8878

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 Gear Housing - EZ Shift

Leakage Tester Kit FT8950

Checks gear housing for leakage prior to filling with gear

lubricant.

ob01632

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Gear Housing - EZ Shift

Gear Housing (Driveshaft) EZ Shift Components

30
35 20
7
31
28 7

95 21 95

33

27

29 19
34
23
7

22

25 26 32 42
95
24
18 7
40
11 41
17
10 38
95
12
8 6 39
14 87 37
9
3
36

12 2
13

7 1

15

16
4 5

2068

4 5

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 Gear Housing - EZ Shift

Gear Housing (Driveshaft) EZ Shift Components

Torque
Ref. No. Qty. Description Nm lb. in. lb. ft.
1 1 Gear housing
2 1 Dowel pin (front)
3 1 Oiler tube
4 3 Drain screw 7 60
5 3 Sealing washer
6 1 Dowel pin (rear)
7 1 Trim tab
8 1 Screw 30 22
9 1 Washer
10 1 Carrier
11 1 Needle bearing
12 2 Anode
13 1 Nut
14 1 Screw (M6 x 40) 7 60
15 1 Pinion gear (14 teeth)
16 1 Nut 95 70
17 1 Tapered roller bearing
18 AR Shim assembly (sizes 0.006 ‑ 0.048)
19 1 Driveshaft assembly
20 1 Wear sleeve assembly
21 1 Ring seal
22 1 Water pump base assembly
23 1 Gasket
24 1 Gasket
25 1 Oil seal (upper)
26 1 Oil seal (lower)
27 1 Gasket
28 1 Upper water pump housing
29 1 Face plate
30 4 Screw (M6 x 30) 7 60
31 1 Seal
32 1 Key
33 1 Impeller
34 6 Screw (M6 x 25) 7 60
35 1 Face seal
36 1 Shift shaft assembly
37 1 E‑ring
38 1 Bushing assembly
39 1 O‑ring
40 1 Oil seal

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Torque
Ref. No. Qty. Description Nm lb. in. lb. ft.
41 2 Screw (M6 x 25) 7 60
42 1 Bushing

Tube Ref No. Description Where Used Part No.

Pinion nut, shift shaft seal
outside diameter, water pump
7 Loctite 271 Threadlocker 92-809819
base screws, water pump cover
screws, driveshaft ring seal
High Performance Gear
87 Gearcase 92-802854A1
Lubricant
2-4-C Marine Lubricant with Shift shaft O-ring, inside
95 92-802859A1
Teflon diameter of all seals

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 Gear Housing - EZ Shift

Gear Housing (Driveshaft) EZ Shift Components

30
35 20
7
31
28 7

95 21 95

33

27

29 19
34
23
7

22

25 26 32 42
95
24
18 7
40
11 41
17
10 38
95
12
8 6 39
14 87 37
9
3
36

12 2
13

7 1

15

16
4 5

2068

4 5

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Gear Housing - EZ Shift

Gear Housing (Propeller Shaft) EZ Shift Components

31
13 1

14
15
11
12

95
9 2
8 4
6

10

7 5
21
3
95 19

95

17

18

24
23
22 20 16

95
30
28
29
7

95
25
26
27 12230

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 Gear Housing - EZ Shift

Gear Housing (Propeller Shaft) EZ Shift Components

Torque
Ref. No. Qty. Description Nm lb. in. lb. ft.
1 1 Gear housing
2 2 Insert
3 1 Cam follower
4 1 Shift cam
5 1 Rod ‑ Clutch actuator
6 1 Cross pin
7 1 Pin ‑ Spring locator
8 1 Spring
9 1 Washer
10 A/R Shim assembly (size 0.006 ‑ 0.038)
11 1 Tapered roller bearing
12 1 Cup
13 1 Forward gear (29 teeth)
14 1 Roller bearing
15 1 Retaining ring
16 1 Clutch
17 1 Propeller shaft
18 1 Spring
19 1 Reverse gear (29 teeth)
20 1 Bearing carrier assembly
21 1 O‑ring
22 1 Roller bearing
23 1 Oil seal (inner)
24 1 Oil seal (outer)
25 1 Roller bearing
26 1 Thrust washer
27 1 Thrust bearing
28 2 Stud (M8 x 48) Drive tight
29 2 Washer
30 2 Nut 30 22
31 1 Decal ‑ Gear housing pinion identification

Tube Ref No. Description Where Used Part No.

Bearing carrier stud, outside
7 Loctite 271 Threadlocker 92-809819
diameter of prop shaft seals
Bearing carrier O-ring, inner
2-4-C Marine Lubricant with
95 diameter of prop shaft seals, 92-802859A1
Teflon
cam follower

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Gear Housing - EZ Shift

General Service Recommendations

There may be more than one way to disassemble or re‑assemble a particular part,
therefore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub‑assembly may not be necessary, until cleaning and
inspection reveals that disassembly is required for replacement of one or more
components.
Service procedure order in this section is a normal disassembly/re‑assembly sequence. It
is suggested that the sequence be followed without deviation to assure proper repairs.
When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to re‑assembly and installation of that
component in the re‑assembly part of this section. Use the Table of Contents (on back of
section divider) to find correct page number.
Threaded parts are right hand (RH), unless otherwise indicated.
Clean surfaces and/or threads with an appropriate solvent before applying Loctite (Mercury
Marine recommends using electrical contact surface cleaner). A primer is not required
unless using Loctite 271 Threadlocker .
IMPORTANT: Primer T must be used with Loctite 271 Threadlocker on all brass,
cadmium‑plated, stainless steel, and instances where two dissimilar metal surfaces are
being joined. Regular steel surfaces do not require a primer, but do require that their contact
surfaces be cleaned using an appropriate solvent.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in air line.
Bearings
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing
so that it passes through the bearing. Do not spin bearing with compressed air, as this may
cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with High
Performance Gear Lubricant. Do not lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing
race in and out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condition of rollers and inner bearing race
by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles
and/or discoloration from overheating. Always replace tapered bearing and race as a set.
Inspect gear housing for bearing races that have spun in their respective bores. If race has
spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that
the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded
particles, uneven wear and/or discoloration from overheating. The shaft and bearing must
be replaced, if the conditions described are found.
Shims
Keep a record of all shim amounts and location during disassembly to aid in re‑assembly.
Be sure to follow shimming instructions during re‑assembly, as gears must be installed to
correct depth and have the correct amount of backlash to avoid noisy operation and
premature gear failure.

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 Gear Housing - EZ Shift

Seals
As a normal procedure, all O‑rings and oil seals should be replaced without regard to
appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter of
all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean
and dry. To ease installation, apply 2‑4‑C with Teflon on all O‑rings. To prevent wear, apply
2‑4‑C with Teflon on inner diameter of oil seals.

Draining and Inspecting Gear Housing Lubricant

! WARNING
If gear housing is installed on outboard, disconnect and isolate spark plug leads from
spark plugs before working near the propeller.

1. Position a clean drain pan under gear housing and remove vent screws and fill/drain
screw with gaskets from gear housing.

a
b
ob00441

a - Vent screws b - Fill/drain screw

2. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal
particles resembling powder indicates normal wear. Presence of larger particles or a
large quantity of fine particles, indicates need for gear housing disassembly and
inspection.
3. Note the color of gear lubricant. White or cream color indicates presence of water in
lubricant. Check drain pan for water separation from lubricant. Presence of water in
gear lubricant indicates the need for disassembly, and inspection of oil seals, seal
surfaces, O‑rings and gear housing components. Pressure check gearcase prior to
disassembly.
NOTE: When draining gearcase for the first time, lubricant may appear cream colored due
to the mixing of assembly lubricant and gear lubricant. This is not an indication of water
intrusion. If, during subsequent draining of gearcase, lubricant appears cream colored or
milky, water may be present. Gearcase should be disassembled and all gaskets, seals and
O‑rings replaced. Inspect all components for water damage.
NOTE: Gear lubricant drained from a recently run gearcase will be a light chocolate brown
in color due to agitation/aeration. Oil which is stabilized will be a clear yellow brown in color.

Gear Housing Removal

1. Shift the engine into forward gear.
2. Tilt the engine to full up position.

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Gear Housing - EZ Shift

! WARNING
To prevent accidental engine starting, remove battery cables from battery before
removing or installing gear housing.
3. Remove the four fasteners.
4. Remove the locknut and washer.

a
b

7156
a - Fasteners (2 each side) b - Locknut and washer (recessed)

5. Remove the gear housing.

Gear Housing Disassembly

Water Pump Disassembly
NOTE: Ensure the water tube seal has been removed from the water tube after gear
housing removal.
1. Replace the water tube seal, if damaged.
2. Remove the two screws on each side of the water pump housing. Remove the washers
and isolators.
3. Remove the cover.

b
c

7157
a
a - Screws (4) c - Cover
b - Water tube seal

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 Gear Housing - EZ Shift

IMPORTANT: Disregard the circular groove formed by the impeller sealing bead when
inspecting the cover and plate, as the depth of the groove will not affect the water pump
output.
4. Replace the cover if the thickness of steel at the discharge slots is
1.50 mm (0.060 in.) or less, or if grooves other than the impeller sealing bead groove
in the cover roof are more than 0.75 mm (0.030 in.) deep.
5. Lift the impeller, drive key, and gasket from the driveshaft.

c
b

7153
a - Impeller c - Gasket
b - Drive key

6. Inspect the impeller. Replace the impeller if any of the following conditions exist:
• Impeller blades are cracked, torn, or worn
• Impeller is glazed or melted
• Rubber portion of impeller is not bonded to impeller hub
7. Remove the plate and gasket.
8. Replace the plate if the grooves, other than the impeller sealing bead groove, are more
than 0.75 mm (0.030 in.) deep.
a
c

7165
a - Plate c - Impeller sealing bead groove
b - Gasket

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Gear Housing - EZ Shift

9. Remove the screws and washers.

a
7168
a - Screws and washers (6)

10. Remove the water pump base using flat screwdrivers to lightly pry up on the base.
a

7171
a - Water pump base

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 Gear Housing - EZ Shift

11. Remove and discard the seals. Do not scar the seal surface in the water pump base
while removing the seals. If the seal surface is scarred, replace the water pump base.

7173
a - Seals

12. Remove the gasket.

7174
a - Gasket

Shift Shaft Disassembly

1. Remove the shift shaft bushing attaching screws.

7206
a - Screws (2) (M6 x 25)

NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing.

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Gear Housing - EZ Shift

2. Remove the shift shaft bushing, and the shift shaft.

b
a

7207
a - Bushing b - Shift shaft

3. Remove the shift shaft bushing and the clip from the shift shaft.
4. Replace the shift shaft if the splines are worn or the shaft is twisted.
5. Remove and discard the O‑ring.
e
a b d a

c
7209
a - Splines d - O‑ring
b - Shift shaft e - Bushing
c - E‑clip

6. Remove and discard the seal. Do not scar the seal surface in the shift shaft bushing
while removing the seal. If the seal surface is scarred, replace the shift shaft bushing.

b 7210

a - Seal b - O‑ring

Bearing Carrier and Propeller Shaft Removal

1. Ensure the gear housing is in neutral.

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 Gear Housing - EZ Shift

2. Remove the locknuts and washers.

a
7175
a - Locknuts and washers

NOTE: The shift cam must be in the neutral postion before the propeller shaft can be
removed from the grearcase.
3. With the propeller shaft horizontal, use the puller jaws and bolt to break the bearing
carrier to gear housing seal.
4. Remove the bearing carrier/propeller shaft components as an assembly by pulling back
on the propeller shaft.
5. Remove the propeller shaft from the bearing carrier.

b a
c

e
d
7177
a - Bearing carrier d - Propeller shaft
b - Puller jaws e - Thrust hub
c - Puller bolt

Puller Jaws Assembly 91‑46086A1

Puller Bolt 91‑85716

6. Lift the reverse gear, thrust bearing and thrust washer from the bearing carrier. Replace
the thrust bearing and thrust washer if they are rusted or damaged.

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Gear Housing - EZ Shift

7. Replace the reverse gear if the gear teeth or clutch teeth on reverse gear are rounded
or chipped. If the reverse gear must be replaced, the pinion gear and sliding clutch
should be inspected for damage.

a
b

7178
a - Reverse gear c - Thrust washer
b - Thrust bearing

8. If the reverse gear roller bearing is rusted or does not roll freely, remove the bearing
with a slide hammer and appropriate jaws.
a

7180
a - Roller bearing

Slide Hammer 91‑34569A 1

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 Gear Housing - EZ Shift

9. If bearing replacement is necessary, remove the oil seals and bearing using a mandrel
and driver rod. Discard the oil seals.

a
b

21618

a - Bearing c - Driver rod

b - Mandrel d - Oil seals

Bearing Removal and Installation Kit 91‑31229A7

10. Remove the propeller shaft seals (if not removed previously) and the bearing carrier
O‑ring.

7187
a - O‑ring

Propeller Shaft Disassembly

1. Remove the shift cam from the cam follower.

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Gear Housing - EZ Shift

2. Insert a thin blade screwdriver or awl under the first coil of the cross pin retainer spring,
and rotate the propeller shaft to unwind the spring from the sliding clutch. Do not
over‑stretch the spring.

7395

a - Awl b - Cross pin retainer spring

3. Push the cross pin out of the sliding clutch with a slotted cross pin tool.
4. Pull the sliding clutch off of the propeller shaft.

a
b

c 7397

a - Slotted cross pin tool c - Cross pin

b - Sliding clutch

Slotted Cross Pin Tool 91‑86642‑‑1

5. Pull the cam follower, and clutch actuator rod out of the propeller shaft. Do not force
the cam follower up or down, or side to side when removing it from the propeller shaft.
IMPORTANT: The actuator rod cross pin is free and can fall out of the actuator rod. Care
must be taken not to lose the pin.
6. Remove the actuator rod cross pin from the actuator rod.
7. Remove the washer and spring from the actuator rod.

a f
b d e

c 7398

a - Cam follower d - Spring

b - Clutch actuator rod e - Washer
c - Actuator rod cross pin f - Propeller shaft

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 Gear Housing - EZ Shift

Propeller Shaft Inspection

1. Clean propeller shaft with solvent and dry with compressed air.
2. Inspect bearing carrier oil seal surfaces for grooves. Replace shaft if groove is found.
3. Visually check bearing surfaces of propeller shaft for pitting, grooves, scoring, uneven
wear or bluish discoloration from overheating. Replace shaft and corresponding needle
bearing if any of these conditions are found. The bearing carrier needle bearing
contacts propeller shaft just in front of oil seal surface. The forward gear needle bearing
contacts propeller shaft in front of sliding clutch splines.
4. Inspect propeller shaft splines for wear and/or corrosion damage.
5. Check propeller shaft for straightness.
• Position propeller shaft roller bearing surfaces on V‑blocks. Mount a dial indicator
at front edge of propeller splines. Rotate propeller shaft. Dial indicator movement
of more than 0.228 mm (0.009 in.) or a noticeable wobble, is reason for
replacement.

a ob01640

a - Measuring point b - Bearing surface

Dial Indicator 91‑58222A1

6. Replace propeller shaft if any of the following exist:

• Splines are twisted or worn.
• Bearing surfaces of propeller shaft are pitted or worn.
• Oil seal surface is grooved.
• Shaft has a noticeable wobble or is bent more than 0.228 mm (0.009 in.). Prop
shaft trueness should be measured with a dial indicator with prop shaft on
V‑blocks.
7. Inspect sliding clutch jaws for damage. Jaws must not be chipped or rounded off.
Replace the clutch if damaged. Rounded jaws indicate one or more of the following:
• Improper shift cable adjustment.
• Improper shift habits of operators. Shifting from neutral to reverse gear too slowly.

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Gear Housing - EZ Shift

• Engine idle speed too high while shifting.

a a

9711

a - Clutch jaws

8. Check the cam follower for wear, pitting, scoring or rough surface. If replacement is
needed, replace cam follower and shift cam together.
Pinion Gear, Driveshaft, and Forward Gear Removal
1. Hold the driveshaft using the Driveshaft Holding Tool. Remove and discard the pinion
nut.
2. Remove the driveshaft, pinion gear, lower tapered driveshaft bearing, and forward
gear.
3. Replace the pinion gear if it is chipped or worn.
4. Replace the lower tapered driveshaft bearing and race if either are rusted, pitted, or
damaged; or if the bearing does not roll freely. To remove the race, refer to Lower
Driveshaft Bearing Race Removal.
5. Replace the forward gear if the gear teeth or clutch jaws are chipped or worn.
a
b

d
e

21531
a - Driveshaft d - Pinion gear
b - Driveshaft Holding Tool e - Pinion nut
c - Lower tapered driveshaft bearing f - Forward gear/bearing

Page 6A-26 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

Driveshaft Holding Tool 91‑889958T

6. Replace the forward gear needle bearing if it is rusted or does not roll freely.
7. Use a suitable tool to remove the retaining ring.
a

ob01641

a - Retaining ring

8. Use a punch and hammer to remove the forward gear needle bearing.

a 7198

a - Forward gear needle bearing

9. Replace the forward gear bearing and race if it is rusted, pitted, or damaged; or if the
bearing does not roll freely. Remove the bearing from the gear using a Universal Puller
Plate and mandrel. To remove the race refer to Forward Gear Bearing Race Removal.

a c

b
ob01638

a - Forward gear bearing c - Mandrel

b - Universal Puller Plate

Universal Puller Plate 91‑37241

90-899185 SEPTEMBER 2006 Page 6A-27

Gear Housing - EZ Shift

Bearing Removal and Installation Kit 91‑31229A7

10. Replace the driveshaft if the splines are worn or twisted.

11. If the bearing surface is damaged, replace the driveshaft and the corresponding
bearing.
IMPORTANT: Do not tighten the vise against the driveshaft.
12. If the wear sleeve is deeply grooved allowing water to enter the gearcase, remove and
discard the sleeve using a Universal Puller Plate and mallet.
e

c
d

b
a 21538

a - Crankshaft/driveshaft splines d - Universal Puller Plate

b - Bearing surface e - Mallet
c - Wear sleave

Universal Puller Plate 91‑37241

13. Remove and discard the rubber ring.

a

7200
a - Rubber ring

Upper Driveshaft Bearing Removal

1. Replace upper driveshaft bearing and sleeve if either are rust stained, or if bearing will
not roll freely.

Page 6A-28 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

2. Remove bearing and then sleeve using Puller Assembly with suitable jaws.

b 7201

a - Upper driveshaft bearing c - Puller assembly

b - Sleeve

Bearing Puller Assembly. 91‑83165T

Oil Sleeve Removal

IMPORTANT: The upper driveshaft bearing and sleeve must be removed prior to oil sleeve
removal. Refer to Upper Driveshaft Bearing Removal.
Remove oil sleeve if necessary using Puller Assembly with suitable jaws.

7202
a - Oil sleeve b - Puller Assembly

Bearing Puller Assembly 91‑83165T

90-899185 SEPTEMBER 2006 Page 6A-29

Gear Housing - EZ Shift

Lower Driveshaft Bearing Race Removal

IMPORTANT: Upper driveshaft bearing/sleeve and oil sleeve do not have to be removed
for lower driveshaft bearing race removal.
IMPORTANT: Retain shims for reassembly.
Remove race and shims using bearing race tool.

a
c
7203
a - Bearing race c - Bearing Race Tool
b - Shim

Bearing Race Driver 91‑14308T02

Forward Gear Bearing Race Removal

IMPORTANT: Retain shims for reassembly. If shims are damaged, replace with new shims
of equal thickness.
Remove race and shims using Slide Hammer.

b c
7211
a - Race c - Slide Hammer
b - Shims

Page 6A-30 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

Slide Hammer 91‑34569A 1

Gear Housing Assembly

Forward Gear Bearing Race Assembly
NOTE: Propeller shaft should be vertical when installing bearing race.
1. Place shims retained from disassembly into housing. If shims were lost, or a new gear
housing is used for reassembly, start with 0.254 mm (0.010 in.) shim.
2. Assemble components as shown using bearing cup driver. Apply 2‑4‑C with Teflon to
outside diameter of race. Drive race into housing by striking propeller shaft end with a
dead blow hammer.
NOTE: Install a nut on the end of the propeller shaft to prevent damage to the threads while
performing step 2.

e
d c
a

b 7212

a - Shims d - Disassembled propeller shaft

b - Race e - Assembled bearing carrier
c - Bearing cup driver

Bearing Cup Driver 91‑31106T

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with Outside diameter of forward
95 92-802859A1
Teflon gear bearing race

Bearing Carrier Assembly

1. Lubricate outside diameter of bearing and bearing carrier bore with 2‑4‑C with Teflon.
2. Protect lip on forward side of bearing carrier, using Bearing Installation Tool.

90-899185 SEPTEMBER 2006 Page 6A-31

Gear Housing - EZ Shift

3. Press propeller shaft needle bearing number side toward mandrel, into carrier until
bearing bottoms out.

7224
a - Bearing Installation Tool c - Driver Rod
b - Mandrel

Bearing Installation Driver 91‑13945

Driver Rod 91‑37323

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with Outside diameter of needle
95 92-802859A1
Teflon bearing and bearing carrier bore

4. Place smaller diameter seal on longer shoulder of Oil Seal Driver with seal lip away
from shoulder.

Page 6A-32 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

5. Protect lip on front side of bearing carrier using Bearing Installation Driver. Apply Loctite
271 threadlocker on the outside diameter of seal. Press seal into carrier until tool
bottoms.

a
b

7225
a - Seal c - Bearing Installation Driver
b - Oil Seal Driver

Oil Seal Driver 91‑31108T

Bearing Installation Driver 91‑13945

Tube Ref No. Description Where Used Part No.

Outside diameter of bearing
7 Loctite 271 Threadlocker 92-809819
carrier seal

6. Place larger diameter seal on shorter shoulder of Oil Seal Driver with seal lip toward
shoulder.

90-899185 SEPTEMBER 2006 Page 6A-33

Gear Housing - EZ Shift

7. Protect lip on front side of bearing carrier using Bearing Installation Tool. Apply Loctite
271 threadlocker on outside diameter of new seal. Press seal into carrier until tool
bottoms.

b
c

7228
a - Bearing Installation Tool c - Oil Seal Driver
b - Seal

Oil Seal Driver 91‑31108T

Bearing Installation Driver 91‑13945

Tube Ref No. Description Where Used Part No.

7 Loctite 271 Threadlocker Outside diameter of seal 92-809819

8. Install O‑ring. Lubricate O‑ring with 2‑4‑C with Teflon. Lubricate seal lips with 2‑4‑C
with Teflon.
9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light
coating of 2‑4‑C with Teflon.

Page 6A-34 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

10. Press bearing into carrier until tool bottoms.

b
c

7230

a - O‑ring c - Bearing Installation Tool

b - Bearing

Bearing Installation Driver 91‑13945

Tube Ref No. Description Where Used Part No.

O-ring and seal lips; outside
2-4-C Marine Lubricant with
95 diameter of reverse gear 92-802859A1
Teflon
bearing and bearing carrier bore

11. Install thrust washer. Coat thrust washer with High Performance Gear Lubricant.

7232
a - Thrust washer

Tube Ref No. Description Where Used Part No.

High Performance Gear
87 Thrust washers 92-802854A1
Lubricant

90-899185 SEPTEMBER 2006 Page 6A-35

Gear Housing - EZ Shift

12. Install thrust bearing. Coat thrust bearing with High Performance Gear Lubricant.
a

7233
a - Thrust bearing

Tube Ref No. Description Where Used Part No.

High Performance Gear
87 Thrust bearing 92-802854A1
Lubricant

13. Apply High Performance Gear Lubricant to bearing surface of reverse gear and install
reverse gear.
a

7234
a - Reverse gear b - Bearing surface

Tube Ref No. Description Where Used Part No.

High Performance Gear
87 Reverse gear bearing surface 92-802854A1
Lubricant

Page 6A-36 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

Forward Gear Assembly

1. Apply 2‑4‑C with Teflon to the inside diameter of the bearing. Press bearing onto gear
using suitable mandrel. Press only on inner race of bearing. The gear hub is longer
than the bearing and you must use a tube type mandrel to install the bearing. This will
allow the bearing to bottom out on the gear.

7235

a - Mandrel b - Bearing

Pilot Mandrel 91‑37350T

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with
95 Inside diameter of bearing 92-802859A1
Teflon

2. Replace the forward gear needle bearing with the forward gear bearing installer tool.
The 6 jaw clutch requires the forward gear needle bearing be installed with the
non‑stepped side of the forward gear bearing installer tool.

c b 7239

a - Non‑stepped side of tool c - 6 jaw reverse clutch

b - Numbered end of needle bearing

Bearing Driver 91‑856875A 1

90-899185 SEPTEMBER 2006 Page 6A-37

Gear Housing - EZ Shift

3. Apply High Performance Gear Lubricant to inside diameter of forward gear and outside
diameter of needle bearing. Press the needle bearing into the forward gear until the
tool bottoms out on the gear.

b
a

7236

a - Needle bearing b - Forward Gear Bearing Installer

Bearing Driver 91‑856875A 1

Tube Ref No. Description Where Used Part No.

Inside diameter of forward gear
High Performance Gear
87 and outside diameter of needle 92-802854A1
Lubricant
bearing

4. Install retaining ring into groove of forward gear by starting at one end of retaining ring
and working it around until seated in groove.
a

ob01641

a - Retaining ring

Clutch Actuator Rod Assembly and Installation

1. Insert spring then washer into clutch actuator rod.
2. Insert spring retaining pin with flat towards spring.
3. Place a small amount of 2‑4‑C with Teflon on actuator rod and install cam follower.

a f
b d e

c 7398

a - Cam follower d - Spring

b - Clutch actuator rod e - Washer
c - Retaining pin f - Propeller shaft

Page 6A-38 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with
95 Actuator rod 92-802859A1
Teflon

Propeller Shaft Assembly

1. Insert assembled clutch actuator rod/cam follower into propeller shaft.
2. Position sliding clutch onto propeller shaft with grooved ring (on sliding clutch) toward
propeller end of propeller shaft. Cross pin hole in sliding clutch must line up with cross
pin slot on propeller shaft.
NOTE: When installing the clutch make sure the angled ratcheting clutch teeth are toward
forward gear, and non‑ratcheting (square on both sides) are toward reverse gear.

b
e c
d
f

g 7399

a- Cross pin hole e - Grooved ring

b- Clutch actuator spring (not shown) f - Cross pin hole
c- Propeller shaft g - Sliding clutch
d- Cam follower

3. Lubricate tapered end of Cross Pin Tool. Insert tapered end of tool into clutch cross
hole while pushing clutch actuator spring towards propeller end of shaft. Using a
screwdriver, rotate and push tool through cross hole of clutch.

7400
a - Cross Pin Tool

Slotted Cross Pin Tool 91‑86642‑‑1

90-899185 SEPTEMBER 2006 Page 6A-39

Gear Housing - EZ Shift

4. Apply a small amount of 2‑4‑C with Teflon on cross pin. Position cross pin in hole of
sliding clutch with flat side of pin toward spring.

b 7401

a - Cross pin b - Cross Pin Tool

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with
95 Surface of cross pin 92-802859A1
Teflon

5. Push cross pin through sliding clutch, propeller shaft and actuator rod, forcing cross
pin tool out.

! CAUTION
Until bearing carrier is installed into gear housing, extreme care MUST BE taken not to
apply any side force on propeller shaft. Side force on propeller shaft may break the neck
of the clutch actuator rod.
6. Install cross pin retaining spring onto sliding clutch.
IMPORTANT: Do not over‑stretch retaining spring when installing onto sliding clutch.
7. Spirally wrap spring into groove on sliding clutch.
8. Verify that spring coils do not overlap each other.

7395

a - Awl b - Cross pin spring

Page 6A-40 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

Driveshaft Wear Sleeve Installation

1. Install a new rubber ring and apply a light coat of Loctite 271 Threadlocker on the
outside diameter.
a

7200
a - Rubber ring

Tube Ref No. Description Where Used Part No.

Outside diameter of driveshaft
7 Loctite 271 Threadlocker 92-809819
rubber ring

2. Insert the sleeve into the holder.

a
b

7243
a - Sleeve b - Holder

90-899185 SEPTEMBER 2006 Page 6A-41

Gear Housing - EZ Shift

3. Press the sleeve onto the driveshaft using the Wear Sleeve Installation Tool. Continue
pressing until the upper and lower part of the tool make surface to surface contact.

a 7244
a - Driveshaft c - Upper part of tool
b - Wear Sleeve Installation Tool d - Lower part of tool

Wear Sleeve Installation Tool 91‑14310T 1

4. Remove excess Loctite from the assembled shaft.

Lower Driveshaft Bearing Race Installation
1. Lubricate outside diameter of bearing race with 2‑4‑C with Teflon.
2. Install shims and bearing race into housing. If shims were lost or a new gear housing
is used during reassembly, start with 0.635 mm (0.025 in.) shims.

Page 6A-42 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

NOTE: Verify shims are not displaced when drawing up race. Once shims and bearing cup
are in place, position gearcase assembly so the driveshaft is vertical. This will aid in
preventing the bearing cup from becoming misaligned in the bore.

f
d

c
7246
a - Shims d - Mandrel
b - Bearing race e - Threaded rod
c - Mandrel f - Nut

Bearing Removal and Installation Kit 91‑31229A7

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with Outside diameter of bearing
95 92-802859A1
Teflon race

90-899185 SEPTEMBER 2006 Page 6A-43

Gear Housing - EZ Shift

Oil Sleeve Installation

Install oil sleeve with tab positioned as shown.
b

7263
a - Oil sleeve b - Tab

Driveshaft Upper Bearing Installation

1. Lubricate inside diameter of bearing sleeve and outside diameter of bearing with 2‑4‑C
with Teflon.
2. Press bearing into sleeve with a mandrel.

c b

7264
a - Mandrel c - Bearing sleeve
b - Bearing d - Tapered end

Bearing Installation Puller 91‑14309T02

Tube Ref No. Description Where Used Part No.

Inside diameter of bearing
2-4-C Marine Lubricant with
95 sleeve and outside diameter of 92-802859A1
Teflon
upper driveshaft bearing

3. Install bearing/sleeve into housing.

Page 6A-44 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

IMPORTANT: Oil sleeve must be installed prior to upper driveshaft bearing installation.
IMPORTANT: Lower driveshaft bearing cup pilots the mandrel during installation of the
upper driveshaft bearing/sleeve. Lower bearing cup must be installed prior to installing
upper bearing/sleeve.

b
d c

f
7268
a - Threaded rod d - Bearing/sleeve
b - Nut e - Tapered end of sleeve
c - Mandrel f - Mandrel

Bearing Removal and Installation Kit 91‑31229A7

Pinion Gear Depth

IMPORTANT: The forward gear assembly pilots the end of the pinion gauge, and must be
installed in the gear housing when checking pinion gear depth. An inaccurate measurement
will be obtained without the forward gear assembly installed.
NOTE: Read the entire procedure before attempting any change in shim thickness.
1. Clean the gear housing bearing carrier shoulder and diameter.

90-899185 SEPTEMBER 2006 Page 6A-45

Gear Housing - EZ Shift

2. Position the gear housing with the driveshaft in a vertical position. Install the Bearing
Preload Tool with the 19 mm (3/4 in.) sleeve over the driveshaft in the sequence shown.
Ensure the holes in the sleeve are in alignment with the set screws.

c e

f
g
m
h
b i
j
a k

l
13288
a- Coupler h - Spring
b- Threaded rod i - Thrust washer
c- Sleeve ‑ 22 mm (7/8 in.) j - Thrust bearing
d- Sleeve ‑ 19 mm (3/4 in.) k - Adapter
e- Split sleeve ‑ 16 mm (5/8 in.) l - Plate
f- Set screw (2) m -Nut
g- Bolt

Bearing Preload Tool 91‑14311A04

3. Measure the distance between the top of the nut and the bottom of the bolt head.
4. Increase the distance by 25.4 mm (1 in.).
5. Rotate the driveshaft 5 ‑ 10 revolutions to properly seat the driveshaft tapered roller
bearing.
a

7275
a - Bolt head c - 25.4 mm (1 in.)
b - Nut

Page 6A-46 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

6. Assemble the Pinion Gear Locating Tool as shown. Do not tighten the collar retaining
screw at this time. Install the gauging block with the numbers away from the split collar.

b d
e
2 3
1

4
8
7 5

a
6

c f
7277
a - Arbor d - Split collar
b - Gauging block e - Collar retaining screw
c - Screw (2) f - Snap ring

Pinion Gear Locating Tool 91‑12349A05

7. Insert the Pinion Gear Locating Tool into the forward gear assembly. Position the
gauging block under the pinion gear as shown.

7279
a - Gauging block

8. Remove the tool, taking care not to change the gauging block position, and tighten the
collar retaining bolt.
9. Insert the tool into the forward gear assembly. Ensure flat # 2 of the gauging block (for
115 model) or flat # 8 of the gauging block (for 75/90 or EU 80/100 models) is under
the pinion gear.
10. Install locating disc # 3 (for 75/90/115 or EU 80/100 models) against the bearing carrier
shoulder in the gear housing.

90-899185 SEPTEMBER 2006 Page 6A-47

Gear Housing - EZ Shift

11. Position the access hole as shown.

a
b

7282

a - Locating disc b - Access hole

Gear Ratio (Pinion Gear Teeth/Forward Gear

Model Disc Number Flat Number
Teeth)
75/90/ EU 80/100 EFI (4‑Stroke) 2.33:1 (12/28) 3 8
115 EFI (4‑Stroke) 2.07:1 (14/29) 3 2

12. Determine the pinion gear height by inserting a feeler gauge through the access hole
in the locating disc.
13. Ensure the pinion gear is within the specification clearance of the gauging block.
Pinion Gear Height Specification
Gauging block clearance 0.635 mm (0.025 in.)

14. If the clearance is correct, leave the Bearing Preload Tool on the driveshaft and proceed
to Determining Forward Gear Backlash, following.
15. If the clearance is more than 0.635 mm (0.025 in.) add shims behind the lower
driveshaft bearing race. If the clearance is less than 0.635 mm (0.025 in.) remove shims
from behind the lower driveshaft bearing race. When reinstalling pinion nut, apply
Loctite 271 Threadlocker on the threads of the nut.
NOTE: Clean the driveshaft threads and pinion nut threads with Loctite 7649 Primer N or
suitable degreaser before applying Loctite 271 Threadlocker.
d
c a

7283
a - Feeler gauge c - Pinion gear
b - Gauging block d - Bearing race

Page 6A-48 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

Tube Ref No. Description Where Used Part No.

Pinion nut threads and
117 Loctite 7649 Primer N 92-809824
driveshaft threads
7 Loctite 271 Threadlocker Pinion nut threads 92-809819

Forward Gear, Driveshaft Lower Bearing, Pinion Gear and Driveshaft Installation
1. Allow High Performance Gear Lubricant to penetrate into the bearing rollers. Install the
forward gear/bearing assembly and lower driveshaft tapered roller bearing.
2. Clean the pinion nut threads and the driveshaft threads with Loctite 7649 Primer N or
other suitable degreaser.
3. Install the pinion gear, driveshaft and pinion nut.
4. Install the original pinion nut for checking the gear lash. After ensuring the pinion gear
depth and forward gear backlash are within specification, remove the original pinion
nut and apply Loctite 271 Threadlocker to the threads on the new pinion nut. Tighten
the nut to the specified torque.
a
b

d
e

21531
a - Driveshaft d - Pinion gear
b - Driveshaft Holding Tool e - Pinion nut
c - Lower driveshaft tapered bearing f - Forward gear/bearing assembly

Driveshaft Holding Tool 91‑889958T

Tube Ref No. Description Where Used Part No.

Forward gear roller bearing and
High Performance Gear
87 the lower driveshaft tapered 92-802854A1
Lubricant
roller bearing

90-899185 SEPTEMBER 2006 Page 6A-49

Gear Housing - EZ Shift

Tube Ref No. Description Where Used Part No.

Pinion nut threads and
117 Loctite 7649 Primer N 92-809824
driveshaft threads
7 Loctite 271 Threadlocker Pinion nut threads 92-809819

Description Nm lb. in. lb. ft.

Pinion Nut 95 70

Bearing Carrier and Propeller Shaft Installation

1. Place the gear housing in a soft jaw vise with the driveshaft in a vertical position.
2. Coat the cam pocket of the cam follower with 2‑4‑C with Teflon.
3. Place the shift cam into the cam pocket of the cam follower.
b
a

7402
c
a - Cam pocket c - Shift cam
b - Cam follower

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with
95 Cam pocket of cam follower 92-802859A1
Teflon

4. Insert the propeller shaft assembly into the bearing carrier.

5. Before installing the bearing carrier assembly into the gear housing, obtain a
152 mm (6 in.) long by 32 ‑ 38 mm (1‑1/4 in. ‑ 1‑1/2 in.) diameter piece of PVC pipe.
Install the PVC pipe over the propeller shaft and secure the pipe against the bearing
carrier assembly with the propeller nut and tab washer. This holds the reverse gear
and thrust bearing tight against the bearing carrier preventing possible bearing damage
during installation.
a

b
c

d
e
7289
a - Bearing carrier assembly d - Propeller shaft
b - PVC pipe e - Tab washer
c - Propeller nut

Page 6A-50 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

6. Lubricate the O‑ring, bearing carrier, and gear housing mating surfaces with 2‑4‑C with
Teflon.
7. Install the bearing carrier and propeller shaft into the housing with the word
"TOP" (located on flange) toward the top of the housing.

a
b

7308
a - O‑ring b - "TOP"

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with O-ring, bearing carrier, and gear
95 92-802859A1
Teflon housing mating surfaces

8. Secure the bearing carrier with locknuts and washers. Torque the locknuts to
specification.
NOTE: Use thick 2.29mm (0.090 in.) washers (12‑855941) under the locknuts if not
previously installed.

a
7175
a - Locknuts

Description Nm lb. in. lb. ft.

Locknut 30 22

90-899185 SEPTEMBER 2006 Page 6A-51

Gear Housing - EZ Shift

Forward Gear Backlash

NOTE: Read the entire procedure before attempting any change in the shim thickness.
1. Verify that the pinion gear depth is correct. Refer to Determining Pinion Gear Depth.
2. Install the propeller shaft and the propeller shaft bearing carrier. Tighten the propeller
shaft bearing carrier locknuts to the specified torque.
Description Nm lb. in. lb. ft.
Bearing carrier locknuts 30 22

3. Install the puller jaws and the puller bolt.

4. While holding the driveshaft to prevent from turning, torque the puller bolt to the
specified torque.
5. Ensure the gear shift is in neutral and rotate the driveshaft 5 ‑ 10 revolutions to seat
the forward gear tapered roller bearing. Re‑torque the puller bolt to specification.

c
a b

d 7286
a - Puller bolt c - Bearing carrier
b - Propeller shaft d - Puller jaws

Puller Jaws Assembly 91‑46086A1

Puller Bolt 91‑85716

Description Nm lb. in. lb. ft.

Puller bolt 5 45

6. Install the preload tool on the driveshaft.

Page 6A-52 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

7. Install the components as shown.

d f
e

c
7287

b
a - Threaded rod (obtain locally) d - Dial Indicator Adapter Kit
b - Washer (2) e - Dial Indicator
c - Nut (2) f - Backlash Indicator Tool

Dial Indicator 91‑58222A1

Dial Indicator Adapter 91‑83155

Backlash Indicator 91‑19660‑‑1

8. Align the dial indicator with the appropriate mark on the backlash indicator tool. Ensure
the dial indicator is perpendicular to the indicator tool or an inaccurate reading will be
obtained.
Model Gear Ratio Tool Indicator Number
75/90/ EU 80/100 (4‑Stroke) 2.33:1 4
115 (4‑Stroke) 2.07:1 1

9. Lightly turn the driveshaft back and forth. No movement should be noticed at the
propeller shaft.
10. The Dial Indicator registers the amount of backlash. Ensure the forward gear backlash
is within specifications.
Forward Gear Backlash (all models)
Forward gear backlash 0.33 ‑ 0.48 mm (0.013 ‑ 0.019 in.)

11. If the backlash is less than the minimum specification, remove the shims from in front
of the forward gear bearing race. If the backlash is more than the maximum
specification, add shims in front of the forward gear bearing race.
12. When re‑installing the pinion nut, apply Loctite 271 Threadlocker on the threads of the
nut.

90-899185 SEPTEMBER 2006 Page 6A-53

Gear Housing - EZ Shift

Tube Ref No. Description Where Used Part No.

7 Loctite 271 Threadlocker Pinion nut threads 92-809819

NOTE: By adding or subtracting a 0.025 mm (0.001 in.) shim, the backlash will change
approximately 0.025 mm (0.001 in.).
Shift Shaft Assembly
1. Apply Loctite 271 Threadlocker on the outside diameter of the new seal.
2. Press the seal into the shift shaft bushing until the seal is seated against the shoulder.
3. Install the new O‑ring.
4. Apply 2‑4‑C with Teflon onto the O‑ring, and the inside diameter of the seal.

b 21627

a - Oil seal b - O‑ring

Tube Ref No. Description Where Used Part No.

Outside diameter of shift shaft
7 Loctite 271 Threadlocker 92-809819
bushing oil seal
Inside diameter of shift shaft
2-4-C Marine Lubricant with
95 bushing oil seal; shift shaft 92-802859A1
Teflon
bushing O-ring

5. Assemble the components as shown.

a b

c 7220

a - Shift shaft c - Shift shaft bushing

b - E‑clip

Page 6A-54 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

6. Install the shift shaft assembly. Insert the splines into the shift cam.

7223
a - Shift shaft assembly b - Splines

7. Apply Loctite 271 Threadlocker to the bottom half of the threads on each shift shaft
bushing screw. Install the screws and tighten to the specified torque.

7206
a - Shift shaft bushing screw (2)

Tube Ref No. Description Where Used Part No.

7 Loctite 271 Threadlocker Shift shaft bushing screws 92-809819

Description Nm lb. in. lb. ft.

Shift shaft bushing screw 7 60

Water Pump Assembly and Installation

1. Place water pump base upper seal on longer shoulder side of Oil Seal Driver with seal
lip away from shoulder.

90-899185 SEPTEMBER 2006 Page 6A-55

Gear Housing - EZ Shift

2. Apply Loctite 271 Threadlocker on outside diameter of seal. Press seal into water pump
base until tool bottoms.

b a
e

7313
a - Upper seal d - Short shoulder side of driver
b - Long shoulder side of driver e - Spring
c - Oil seal driver

Oil Seal Driver 91‑13949

Tube Ref No. Description Where Used Part No.

Outside diameter of water pump
7 Loctite 271 Threadlocker 92-809819
upper seal

3. Place water pump base lower seal on shorter shoulder side of Oil Seal Driver with seal
lip toward shoulder.
4. Apply Loctite 271 Threadlocker on outside diameter of seal. Press seal into water pump
base until tool bottoms.

Page 6A-56 90-899185 SEPTEMBER 2006

 Gear Housing - EZ Shift

5. Lubricate lip of each seal with 2‑4‑C with Teflon.

b c

a
7315
a - Lower seal d - Oil seal driver
b - Spring e - Long shoulder side of driver
c - Short shoulder side of driver

Oil Seal Driver 91‑13949

Tube Ref No. Description Where Used Part No.

Outside diameter of lower water
7 Loctite 271 Threadlocker 92-809819
pump seal
2-4-C Marine Lubricant with
95 Lip of each seal 92-802859A1
Teflon

6. Install gasket.

7174
a - Gasket

IMPORTANT: To prevent seal lip damage, remove any burrs or sharp edges from the
driveshaft splines before installing water pump base assembly.

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Gear Housing - EZ Shift

7. Install water pump base and secure with screws. Apply Loctite 271 Threadlocker on
bottom half of threads. Tighten in sequence shown to the specified torque.

b
7320
a - Screws b - Water pump base

Tube Ref No. Description Where Used Part No.

Water pump base screw
7 Loctite 271 Threadlocker 92-809819
threads

Description Nm lb. in. lb. ft.

Screw 7 60

8. Install gasket and plate.

a
c

7165
a - Gasket c - Impeller sealing groove
b - Plate

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 Gear Housing - EZ Shift

9. Install gasket, drive key and impeller.

c
b

7153
a - Impeller c - Gasket
b - Key

10. Lubricate inside diameter of cover with 2‑4‑C with Teflon.

11. Rotate driveshaft clockwise and push impeller housing down and over impeller until it
contacts water pump base.
12. Apply Loctite 271 Threadlocker to bottom threads of cover screws. Install cover screws
and tighten to specified torque.

b
c

7157
a
a - Screws c - Cover
b - Water tube seal

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with Inside diameter of water pump
95 92-802859A1
Teflon cover
Water pump cover screw
7 Loctite 271 Threadlocker 92-809819
threads

Description Nm lb. in. lb. ft.

Water pump cover screw 7 60

NOTE: It is recommended that the gearcase be pressure tested for leaks for 5 minutes
after reassembly and before gear lubricant is added.

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Gear Housing - EZ Shift

Gearcase Test Pressure

Applied Air Pressure 69 ‑ 83 kPa (10 ‑ 12 psi)
Length of time 5 minutes

Gear Housing Pressure Test

1. Remove vent plug and install pressure test gauge FT8950.
60 80100
40 120
20 140
0 160

7362

2. Pressurize housing to and observe gauge for 5 minutes.

3. Rotate driveshaft, prop shaft and shift shaft while housing is pressurized to check for
leaks.
4. If pressure drop is noted, immerse housing in water.
5. Re‑pressurize and check for air bubbles.
6. Replace leaking seals as necessary. Retest housing after seal replacement
Gearcase Test Pressure
Applied Air Pressure 69 ‑ 83 kPa (10 ‑ 12 psi)
Length of time 5 minutes

Leakage Tester Kit FT8950

7. Remove tester from housing and install vent plug and sealing washer.

Gearcase Installation
1. Position outboard shift linkage into forward gear position.
F N R

7368

2. Tilt engine to full up position and engage tilt lock lever.

! WARNING
To prevent accidental engine starting, remove battery cables from battery before
removing or installing gear housing.
3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either
direction.
4. Install water tube seal. Apply 2‑4‑C with Teflon to inside diameter of seal.
5. Apply a bead of RTV 587 Silicone Sealer to the water pump exhaust dam as shown.

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 Gear Housing - EZ Shift

NOTE: For ease of gear housing installation, install water tube seal labyrinth end onto water
tube in driveshaft housing. Tapered end of water tube seal goes onto water pump.

b
7377
a - Water tube seal b - RTV 587 Silicone Sealer

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with
95 Water tube seal inner diameter 92-802859A1
Teflon
RTV 587 Ultra Blue Silicone
116 Water pump exhaust dam 92-809825
Sealer

! CAUTION
Do not allow lubricant on top of driveshaft. Excess lubricant, that is trapped in clearance
space, will not allow driveshaft to fully engage with crankshaft. Subsequently, tightening
the gear housing screws (while excess lubricant is on top of driveshaft) will load the
driveshaft/crankshaft and damage either or both the powerhead and gear housing. Top
of driveshaft is to be wiped free of lubricant.
6. Apply a light coat of 2‑4‑C with Teflon onto driveshaft splines.
7. Apply a light coat of 2‑4‑C with Teflon on gearcase shift shaft splines and upper shift
shaft splines. Do not use lubricant on ends of shift shafts.

Tube Ref No. Description Where Used Part No.

2-4-C Marine Lubricant with Driveshaft splines and shift
95 92-802859A1
Teflon shaft splines

8. Shift gear housing into forward gear position. In forward gear the gear housing will
ratchet when propeller shaft is turned clockwise. Resistance will be felt when propeller
shaft is rotated counterclockwise.
NOTE: During installation of gear housing, it may be necessary to move the shift block
located under cowl slightly to align upper shift shaft splines with shift shaft coupler splines.
9. Apply Loctite 271 on threads of gear housing retaining screws.
10. Position gear housing so that the driveshaft is protruding into driveshaft housing.
11. Move gear housing up toward driveshaft housing, while aligning upper shift shaft
splines with shift shaft coupler splines, water tube with water tube seal, and crankshaft
splines with driveshaft splines.
12. Install 4 fasteners and washers (two each side). Install locknut and washer.

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Gear Housing - EZ Shift

13. Torque screws and locknut (or nuts only if applicable) to specified torque.

a
b

7156
a - Fasteners b - Locknut and washer

Tube Ref No. Description Where Used Part No.

Threads of gear housing
7 Loctite 271 Threadlocker 92-809819
retaining screws

Description Nm lb. in. lb. ft.

Screw or Nut 54 40

14. Check shift operation as follows:

• Place shift lever in forward gear. Gear housing should ratchet when propeller shaft
is turned clockwise. Resistance should be felt when propeller shaft is turned
counterclockwise.
• Place shift lever in neutral. Propeller shaft should rotate freely in either direction.
• While rotating propeller shaft, place shift lever in reverse gear. Resistance should
be felt when propeller shaft is rotated in either direction.
IMPORTANT: If shift operation is not as described above, the gear housing must be
removed and the cause of the problem corrected.

Filling Gear Housing with Lubricant

IMPORTANT: Do not use automotive grease in the gear housing. Use only High
Performance Gear Lubricant.
1. Remove any gasket material from fill and vent screws and housing.
2. Install new sealing washer on fill and vent screws.
IMPORTANT: Never apply lubricant to gear housing without first removing vent screw or
gear housing cannot be filled because of trapped air. Fill gear housing only when housing
is in a vertical position.
3. Slowly fill housing through fill hole until lubricant flows out of one vent hole.
4. Reinstall this vent screw and sealing washer only and continue filling until excess starts
to flow out of second vent hole.
5. Rotate driveshaft clockwise approximately 10 revolutions. Let gearcase sit for at least
one minute to allow any trapped air to settle out, then top off lubricant.
6. Replace second vent screw and sealing washer.

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 Gear Housing - EZ Shift

7. Remove grease tube from fill hole and quickly install fill/drain screw and sealing washer.

c
b a d
e
ob00442

a - First vent screw d - Second vent screw

b - First vent hole e - Fill/drain screw
c - Second vent hole

IMPORTANT: Do not lose more than 30 cc (1 oz.) of gear lubricant while reinstalling the
fill/drain screw.

Tube Ref No. Description Where Used Part No.

High Performance Gear
87 Gear housing 92-802854A1
Lubricant

Description Nm lb. in. lb. ft.

Vent screw 6.7 60

Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is now painted and does not aid in protecting the driveshaft
housing and gear housing from galvanic corrosion and pitting of metal surfaces. Side
anodes now provide protection. Do not paint or place protective coating on the side anodes,
or corrosion protection function will be lost.
Replacement
Replace trim tab if damaged. Mark location of old trim tab on anti‑ventilation plate before
removal. Install new trim tab in same location.
Adjustment
NOTE: The trim tab provides a means to offset balance some of the steering load that is
caused by propeller torque at higher operating speeds.
NOTE: Loosen trim tab bolt sufficiently to allow trim tab to disengage from locking ridges
in gearcase before attempting to move tab. Do not strike trim tab with a hard object to make
adjustments.
1. Shift engine control into neutral and turn ignition key switch to "OFF" position.
2. If at higher speeds the boat turns more easily to the left, loosen screw and move the
trim tab trailing edge to the left when viewed from behind. Tighten retaining screw to
specified torque.

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Gear Housing - EZ Shift

3. If the boat turns more easily to the right, loosen screw and move the trim tab trailing
edge to the right when viewed from behind. Tighten trim tab retaining screw to specified
torque.
c

b a 7383

a - Trim tab c - Retaining screw and washer

b - Anti‑ventilation plate

Description Nm lb. in. lb. ft.

Trim tab retaining screw 30 22

Page 6A-64 90-899185 SEPTEMBER 2006