Mercury Mercruiser #6 Service Manual Sterndrive Units R-MR-Alpha One-Alpha One SS (PDF, EnG, 16.7 MB)
Mercury Mercruiser #6 Service Manual Sterndrive Units R-MR-Alpha One-Alpha One SS (PDF, EnG, 16.7 MB)
Mercury Mercruiser #6 Service Manual Sterndrive Units R-MR-Alpha One-Alpha One SS (PDF, EnG, 16.7 MB)
Number 6
Sterndrive Units
R·MR·Alpha One·
Alpha One SS
0
90-12934--2
Models Covered in This Manual
Transom Assemblies
Sterndrive Units
MC 120R-260R
Original Ratio Ratio If Serviced With 13:21 Gears Serial Number
1.98:1 1.94:1 6237861-6854392
1.84:1 1.81:1 6225577-6862701
1.65:1 1.62:1 6268065-6810537
1.50:1 1.47:1 6229158-6847029
1.32:1 1.29:1 6231571-6663947
90-12934--2 1097 i
Sea Ray Sterndrive Units and Transom Assembly (Oyster White)
Original Ratio Ratio If Serviced With 13:21 Gears Serial Number
1.98:1 0B803866-0C348031
1.84:1 0B800854-0C343526
1.50:1 0B796473-0C340666
1.32:1 0B804807-0C340030
Transom Assembly 0B815811-0C340333
When making repairs to Sea Ray (Oyster White) sterndrives, follow procedures as outlined for corresponding
MerCruiser models as shown in the cross-reference chart below.
ii 90-12934--2 1097
Notice Notice To Users of This Manual
Throughout this publication, “Warnings” and “Cau- This service manual has been written and published
tions” (accompanied by the International HAZARD by the service department of the manufacturer to aid
symbol ! ) are used to alert the mechanic to special our dealers’ mechanics and company service per-
instructions concerning a particular service or opera- sonnel when servicing the product described herein.
tion that may be hazardous if performed incorrectly It is assumed that these personnel are familiar with
or carelessly. — OBSERVE THEM CAREFULLY! the servicing procedures of this product, or like or
These “Safety Alerts” alone cannot eliminate the similar products. That they have been trained in the
hazards that they signal. Strict compliance to these recommended servicing procedures of these prod-
special instructions when performing the service, ucts which includes the use of mechanics’ common
plus “common sense” operation, are major accident hand tools from other suppliers.
prevention measures. We could not possibly know of and advise the service
trade of all conceivable procedures by which a
! DANGER service might be performed and of all possible
hazards and/or result of each method. We have not
DANGER - Immediate hazards which will result in
undertaken any such wise evaluation. Therefore,
severe personal injury or death.
anyone who uses a service procedure and/or tool
which is not recommended by the manufacturer, first
! WARNING must completely satisfy himself that neither his nor
the product’s safety will be endangered by the
WARNING - Hazards or unsafe practices which service procedure selected.
COULD result in severe personal injury or death.
All information, illustrations, and specifications con-
! CAUTION tained in this manual are based on the latest product
information available at time of publication.
CAUTION - Hazards or unsafe practices which
could result in minor personal injury or product As required, revisions to this manual will be sent to
or property damage. all dealers contracted by us to sell and/or service
these products.
IMPORTANT: Indicates information or instruc-
tions that are necessary for proper operation
and/or maintenance.
! WARNING
Electrical system components on diesel engines
are not external ignition protected. DO NOT
STORE OR UTILIZE GASOLINE ON BOATS
EQUIPPED WITH THESE ENGINES, UNLESS
PROVISIONS HAVE BEEN MADE TO EXCLUDE
GASOLINE VAPORS FROM ENGINE COMPART-
MENT (ref: 33 CFR). Failure to comply could result
in fire, explosion and/or severe personal injury.
iv 90-12934--2 1097
Service Manual Outline
Section 1 - Important Information
A - Important Information
B - Maintenance
Important
Information
1
C - Troubleshooting
Section 2 - Removal, Installation and Adjustments
A - All Models
Section 3 - Sterndrive Unit
Removal, Installation
and Adjustments
2
A - Drive Shaft Housing
B - Gear Housing - MR/Alpha One/Alpha One SS
C - Gear Housing - I-R
D - Gear Housing - Alpha One Counter Rotation
Sterndrive Unit
3
Section 4 - Transom Assembly
A - Service Procedures Requiring Minor
Disassembly
B - Service Procedures Requiring Major
Disassembly
Transom Assembly
4
5
Section 5 - Power Trim
A - Oildyne Power Trim Pump (Plastic Reservoir) Power Trim
B - Oildyne Power Trim Pump (Aluminum Reservoir)
C - Prestolite Power Trim Pump
D - Trim Cylinders
E - Dual Power Trim Control
F - Auto Trim II
Section 6 - Steering Systems
Steering Systems
6
A - Power Steering
B - Manual Steering
Section 7 - Corrosion Protection
A - All Models
Corrosion Protection
7
90-12934--2 1097 v
GENERAL INFORMATION 1
A
23253
IMPORTANT INFORMATION
Table of Contents
Page
How To Use This Manual . . . . . . . . . . . . . . . . . . 1A-1
Page Numbering . . . . . . . . . . . . . . . . . . . . . . 1A-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Special Product Information . . . . . . . . . . . . . . . 1A-1
Directional References . . . . . . . . . . . . . . . . . . . . 1A-1
Propeller Rotation . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Serial Number Locations . . . . . . . . . . . . . . . . . . 1A-2
Hi-Performance Boating . . . . . . . . . . . . . . . . . . . 1A-2
Sterndrive Unit 10-Hour Break-In Period . . . . 1A-2
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
Surface Preparation . . . . . . . . . . . . . . . . . 1A-2
Decal Application . . . . . . . . . . . . . . . . . . . . . . 1A-2
Painting Procedures . . . . . . . . . . . . . . . . . . . . . . 1A-3
Cleaning & Painting Aluminum Propellers
& Gear Housings . . . . . . . . . . . . . . . . . . . . . . 1A-3
Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Gear Housings . . . . . . . . . . . . . . . . . . . . . 1A-3
Page Numbering
Two number groups appear at the bottom of each
page. Following is an example and description.
Propeller Rotation
Propeller rotation for sterndrive can be right hand or
left hand rotation as viewed from the aft end of the
propeller.
Introduction
This comprehensive overhaul and repair manual is
designed as a service guide for the MerCruiser
models previously listed. It provides specific
information, including procedures for disassembly,
inspection, assembly and adjustment, to enable
dealers and service mechanics to repair these
products.
Before attempting repairs, it is suggested that proce-
dure first be read through to gain knowledge of the
methods and tools used and the cautions and
22266 22267
warnings required for safety.
23254
Decal Removal
1. Mark decal location before removal to assure
proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a
heat gun or heat blower while removing old decal.
3. Clean decal contact area with a 1:1 mixture of iso-
propyl alcohol and water.
4. Thoroughly dry decal contact area and check for
a completely cleaned surface.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should
not be attempted while in direct sunlight. Air and
23254 surface temperature should be between 60°F
Sterndrive Unit Serial Number Location – Port Decal (15°C) and 100°F (38°C) for best application.
a - Sterndrive Unit Serial Number
b - Sterndrive Unit Gear Ratio SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum
based solvents to clean application surface.
Hi-Performance Boating
Written by marine engineers, order Part No. Decal Application
90-86168, entitled “Hi-Performance Boat Opera-
tion.” NOTE: Ensure area where decal will be applied is
clean.
1. Remove backing from decal.
2. Apply to drive unit.
3. Carefully smooth decal on surface.
Procedure:
1. Wash gear housing with a muriatic acid base
cleaner to remove any type of marine growth and
rinse with water, if necessary.
2. Wash gear housing with soap and water, then
rinse.
22062
ALL MODELS
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
Torque Specifications . . . . . . . . . . . . . . . . . . 2A-1
Lubricants/Sealers/Adhesives . . . . . . . . . . . . 2A-1
Special Installation Tools . . . . . . . . . . . . . . . . 2A-1
Special Information . . . . . . . . . . . . . . . . . . . . . 2A-1
Transom Specifications . . . . . . . . . . . . . . . . 2A-1
Checking Transom Thickness . . . . . . . . . . . . 2A-2
Sterndrive Unit Removal . . . . . . . . . . . . . . . . 2A-2
Transom Assembly Removal . . . . . . . . . . . . 2A-3
Transom Assembly Installation . . . . . . . . . . . 2A-7
Sterndrive Unit Installation . . . . . . . . . . . . . . 2A-15
Shift Cable Adjustment . . . . . . . . . . . . . . . . . 2A-18
Installing Shift Cables . . . . . . . . . . . . . . . . 2A-19
Propeller Installation . . . . . . . . . . . . . . . . . . . 2A-24
DESCRIPTION
TORQUE Special Information
lb. in. lb. ft. N⋅m
Exhaust Pipe To Gimbal
20-25 27-34
Transom Specifications
Housing Screws
Power Trim Cylinder To An- Tighten Until Nut Just
chor Pin Nut Bottoms Out
55 75
Propeller
(Min.) (Min.)
Tighten Until Nut Bot-
Shift Cable End Guide At-
toms And Then Loosen
taching Nuts
1/2 Turn
Steering Cable Coupler
35 48
Nut
Steering Cable Coupler
60-72 7-8
Nut Locking Plate Screw
Steering System Pivot
25 34
Bolts
Sterndrive Unit To Bell
50 68
Housing Attaching Nuts
Transom Assembly Attach-
20-25 27-34
ing Screws and Nuts
Power Steering Hydraulic
20-25 27-34
Hose Fitting - Large
Power Steering Hydraulic
96-108 11-12
Hose Fitting - Small
22170
b
22060
70004
a - Measuring Thickness
b - Measuring Flatness
22441
a - Anchor Pin
a b - Washers (2)-Large I.D.
c - Rubber Bushings (4)
d - Washer (2)-Small I.D.
e - Locknuts (2)
f - Plastic Caps (2)
75479
22062
22062
22023
a - Locknuts (6)-Remove a - Cable End
b - Washers (5)-Remove b - Clevis
c - Ground Plate c - Cotter Pin
d - Sterndrive Unit d - Clevis Pin
e - Locking Plate
f - Cable Retaining Nut
g - Steering Lever
h - Cotter Pin
i - Clevis Pin
22055
50483
22945
22031
23256
50483
V6/V8 Models
a - Exhaust Pipe
b - Screws
50483
22028
a - Steering Lever
b - Ground Wire
c - Screws
22054
22028
22058
! CAUTION
Steering lever ground wire MUST BE positioned
as shown or wire may fatigue.
22028
a - Steering Lever
b - Inner Transom Plate
c - Ground Wire
22058
22057
V6/V8 Models
a - Exhaust Pipe
b - Screws
a - O-ring
b - Mating Surface
22057
22054
! CAUTION
DO NOT cross-thread or overtighten hose fit-
tings when making hydraulic hose connections
to power trim pump.
50483
22031
50483
22167
22168
23256
22946
22944
23256
22032
50483
a - Clevis Pin
b - Clevis
c - Steering Lever
d - Cotter Pin
! WARNING
Steering cable outer casing MUST BE free to
move back and forth for steering to function
properly. DO NOT fasten any wires, cables or oth-
er items to steering cable, as this may prevent it
from moving.
22023
50483
70373
22061
50636
a - Rubber Gasket
b - Water Passage O-ring
c - Studs
22061
a - Shift Shaft
b - Shift Shaft Coupler
c - Shift Slide
50629
22062
a - Gasket
b - Shift Slide
22061
22060
22062
22441
a - Anchor Pin
b - Washers (2)-Large I.D.
c - Rubber Bushings (4)
d - Washers (2)-Small I.D.
e - Locknuts (2)
22948 f - Plastic Caps (2)
a - Gimbal Ring
b - Trim Cylinders (Port And Starboard)
c - Anchor Pin
d - Flat Washers (2)-Large I.D.
e - Rubber Bushings (4)
f - Flat Washers (2)-Small I.D.
g - Locknuts (2)
h - Plastic Caps (2)
71339
23253
a - Shift Lever
a - Adaptor Fitting
b - Throttle Lever
b - Hose Fitting
c - Bracket
NOTE: A difference exists between earlier and later
model shift plates, in that the later models have a pin
Shift Cable Adjustment and cotter pin to secure the remote control shift cable
NOTE: Some models may be equipped with a shift to the shift lever, whereas the earlier models used a
assist assembly. The only difference with these mod- stud with washers and locknut. However, adjustment
els is that the remote control shift cable attaching procedures are the same.
hardware is slightly longer. Shift cable adjustment is
the same as all other versions.
50308
22265
22266
50484
22909
22909
a - End Guide
b - Brass Barrel
50309
c - Shift Lever Clevis Pin Hole
d - Stud
50308
a - End Guide
b - Brass Barrel
22267
50308
22058
50308
! WARNING
Place a block of wood between the anti-ventila-
tion plate and propeller to protect hands from
propeller blades and to prevent propeller from
turning.
a - Adjustable Stud
b - Shift Cutout Switch Roller
3
A
23262
Special Tools
Upper Drive Shaft Bearing Preload
Description Part No.
TORQUE
DESCRIPTION Adaptor 91-38756
lb. in. N⋅m
Engine Alignment Tool 91-57797A3
New Bearings 6-10 0.7-1
Used Bearings* 2.5-4 0.3-0.45 Alignment Tool Assembly 91-805475A1
Bearing Cup Driver 91-38918
*Bearings are considered used if spun under load once.
Bearing Driver Cup 91-33493
Oil Seal Driver 91-43591
Gear Shimming Specifications Shimming Tool (Driven Gear) 91-60526
GEAR LOCATION Shimming Tool (Drive Gear) 91-60523
DESCRIPTION
inches millimeters Slide Hammer Puller 91-34569A1
Drive Gear Height Torque Wrench (lb. in.) 91-66274
.32 0.8
(Gears Marked “G-7”)
U-joint Bearing Retainer Wrench 91-17256
Drive Gear Height
.025 0.64 Universal Puller Plate 91-37241
(All Others)
Driven Gear Height .025 0.64
S: Standard
O: Optional
H: High Elevation Only
S: Standard
O: Optional
H: High Elevation Only
S: Standard
O: Optional
H: High Elevation Only
1: Ratio Changed in Gear Housing must be changed by dealer-not a factory option
2: Use 1.5:1 Heavy Duty Gears P/N 43-14010A1 set (320 EFI Only)
3: Drive Shaft Housing Gears P/N 43-18410A2 Gear set is replacement for P/N 43-59832A2 gear set
4: Use Replacement Lower Gear Housing Gears P/N 43-17064A3 (Propeller shaft identified with letter “M”)
S: Standard
O: Optional
H: High Elevation Only
1: Ratio Changed in Gear Housing must be changed by dealer-not a factory option
2: Use 1.5:1 Heavy Duty Gears P/N 43-14010A1 set (320 EFI Only)
3: Drive Shaft Housing Gears P/N 43-18410A2 Gear set is replacement for P/N 43-59832A2 gear set
4: Use Replacement Lower Gear Housing Gears P/N 43-17064A3 (Propeller shaft identified with letter “M”)
23263
22179
C-ring Installation
On click-stop or dial type torque wrenches, 3. Torque retainer until prescribed reading is at-
measure from square drive to reference mark tained on torque wrench.
on handle (2 bands, etc.).
26363
c - Vent Screw
d - Sealing Washer
23261
a - Top Cover
23253
b - Screws (4)
a - Trim Tab
b - Plastic Plug 2. Loosen bearing retainer.
c - 3/8 in. Hex Wrench
23263
23268
a - Bearing Retainer
b - Bearing Retainer Wrench (P/N 91-17256)
23261
c - Locknut (1)
d - Locknut (2)-One each side
23268
a - U-joint Assembly
50316
23266
a - Shims
23262 50316
a - Upper Drive Shaft And Driven Gear Assembly a - Water Pocket Cover (Gasket Beneath)
b - Screws (4)
23261
23263
9. Remove intermediate shift shaft bushing with a
suitable mandrel (earlier models only). Discard a - Bearing Cup (Shims Underneath)
the bushing on Alpha l, SS model drive units. b - Slide Hammer Puller (P/N 91-34569A1)
23261
a - Bushing 23007
23007
22179
a - Oil Seal
23267
! CAUTION
When disassembling drive gear and bearing as- a - Drive Gear
b - Tapered Roller Bearing
sembly, be careful not to switch tapered roller
c - Bearing Cup
bearings and cups. Bearings must be matched d - Small Spacer (Note 1)
with its original bearing cup. Be sure to note or- e - Large Spacer
der of components for reassembly. If bearings f - Bearing Cup
are to be replaced, replace both bearings and g - Tapered Roller Bearing
small and large spacers as an assembly, to en- h - Oil Seal Carrier
sure correct amount of preload when reassem- i - O-ring
bling. j - Roller Bearing Retainer Ring
k - Retainer
NOTE 1-This item will not be included in Later Model units or
when ordering the following gear sets:
43-18411A2
43-45814A5
43-55778A3
43-75325A3
22180
23009
a - U-joint Press
a - Oil Seal b - Adaptor
b - Oil Seal Carrier
5. Turn U-joint assembly 180 degrees and press on
IMPORTANT: If cross and bearings are to be re- cross until second bearing is pressed out into
used, liberally lubricate crosses with 2-4-C adaptor. Remove each pair of bearings in this
Marine Lubricant to help retain needle bearings manner.
in cap during disassembly.
6. Remove both O-rings from coupling end of U-
joint shaft. Discard the O-rings.
If inspection determines that U-joint cross and bear-
ings should be replaced proceed as follows:
3. Drive off C-rings with punch and hammer.
22249
a - O-rings
b - U-joint Shaft
c - O-ring Grooves
Cleaning
1. Clean all parts (except O-rings) with cleaning sol-
vent.
22179 2. Remove all foreign debris.
a - C-ring
! CAUTION
DO NOT spin bearings when drying parts with air
as damage to bearings could occur.
3. Dry all parts with air or a lint free cloth. Ensure all
cleaning solvent has been removed.
5. Press oil seal into oil seal carrier with lip of seal
facing away from stepped side of carrier. Use oil
seal driver (P/N 91-36577) to press seal into
place.
22181
a - Bearings
b - Yoke
c - Adaptor
d - U-joint Press
e - Cross
23009
2. Install C-rings into edge of bearing cap. a - Oil Seal
b - Oil Seal Carrier
c - Oil Seal Driver
! CAUTION
When reassembling drive gear and bearing as-
sembly, be careful not to switch tapered roller
bearing cups. Each bearing must be matched
with its original bearing cup. If using old bear-
ings, be sure to use original small and large
spacers. If new bearings are being used, be sure
to use new spacers. This will ensure proper bear-
ing preload.
a - C-ring 22182
b - Hammer
23268
23010
a - Retainer h- Small Spacer (Note) a - Bearing Assembly
b - Anti-galling Retainer i - Bearing Cup b - Torque Wrench
c - O-ring j - Tapered Roller Bearing
d - Seal Carrier k - Drive Gear Reassembly without Small Spacer:
e - Tapered Roller Bearing l - Washer
f - Bearing Cup m- Locknut 1. Insert a suitable tool, such as a screwdriver, be-
g - Large Spacer tween the U-joint yokes as shown in the next fig-
ure, to prevent the U-joint from rotating when
NOTE: This item will not be included in Later Model tightening down the pinion nut. Tighten the pinion
units or when ordering the following gear sets; nut down until the preload on the bearings starts
43-18411A2 to go up just slightly and remove the hose clamp.
43-45814A5
43-55778A3
43-75325A3
70210
a - U-joint Assembly
b - Vice
c - U-joint Retainer Tool (P/N 91-17256)
d - Screwdriver
e - Socket And Ratchet Wrench
23267
a - Clamp
b - Bearing Cups
70212
23266
23264
a - Driven Gear
e - Universal Puller Plate b - Upper Drive Shaft
f - Driven Gear c - Suitable Tool
g - Tapered Roller Bearing d - Arbor Press
h - Arbor Press
50313
a - O-ring
b - Upper Drive Shaft
23265
! CAUTION
DO NOT spin bearings when drying components
off with compressed air, as damage to bearings
could occur.
3. Dry all parts with compressed air or a lint free
cloth. Ensure all solvent has been removed.
Reassembly
1. Place new O-ring on the upper drive shaft.
23264
23263
23264
a - Tapered Roller Bearing (Larger)
a - Driven Gear b - Driven Gear
b - Upper Drive Shaft c - Suitable Tool
c - Universal Puller Plate d - Arbor Press
d - Arbor Press
50316 50316
a - Rubber Seal
b - Water Pocket Cover
23261 50366
23261
50316
! CAUTION
Alpha One SS has a shorter water tube than the
Alpha One or MR drive units. Be careful not to
install a short tube (Alpha One SS) in an Alpha
One or MR drive unit, as this would substantially
reduce water flow to the engine, causing engine
to overheat.
23011
a - Shims
b - Bearing Cup
c - Bearing Cup Driver (P/N 91-33493)
d - Driver Rod (Old Propeller Shaft Shown)
50316
a - Water Tube
23262
23261
8. Place shims in top cover.
a - Top Cover
NOTE: If using new shims, start with .015-.020 in. b - Screws (4)
shim pack.
11. Check upper drive shaft bearing preload and
9. Install upper drive shaft bearing cup into top cov- shim as follows:
er. Install O-ring.
a. Invert upper drive shaft housing.
b. Insert gear housing drive shaft (with pinion gear
nut installed) into upper drive shaft splines.
23262
23264
23262
50366
23266
a - Shims
23012
23268
23006
a - Bearing Retainer
b - Bearing Retainer Wrench
a - Drive Gear Index Marks IMPORTANT: The following procedure must be
b - Driven Gear Index Marks performed exactly as stated to position shim-
c - U-joint Assembly ming tool gauging surface parallel with gear to
All Units without 1.65:1 Gear Ratio obtain an accurate measurement.
a. Push U-joint assembly straight into drive
shaft housing so that gear teeth mesh. IMPORTANT: When using heavy duty gears with
date code “G-7” stamped on face of gear, use of
a .032 in. feeler gauge should be used instead of
.025 in.
23006
a - U-joint Assembly
50366
a - Drive Gear
b - Date Code “G-7”
d. Without moving shimming tool, remove feeler Example: .025 in.-.023 in. = .002 in.
gauge and insert gauge between other tooth (0.64 mm-.584 mm = .056 mm)
and gauging surface. Shims equal to the resulting difference must be add-
ed between U-joint assembly bearing cup and drive
shaft housing shoulder.
23012
23261
71185
71185
23265
a - Shift Shaft
23261
a - Locknuts (One Each Side)
b - Locknut
23253
a - Trim Tab
b - Allen Wrench
c - Plastic Plug
23263
c - Locknuts
d - Allen Screw
4
A
23152
22160
71414
22160
23169
Older Style Trim Position Sender
Old Style Shift Cable
a - Shift Cable Retaining Nut
The new style cable can be used on all MerCruiser
models.
NEW
NEW
OLD
50485
Core Wires
a - New Pre-Cut Core Wire Dimension 72-1/8 in. (1832 mm) OLD 50485
b - Front Edge of Anchor
Shift Cable Conduit
NEW OLD
50485
Cable Anchors
REASSEMBLY
22091
a - Trim Position Sender
22160
b - Screws (2)
c - Retainer (2) a - Wires
b - Screws
DISASSEMBLY c - Grooves
22160
a - Insulator
b - Screws 22160
c - Wires a - Index Marks
b - Insulator
22091 71220
a - Trim Position Sender a - Screws, Washers And Retainers
b - Screws (2)
c - Retainer (2) 4. Remove hinge pins. Apply heat to bell housing,
if necessary, to soften Loctite.
23292
a - Hinge Pins
b - Hinge Pin Tool
c - Apply Heat Here
71221
a - Screws, Washers and Retainers
70198
a - Trim Limit Switch Wires
b - Trim Position Sender Wires
23158
a - U-joint Bellows Front Hose Clamp
b - Exhaust Bellows Rear Hose Clamp
c - Bell Housing
d - Shift Cable Bellows
70197
a - Screw
b - Trim Harness Clamp
c - Trim Limit Switch Wires
d - Trim Position Sender Wires
! WARNING
Be sure to read and follow package label direc-
tions when using bellows adhesive.
b. Apply bellows adhesive to mounting surface
on inside of bellows.
c. Position grounding clip clamp over bellows
on bell housing end.
d. Install U-joint bellows on bell housing flange
and tighten clamp.
2. Install exhaust bellows on gimbal housing as fol-
lows:
23363
a. Clean mounting flange with sandpaper and
wipe clean with lacquer thinner. a - Bell Housing
b. Apply bellows adhesive to mounting surface 4. Position U-joint bellows hose clamp as shown
on inside of bellows. and tighten securely.
c. Position grounding clip on bellows.
22079
a - Exhaust Bellows
b - Mounting Surface
c - Ground Clip
75792
a - U-joint Bellows
b - Hose Clamp
22161
a - Expander Tool
23292
a - Bell Housing
b - Gimbal Ring
c - Hinge Pin Tool (P/N 91-78310)
d - Torque Wrench (lb. ft.)
23154
a - Expander Tool
b - Bell Housing Flange
23362
23158
a - Exhaust Bellows
b - Bell Housing Flange
c - Hose Clamp
70141
71218
71220
a - Index Marks a - Trim Position Sender
b - Screws
2. Install trim position sender. Ensure insulator slot
aligns with slot in sender. 3. Turn ignition key to the “RUN” position. DO NOT
START ENGINE.
4. Rotate sender until needle is at bottom of arc.
22175
! CAUTION
Trim limit switch MUST BE adjusted exactly as
outlined. If switch is adjusted incorrectly, drive
unit could move out beyond the gimbal ring sup-
port flanges and cause damage to sterndrive
unit.
1. Loosen screws and turn trim limit switch clock-
71218 wise to end of slots.
a - Index Marks
2. Install trim limit switch.
71221
a - Screws
b - Slots
71221
2. Place drive unit in the full DOWN/IN position.
a - Screws, Washers And Retainers
3. Trim drive unit UP/OUT. Do not use trailer switch.
50464
b - 21-3/4 in. 1/4 in. (554 mm 6 mm)
23151
a - Puller Shaft (91-31229)*
b - Nut (11-24156)*
c - Washer (12-34961)*
d - Plates (2) (91-29310)
e - Slide Hammer Puller
f - Gimbal Bearing Inner Race
g - Gimbal Bearing Carrier
* From Bearing Removal And Installation Tool 91-31229A5
22171
a - Gimbal Housing
23152 b - Grease Seal
a - Driver Rod (91-37323)*
INSTALLATION
b - Plate (91-29310)*
c - Driver Head (91-32325)* 1. Install grease seal as shown.
d - Mandrel (91-30366-1)*
e - Gimbal Bearing Assembly
* From Bearing Removal And Installation Tool 91-31229A7
22171
a - Gimbal Housing
b - Grease Seal
22159
a - Gimbal Bearing Carrier
b - Tolerance Ring
22183
a - Carrier
b - Carrier Grease Hole
c - Tolerance Ring
d - Opening In Tolerance Ring
22183
a - Support Tube
b - Core Wire
c - Cut Here
73668
23153
a - Safety Wire - Cut
b - Set Screw
c - Shift Slide
73880
a - Shift Cable
b - Shift Cable Bellows
23262
22030
a - Inner Transom
b - Shift Cable
c - Wrapping
23169
23156
23155
a - Shift Cable
b - Shift Cable Bellows
23156
a - 1/4-18 NPSF Tap
23156
a - Shift Cable
b - Retainer Nut
23262
a - Core Wire
b - Shift Slide
23154
23262
a - Core Wire
b - Shift Slide
c - Shift Cable
22030
a - Shift Cable
b - Shift Cable Wrapping
c - Inner Transom Plate
22183
23153
23170
a - Set Screw
b - Shift Slide a - Core Wire
c - Safety Wire b - Propeller Shaft
8. Install thread tube on shift cable and tighten until 11. (If using older style core wire equipped with
it just bottoms. Secure jam nut against shift cable support tube) Position support tube so that 1/2
end. in. (13 mm) of core wire extends from edge of
support tube. Crimp end of support tube.
22183
22183
a - Threaded Tube
a - Support Tube
b - Core Wire
b - Core Wire
c - Jam Nut
9. Install sterndrive unit (Refer to Section 2A). 12. Install shift cable end guide over core wire and in-
sert core wire through cable anchor. Tighten
screws securely.
22183
a - Shift Cable End Guide
b - Core Wire
c - Cable Anchor
d - Screws (2)
50484
a - End Guide
b - Brass Barrel
c - 6 in. (153 mm)
! CAUTION
Bellows clamps may corrode if grounding clips 22161
are not installed.
c. Pull tool until tool touches the flange on bell
2. Position grounding clips on bellows. housing (hose starts to slip onto flange); then
release tool.
22079
a - Mounting Surface (Apply Bellows Adhesive)
b - Grounding Clips
23154
22081
a - Exhaust Bellows
b - Hose Clamp
c - Gimbal Housing Access Hole
! CAUTION
Support aft end of drive unit as an added safety
measure when working between bell housing
and gimbal housing.
1. Raise drive unit to the full UP/OUT position.
2. Loosen hose clamp and remove exhaust tube.
23158
a - Exhaust Bellows
b - Bell Housing Flange
c - Hose Clamp
23158
a - Hose Clamp
b - Exhaust Tube
INSTALLATION
NOTE: Bellows adhesive is not used when installing
an exhaust tube.
22184
a - Exhaust Tube
b - Grounding Clip
5
A
22163
Special Tools
Description Part No.
Test Gauge Kit 91-52915A6
Multi-Meter 91-99750
Torque Wrench (lb. in.) 91-66274
Hex Lobular Socket Obtain Locally
(Torx Socket)
Jumper Wire Obtain Locally
22031
22124
50389
a - IN/DOWN Trim Hose
b - Hydraulic Connector
c - Plug (22-38609)
Reading NOT OK
Reading NOT OK
Reading Down
Reading NOT OK OK
Install Pump Rebuild Kit and Pressure
Retest (1)* Test
Completed
Reading
Install Trim Pump Rebuild OK Proceed
Kit (1)* to Step 3
Reading NOT OK
Reading NOT OK
Replace Adaptor (2)*
73552
Leak Test
IMPORTANT: The following test assumes that
pump OUT/UP pressure is within specifications
as determined by performing “Power Trim Pump
Test”.
1. Reconnect trim cylinder hoses (if removed in pre-
vious test) as follows:
a. Remove plugs and caps.
b. Install UP hose to forward hole on hydraulic
connector. Tighten securely.
c. Install DOWN hose to aft hole on hydraulic
connector. Tighten securely.
22125
a - Hydraulic Test Gauge
b - Hose Connected To UP (Left Hole)
c - Fittings-(Supplied With Gauge)
d - Black Hose (From Gimbal Housing)
e - Grey Hose (From Gimbal Housing)
50391
a - UP Hose
b - DOWN Hose
c - Hydraulic Connector
50390 22562
a - Trailering Clip
Gauge Connected to Hydraulic Connector
a - Test Gauge
3. Disconnect UP trim hose from trim cylinders.
b - Coupling (Supplied With Gauge)
c - Front Hydraulic Connector Port
! WARNING
Remain clear of drive unit when performing pow-
er trim pump motor tests with pump in the boat
and hydraulic hoses connected.
1. OUT/UP Operation.
a. Connect a jumper wire between positive (+)
solenoid terminal and BLUE/WHITE motor
lead terminal.
b. Motor should run.
22495
a - IN/DOWN Solenoid
b - Positive Terminal (+)
c - GREEN/WHITE Motor Lead Terminal
d - Jumper Wire
22495
a - OUT/UP Solenoid
b - 12 Volt Positive (+) Supply Lead
c - Negative (-) Supply Lead
4. IN/DOWN Operation.
a. Connect a 12 volt positive (+) supply lead to
GREEN/WHITE motor lead terminal.
b. Connect the negative (-) supply lead to a
good ground on pump.
c. Motor should run.
22495
a - OUT/UP Solenoid
b - Positive (+) Solenoid Terminal
c - BLUE/WHITE Harness Wire Terminal
d - Jumper Wire
22494
a - IN/DOWN Solenoid
b - 12 Volt Positive (+) Supply Lead
c - Negative (-) Supply Lead
22494
a - IN/DOWN Solenoid
b - Positive (+) Solenoid Terminal
c - GREEN/WHITE Harness Wire Terminal
d - Jumper Wire
22494
a - IN/DOWN Solenoid
b - 12 Volt Positive (+) Supply Lead
c - Negative (-) Supply Lead
d - Ohmmeter Leads
22493
a - Volt Meter Negative (-) Lead
b - Volt Meter Positive (+) Lead
c - Fuse
22497
a - 20 Amp Fuse
b - Ohmmeter Leads
1. Remove fuse from fuse holder. 4. Remove lag bolts and washers. Lift pump and
floor bracket from boat.
22549
22496 a - Positive Battery Lead
a - Fuse Holder b - Negative Battery Lead
c - Harness Connector
d - Black Hydraulic Hose (UP Hose)
e - Gray Hydraulic Hose (DOWN Hose)
f - Lag Bolts and Washers
Disassembly
1. Disconnect trim motor wires.
22496
a - UP Solenoid
b - DOWN Solenoid
c - Mounting Bolts (2 On Each Solenoid)
22497
a - Blue/White Motor Wire 4. Remove pump reservoir.
b - Green/White Motor Wire
c - Black Ground Wire
22547
a - Pump Reservoir
b - Bolt And O-ring-Spacer
22548
a - Trim Pump
b - Floor Bracket
c - Mounting Bolts
22547
a - Filter
70892 50377
a - Factory Installed UP Pressure Relief Valve
b - Earlier Style Replacement Pressure Relief Valve
22547
a - Filter
b - 5/8 in. Socket
50396
70872
50396 50396
a - Original Factory Installed UP Pressure Relief Valve
b - Jam Nut (a)
c - Pump Body Components (Spring, Eyelet, Check Ball)
d - Replacement UP Pressure Relief Valve (Blue)
e - Jam Nut 70892 50377
f - O-ring
a - Factory Installed DOWN Pressure Relief Valve
b - Earlier Style Pressure Relief Valve
EARLIER STYLE REPLACEMENT PRESSURE
RELIEF VALVE CURRENT REPLACEMENT PRESSURE RELIEF
VALVE
50376
50396
a - UP Pressure Relief Valve 50396
b - Jam Nut
c - Replacement UP Pressure Relief Valve (Blue) a - Replacement DOWN Pressure Relief Valve
d - O-ring b - Color Coded Green
70872
50396 50396
50396
50376
70870
a - DOWN Pressure Relief Valve
b - Jam Nut-DO NOT TURN Or Attempt To Loosen a - Screws
c - Replacement Valve (Green)-Use Base Of Valve To Tighten b - Pinion Assembly Screws
d - O-ring
22548
a - Pump Motor
b - Screws (2)
70869
a - Adaptor
b - O-ring
70870
a - Screws
22549
22498
a - Hex Plug Retainers (2)
a - Adaptor
b - Springs (2)
b - Vent Screw (Dipstick)
c - O-ring
d - Coupling-(Shallow Slot Toward Reservoir) 2. Remove and discard poppet valves.
22548
22549
a - Poppet Valves
22496
a - Motor Shaft
b - Coupling
c - Screws (Opposite Corners)
Use care in removing check valve bodies from 9. Place poppet valves into check valve bodies.
adaptor, so as not to damage poppet valve seat
surface on valve body.
3. Remove check valve bodies and spool.
70874
70868
70875
70867
a - Spool
a - O-rings b - Check Valve Body (2)
b - Hex Plug Retainers c - Poppet Valve (2)
c - Springs d - Check Valve Body O-ring (2)
d - Poppet Valves
e - Check Valve Bodies
10. Lubricate hex plug retainer O-rings with
f - Spool
Quicksilver Power Trim and Steering Fluid, or
10W-30, or 10W-40 motor oil.
7. Lubricate check valve body O-rings with power
trim and steering fluid, or with 10W-30 or 10W-40 11. Place spring into hex plug retainers.
motor oil.
! CAUTION
DO NOT force check valve bodies into adaptor as
damage to O-rings may result.
70870
70871 a - Screws
b - Pump Assembly Screws
a - Spring (2)
b - O-ring (2)
c - Hex Plug Retainer (2) 3. Remove oil seal by prying out with a screwdriver.
! CAUTION
Hex plug retainers MUST BE turned into adaptor
exactly as outlined or damage to check valve
body O-rings may result.
13. Tighten hex plug retainer 1/4 turn, then back off
1/8 turn. Repeat until hex plug is tightened
securely.
50371
a - Oil Seal
70866
70869
a - O-ring
22545 b - Adaptor
a - Oil Seal-Lip Toward Pump
b - O-rings
9. Install reservoir.
7. Install pump and torque screws to 75 lb. in. (8
N·m) using a hex lobular socket or a standard Motor Repair
3/16 inch socket.
Disassembly
1. Remove trim motor from adaptor.
70870
a - Screws
22546
a - Trim Motor
b - Adaptor
c - Screws
22498 22648
a - Adaptor
a - Brush Hold Down Arms
b - O-ring
b - Screws
22639
22638
a - Brush Holder
b - Spring
22640
a - Cover
b - Screws (4)
c - Washer
22637
a - Thermal Switch And Brush
22499
b - Screw
a - Armature
b - Thrust Washer
7. Remove brush assembly mounting bracket.
c - Motor Housing
22636
22646
22501 a - Ohmmeter
a - Field Assembly b - Meter Lead-Place On Armature Shaft
b - Motor Housing c - Meter Lead-Place On All Commutator Bars (One At A
Time)
22645
a - O-ring
b - Motor Housing
22647
a - Commutator
b - Gap
22643
a - Field Frame
b - Field Brush Lead
22631
22642 a - Thermal Switch Spade Connector
a - Ohmmeter Lead-Connected To Brush Lead b - Brush Lead
b - Ohmmeter Lead-Connected To GREEN/WHITE Lead
22648
a - Brush Hold Down Arm
b - Screws
22649
a - Thermal Switch Spade Connector
b - Brush Lead
c - Insulator (Piece Of Paper)
22638
a - Brush Holders
b - Springs
22635
a - Brush Wire
22637 b - Field Wire (Old Brush Wire)
a - Thermal Switch And Brush c - Crimp Connector
b - Screw
c - Connector 6. Reinstall spring and brush in brush holder.
22638
a - Brush Holder
b - Spring
c - Brush
22632
a - Brush Wire
b - Brush
22645
a - O-ring
b - Motor Housing
22633
a - Motor Housing
b - “Front”
c - “Notched Out” Area
22634
a - Brush Wire
22636
a - Brush Assembly Mounting Bracket
b - Screw
22501
a - Field Assembly
b - Motor Housing
22637
a - Thermal Switch
b - Screw
c - Black Wire Connector
22499
a - Armature
b - Thrust Washer
c - Motor Housing
22639
a - Motor End Cover
b - Screws
22638
22498
a - Adaptor
b - O-ring
22648
a - Brush Hold Down Arms
b - Screws
22497
22548 a - BLUE/WHITE Motor Wire
b - GREEN/WHITE Motor Wire
22496 c - BLACK Ground Wire
a - Trim Motor
b - Adaptor
c - Screws (2) (Opposite Corners)
! CAUTION
d - Coupler Solenoid terminal cover screw is attached to 12
e - Motor Shaft volt positive source. DO NOT GROUND screw-
driver when installing cover.
11. Install trim pump on floor bracket. Tighten
securely.
13. Install solenoid terminal cover. Tighten screw
securely.
22548
a - Trim Pump
b - Floor Bracket
c - Screws And Lock Washers
22549
! CAUTION
Fill cap is vented. Be sure to remove “Caplug” (fill
neck seal) from fill neck on new replacement
pumps. Failure to do this can damage pump,
when operated.
22549
a - Positive Battery Lead
b - Negative Battery Lead
c - Harness Connector
d - Black Hydraulic Hose (UP Hose)
e - Gray Hydraulic Hose (DOWN Hose)
f - Lag Bolts and Washers
g - Vent Plug-Earlier Models; Replaced By Vented Fill Cap
h - Vent In Fill Cap
22252
6
A
22147
POWER STEERING
Table of Contents
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Cable Guide Tube . . . . . . . . . . . . . . . . . . . . 6A-18
Torque Specification . . . . . . . . . . . . . . . . . . . 6A-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . .
6A-19
Lubricants/Sealers/Adhesives . . . . . . . . . . . . . . 6A-1 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . .
6A-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-20
Power Steering System . . . . . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-20
Power Steering System . . . . . . . . . . . . . . . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . .6A-22
Power Steering System . . . . . . . . . . . . . . . . . . . 6A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . .
6A-25
Steering Helm and Cable . . . . . . . . . . . . . . . . . . 6A-5 Booster Cylinder . . . . . . . . . . . . . . . . . . . . . .
6A-26
Power Steering Models . . . . . . . . . . . . . . . . . 6A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-26
Filling and Air Bleeding Power Steering Installation . . . . . . . . . . . . . . . . . . . . . . . .
6A-27
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6 Power Steering Pump . . . . . . . . . . . . . . . . . 6A-29
Balancing Power Steering Control Valve . . . . . 6A-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-29
Power Steering Drive Belt Inspection . . . . . . . 6A-9 Flow Control Valve Servicing . . . . . . . . 6A-29
Steering Cable Selection, Removal and Pump Shaft Oil Seal Replacement . . . 6A-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-31
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Cleaning And Inspection . . . . . . . . . . . . 6A-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Reassembly . . . . . . . . . . . . . . . . . . . . . . .6A-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . .
6A-35
Testing Power Steering System . . . . . . . . . . . 6A-11 Determining Tie Bar Length . . . . . . . . . . . . 6A-36
Test Gauge Assembly . . . . . . . . . . . . . . . . . 6A-11 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-36
Power Steering Pump Lugging Test . . . . . 6A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-37
Power Steering System Pressure Test . . . 6A-12 Dual Installations With Steering Cable
Pump Pressure Test . . . . . . . . . . . . . . . . . . 6A-14 Attached To Starboard Power
Booster Cylinder Test . . . . . . . . . . . . . . . . . 6A-15 Package . . . . . . . . . . . . . . . . . . . . . . . . . 6A-37
Power Steering Component Repair . . . . . . . . 6A-16 Dual Installations With Steering Cable
Power Steering Unit . . . . . . . . . . . . . . . . . . . 6A-16 Attached To Port Power Package . . . 6A-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . 6A-16
Special Tools
Description Part No.
Power Steering Test Gauge 91-38053A3
Power Steering Pump Pulley 91-93656A1
Installer
KENT-MOORE SPECIAL TOOLS
Can be ordered from:
Kent-Moore Tools, Inc.
29784 Little Mack
Roseville, MI 48066
Phone: 313-774-9500
Power Steering Pump Kent-Moore Part
Pulley Remover No. J-25034-C
Lubricants/Sealers/
Adhesives
Description Part No.
2-4-C Marine Lubricant 92-825407A2
Special Lubricant 101 92-13872A1
Locquic Primer T 92-59327-1
Loctite No. 35 92-59328-1
Loctite Type A Obtain Locally
22213
22215
22214
! WARNING
Failure to use a steering cable locking device
could cause loss of steering, which could cause
damage to the boat and/or injury.
50629
All current production Quicksilver Ride Guide steer-
a - Locking Plate 92766
ing cables have a self-locking coupler nut and do not b - Screw 10-41209-(See “Torque Specifications”)
require an external locking device. (Other cable c - Washer 12-35462
manufacturers also make cables with self-locking
coupler nut.)
! CAUTION
POWER STEERING EQUIPPED UNITS ONLY-If
cables with improper dimensions are installed,
severe damage to transom assembly and/or
steering system may result. DO NOT attempt to
adjust cable guide tube on power steering unit,
as guide tube and locknut have been torqued
22060
(with Loctite) at the factory, and an attempt to
loosen nut or sleeve may result in damage to
tube.
a - Quicksilver Ride Guide Steering Cable Self-Locking Cou-
pler Nut (Identified By Groove)
1. Steering cable must be the correct length, partic-
NOTE: If using a steering cable that does not have
ularly when installed in larger boats.
a self- locking coupler nut, an external locking device
must be used. 2. Avoid sharp bends, kinks or loops in cable.
3. Power Steering Models: Fully extended steer-
ing cable end dimension must be correct.
22029
Engine Warm from Operation NOTE: If using a test tank or if boat is in the water, en-
a - Recommended Fluid Level sure sterndrive unit gear housing water intake holes
are below water level.
6. Partially open water tap (approximately 1/2 max.)
and allow water to enter cooling system. DO NOT
use full water tap pressure.
7. Start engine and run at idle. During this time, turn
steering wheel back-and-forth to end of travel in
each direction several times.
8. Position drive unit so that it is straight back and
then stop engine. Remove fill cap from pump. Al-
22023 low any foam in pump reservoir to disperse, then
check fluid level and add fluid, if needed. DO NOT
Engine Cold OVERFILL. Reinstall fill cap and tighten securely.
a - Recommended Fluid Level
9. If fluid was foamy in previous step, repeat steps
7 and 8 until fluid does not foam and level remains
constant.
Control Valve
IMPORTANT: Control valve is balanced by the
manufacturer and should not require further ad-
justment. However, if drive unit tends to creep in
one direction or the other (with engine running,
drive unit in neutral, and hands off the steering
wheel), the control valve MUST BE balanced as
explained following.
a - Dust Cover
! CAUTION
DO NOT operate engine without water being sup-
plied to seawater pickup holes in gear housing.
Overheating damage to engine may result.
! WARNING
Remain clear of power steering clevis when start-
ing engine. If control valve is not balanced, unex-
pected movement of clevis could cause injury.
22023
a - Steering Cable 5. Connect a flush test device to drive unit. Partially
b - Clevis open water tap (approximately 1/2 max.) and al-
c - Pin low water to enter cooling system. DO NOT use
d - Cotter Pin full water tap pressure.
22029
22023
a - Clevis
b - Steering Lever
c - Pin
d - Cotter Pin (Hidden)
22032
22023
220023
a - Clevis
10. Install and tighten locking plate on coupler nut.
b - Steering Lever
Secure with self locking bolt and washer. c - Pin
d - Cotter Pin
! CAUTION
If cables with improper dimensions are installed,
severe damage to transom assembly and/or
steering system may result.
! CAUTION
Steering cables MUST BE THE CORRECT
22023 LENGTH, particularly when installed in large
a - Adjustment Nut Cavity boats. Sharp bends or too-short cables result in
kinks; too-long cables require unnecessary
13. Restart engine and observe drive unit. If drive bends and/or loops. Both place an extra stress
unit still creeps in one direction or the other, an on the cable. The proper cable is as short as pos-
external tension may exist on steering cable. En- sible, with the fewest bends and with radii as
sure that nothing is attached to steering cable large as possible.
(pushing or pulling).
22023
22023
a - Steering Cable
b - Cable Coupler Nut
c - Lock Plate
d - Screw And Washer
e - Cotter Pin
f - Clevis Pin
Installation
! WARNING
22032
Steering cable outer casing MUST BE free to
move back-and-forth for steering to function a - Clevis Pin
properly. DO NOT fasten any wires, cables or oth- b - Cotter Pin
c - Locking Plate
er items to steering cable, as this may prevent it
d - Coupler Nut
from moving. e - Steering Cable
f - Self Locking Bolt And Washer
! CAUTION
If Power Steering pump lugs when steering wheel
is turned to end of travel in either direction (left
or right), damage to steering system and/or
sterndrive may result.
IMPORTANT: Make sure that Power Steering
pump is filled to proper level before proceeding.
1. Completely open test gauge.
2. Start engine and run at idle speed.
3. Turn steering wheel to hard left and observe
reading on gauge. If pressure reading is higher
than 300 psi (2069 kPa), stop engine and check
the following:
a. Check for an obstruction between gimbal ring
22146 and gimbal housing and all moving steering
system components.
a - Pump Pressure Hose
b - Gauge Fitting b. Check that steering lever is not contacting
c - Gauge Valve Hose cut-out in transom. If contact is being made,
d - Control Valve modify cutout.
c. Check steering cable guide tube dimensions
and adjust as necessary.
22137
22469
22023
a - Clevis
b - Pins (2)
c - Cotter Pins (2)-Hidden
d - Steering Lever
e - Steering Cable
f - Coupler Nut
g - Locking Plate
22137
! CAUTION
DO NOT lug pump at maximum pressure for more
than 5 seconds, in next step, or damage to Power
Steering pump may occur.
7. Push control valve adaptor block momentarily to
the left and then to the right. Gauge reading
should show an instant increase in pressure
when block is pushed in both directions.
8. Push control valve adaptor block to the right, un-
til booster cylinder piston rod is fully retracted.
With piston rod in this position, momentarily
push adaptor block to the right until maximum
pressure reading is obtained.
22146
22029
22023
22023
a - Clevis
b - Pins (2) 22032
c - Cotter Pins (2)
22023 d - Steering Lever
e - Steering Cable
a - Adaptor Block f - Coupler Nut
b - Top Metal Line g - Locking Plate
22167
a - Bushings
22023
22137 22168
a - Power Steering Unit a - Pivot Bolts
b - Tab Washer b - Tab Washer
c - Pivot Bolt c - Swivel Ring
22169
22023
22032
22032
a - Clevis Pin
b - Cotter Pin
c - Lock Plate
d - Coupler Nut
e - Steering Cable
22023
22023 22137
a - Control Valve a - Adaptor Block
b - Pump Hoses b - Nut
2. Remove steering cable from power steering con- 4. Heat area shown (to break down Loctite), and
trol valve. remove steering tube bushing, guide, and nut.
Remove cable guide tube.
22023
22137
a - Application Area
a - Clevis Pin
b - Cotter Pin
c - Locking Plate
d - Coupler Nut
e - Steering Cable
22137
22137
a - Heat this Area
b - Steering Tube Bushing
c - Steering Tube Guide
d - Steering Tube Nut
e - Cable Guide Tube
22023
4. Remove control valve from adaptor block
assembly.
22143
a - Control Valve
b - Adaptor Block Assembly
c - Screw
d - Washer
22023
DISASSEMBLY
a - Cotter Pins (Hidden)
b - Clevis Pins 1. Remove adaptor block as follows:
c - Power Steering Pump Fluid Hoses Loosen adaptor block nut. Tap adaptor nut with
d - Coupler Unit Lock hammer to loosen block. Remove nut, washer
e - Cable Coupler Nut
f - Steering Cable
and adaptor block.
22137
a - Metal Tubes
22143
22139
a - Dust Cover
b - Adjusting Nut
a - Adjuster Plug
b - Turn Counterclockwise
22145
a - Valve Housing
b - Adaptor
c - Screws (2)
d - Lock Washers (2) 22139
22138
a- Valve Spool
b- Valve Adjustment Spring
c - Reaction Spool
22140
d- Spring Thrust Washer
e- Valve Spring a - Ball Stud-Pull Up into Rubber Boot
f - Spring Retainer b - Sleeve Bearing
g- Annulus Seal c - Lower Ball Seat
h- Large ID Washer
i - Reaction Spool O-ring 8. Clean and inspect metal parts. If any metal part
j - Valve Spool “V” Block Seal shows signs of wear, replace control valve
k - Annulus Spacer assembly.
l - Gasket
m- Small Washer
n- Plug Sleeve Key
o- O-Ring
p- Valve Housing
22140
22140
a - Sleeve Bearing
b - Ball Stud 22139
c - Adaptor Housing
a - Valve Shaft
b - Adjuster Plug
3. Position ball stud in sleeve bearing.
4. Install upper ball seat. 7. Install key. Fit key tangs into notches in sleeve.
22141 22141
22141
a - Reaction Spool
b - O-ring
c - thrust Washer
d - Valve Spring
e - Spring Retainer
f - Annulus Seal-Lip Facing O-ring End of Spool
22142
12. Install valve adjustment spring.
a - O-ring
b - Control Valve Housing
10. Install “V” block seal. Insert valve spool into ad-
justing nut end of control valve.
22142
22142
22143
a - Dust Cover
22144
22143
a - Grease Fitting
b - Rubber Boot
22144 19. Install adaptor block. Torque nut to 30-40 lb. ft.
a - Annulus Spacer (41-54 N·m).
b - Control Valve Housing
c - Adaptor Housing
d - Screws And Washers (2 Each)
22143
22139
a - Adaptor Block
a - Valve Spool b - Internal Lock Washer
b - Valve Shaft c - Nut
c - Locknut
22143
a - Control Valve
b - Adaptor Block Assembly
c - Washer
d - Screw
22137
a - Application Area
22023
22032
a - Clevis Pin
b - Cotter Pin
c - Locking Plate
d - Coupler Nut
e - Steering Cable
22023
22023
Booster Cylinder
REMOVAL
NOTE: If accessibility to booster cylinder area is lim-
ited, remove Power Steering unit from transom as-
sembly to gain easier access to booster cylinder.
22023
22137
a - Metal Lines
22157
3. Remove control valve from adaptor block
assembly. a - Metal Lines
22143
22149
a - Control Valve a - Snap Ring
b - Adaptor Block Assembly b - Large Oil Seal
c - Screw c - Small Oil Seal
d - Washer
INSTALLATION
4. Remove clevis assembly.
1. Install components shown.
22157 22149
22157
a - Metal Lines
22158
a - Cotter Pin
b - Retaining Pins (2)
c - Booster Cylinder
d - Adaptor Block Assembly
22158
22157 22023
a - Clevis Assembly
b - Washer
c - Nut-Tighten Securely 22032
a - Clevis Pin
5. Secure control valve to adaptor block assembly. b - Cotter Pin
Torque screw to 25-35 lb. ft. (34-47 N·m). c - Locking Plate
d - Coupler Nut
e - Steering Cable
a - Control Valve
b - Adaptor Block Assembly
c - Washer
d - Screw
22023
a - Metal Lines
b - Control Valve
22149
2. Push a .005 in. (0.13 mm) shim stock past oil seal
until it bottoms in pump body. (Approximately
22149
2-1/2 in. [64 mm] long)
a - Fitting Assembly 3. Cut seal and tear metal body approximately 1 in.
b - Control Valve Assembly (25 mm).
c - Flow Control Spring
d - O-rings
22149
22152
a - Flow Control Spring
b - Control Valve Assembly a - Oil Seal
c - New O-rings b - Chisel-To Cut Seal
d - Fitting Assembly c - Shim Stock
22152
a - Torn Seal
b - Awl
a -
Power Steering Pump Pulley
b -
Stud
c -
DO NOT Use Spacer
d -
Bearing
e -
Nut
f -
Shaft
g -
Crankshaft Pulley (Shown) Or Water Circulating Pump
Pulley
h - Long Straight Edge
i - Drive Belt Parallel
22151
22150
22155
a - Spring
b - Pressure Plate
c - Pump Ring
d - Pump Vanes
e - Pump Shaft And Rotor Assembly
f - Dowel Pins
22155
a - Fitting Assembly
b - Control Valve Assembly
c - Flow Control Spring
d - Studs
e - Reservoir
f - O-rings
22155
a - Retaining Ring
b - Rotor
c - Thrust Plate
d - Pump Shaft
22151
22150
22155
a - Pump Shaft
b - Thrust Plate
c - Rotor-Countersunk Side Toward Thrust Plate
d - Retaining Ring
22154
22154
a - Vanes-Rounded Edges Toward Pump Ring
a - Pump Shaft And Rotor Assembly
b - Pump Housing 7. Install pressure plate.
22154
a - Pump Ring
22154
a - Pressure Plate
b - Spring Groove-Facing Up
22152
c - Retaining Ring
d - Arbor Press-Use Care Not To Damage End Plate O-ring
22153
a - Reservoir O-rings
22153
a - Magnet
a - Pressure Plate Spring
b - End Plate
22153
a - Reservoir
b - Pump Housing
c - Studs
75753
a -
Power Steering Pump Pulley
b -
Stud
c -
DO NOT Use Spacer
d -
Bearing
22153
e -
Nut
a - Flow Control Spring f -
Shaft
b - Control Valve Assembly g -
Crankshaft Pulley (Shown) Or Water Circulating Pump
c - O-ring-For Fitting Assembly Pulley
d - Fitting Assembly h - Long Straight Edge
i - Drive Belt Parallel
INSTALLATION
1. Install power steering pump on engine. (Refer to
Appropriate Engine Service Manual)
22031
22079
22079
22211
22211
22079
22079
22211
22211
7
22032 A
ALL MODELS
Table of Contents
Page
Continuity Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
Anodic Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
Anodic Trim Tab . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-5
Integral MerCathode System . . . . . . . . . . . . . . . 7A-6
Removing Electrode Assembly . . . . . . . . . . 7A-6
Installing Electrode Assembly . . . . . . . . . . . 7A-6
Connect Electrical Leads to Controller
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-7
Quicksilver Isolator . . . . . . . . . . . . . . . . . . . . . . 7A-11
Corrosion Protection Testing and
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7A-11
Low Reading . . . . . . . . . . . . . . . . . . . . . . . . . 7A-14
High Reading . . . . . . . . . . . . . . . . . . . . . . . . 7A-15
Normal Reading But Corrosion Is
Evident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-16
22061
22028
a - Steering Lever Ground Wire
22230
22650
b - Inner Transom Plate To Gimbal Housing Ground Wire
22755
50383
22062
22079
70764
70748
a - Hydraulic Manifold
b - Rubber Seal
73315
73892
a - Anodic Block
b - Screws
c - Continuity Washer
d - Gasket
e - Seal
70748
a - Screw Holes
b - Hydraulic Manifold
70772
73891
a - Screws (2)
b - Anodic Block
c - Continuity Washers
! CAUTION
73893
To be effective, new anodic block MUST make
good continuity contact with gimbal housing. LATER MODEL ANODE
a - Screws (2)
b - Anodic Block
c - Gasket
73892
22093
a - Plug
22093
a - Plug
23253
a - Trim Tab
b - Plug-(Removed)
c - Allen Wrench
22231
70756
a - O-ring Groove
b - O-ring
EARLIER MODEL ELECTRODE
a
c
d
b
70771
a - Electrode Assembly
b - Screw (2)
c - Flat Washer (2)
d - Lock Washer (2) 71862
e - Hydraulic Connector Block
a - Electrode
b - Rubber Grommet
LATER MODEL ELECTRODE
22234
70757
22443
70757
90-12934--2 3-194
1097 CORROSION PROTECTION - 7A-9
BLK D BLACK
BLU D BLUE
BRN D BROWN
GRY D GRAY
GRN D GREEN
ORN D ORANGE
PNK D PINK
PUR D PURPLE
RED D RED
TAN D TAN
WHT D WHITE
YEL D YELLOW
LIT D LIGHT
DRK D DARK
70757
70972
MAINTENANCE
Table of Contents
Page Page
Maintenance Schedules . . . . . . . . . . . . . . . . . . . 1B-1 Changing Sterndrive Oil . . . . . . . . . . . . . . . . . . . 1B-9
Maintenance Intervals . . . . . . . . . . . . . . . . . . 1B-1 Models Without Gear Lube Monitor . . . . . . 1B-9
Scheduled Maintenance That Can Be Units With Gear Lube Monitor . . . . . . . . . . 1B-10
Performed By Owner/Operator . . . . . . . . . 1B-1 General Maintenance . . . . . . . . . . . . . . . . . . . . 1B-12
Scheduled Maintenance That Can Be Maintaining Power Package Exterior
Performed by Dealer . . . . . . . . . . . . . . . . . . 1B-2 Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Lubricating Shift Cable Pivot Points . . . . . . 1B-4 Steering Head and Remote Control
Lubricating Propeller Shaft . . . . . . . . . . . . . . . . 1B-4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Lubricating Steering System . . . . . . . . . . . . . . . 1B-5 Checking Quicksilver MerCathode
Power Steering Models . . . . . . . . . . . . . . . . . 1B-5 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Manual Steering Models . . . . . . . . . . . . . . . . 1B-5 Maintaining Alloy Trim Tab and Anodic
Lubricating Tie Bar Pivot Points . . . . . . . . . . 1B-5 Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Control Valve Mounted on Starboard Replacing Trim Tab . . . . . . . . . . . . . . . . . 1B-12
Transom . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Maintaining Continuity Circuit . . . . . . . . . . 1B-13
Lubricating Tie Bar Pivot Points . . . . . . . . . . 1B-6 Replacing Anodic Heads - One Each
Control Valve Mounted on Port Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Transom . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-6 Checking Optional Quicksilver
Lubricating Transom Gimbal Housing Anti-Corrosion Anode Kit . . . . . . . . . . . . . 1B-13
Assembly Swivel Shaft, Swivel Pin, Hinge Boat Bottom Care . . . . . . . . . . . . . . . . . . . . 1B-13
Pins and Gimbal Bearing . . . . . . . . . . . . . . . . . 1B-6 Power Package Layup
Checking and Adding Sterndrive Oil . . . . . . . . 1B-7 (Out of Season Storage) . . . . . . . . . . . . . . . . 1B-14
Units Without Gear Lube Monitor . . . . . . . . 1B-7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Models With Gear Lube Monitor . . . . . . . . . 1B-8 Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Checking Lubricant for Water . . . . . . . . . . . . . . 1B-8 Power Package Recommissioning . . . . . . . . . 1B-15
Models Without Gear Lube Monitor . . . . . . 1B-8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Models With Gear Lube Monitor . . . . . . . . . 1B-9 Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Task Interval
Engine Crankcase Oil - Check level.
Closed Cooling Coolant - Check level.
Power Steering Fluid - Check level.
Sterndrive Unit Oil - Check level.
Battery - Check level and inspect for damage.
Weekly
Fuel Pump Sight Tube (If Equipped) - Check that no
fuel is present.
Power Trim Pump Oil - Check level.
Anodes - Inspect for erosion.
Gear Housing Water Pickups - Check for marine
growth or debris.
Every 100 hours of operation or 120 days,
Drive Belts - Inspect condition and check tension.
whichever occurs first.
Propeller Shaft - Lubricate. Saltwater Use: Every 50 hours of operation or 60
days whichever occurs first.
days, first
Power Package - Exterior Surfaces - Spray with rust Freshwater Use: Every 100 hours of operation or
preventative. 120 days, whichever occurs first.
Power Package Exterior Surfaces - Clean and
Once a year
paint.
Cooling System - Flush seawater section. Saltwater Use: After every use.
Task Interval
Whenever insufficient seawater flow is suspected.
Seawater Pickup Pump - Disassemble and inspect.
(If operating temperature exceeds normal range.)
Crankcase Oil and Filter - Change.
Ignition system - Clean and inspect condition.
Flame Arrestor and Crankcase Ventilation Hose -
Clean and inspect.
Positive Crankcase Ventilation (PCV) Valve (If
Equipped) - Change.
Sterndrive Unit Oil - Change.
Gimbal Ring Clamping Screws - Retorque to
50-55 ft. lb. (67-74 N·m).
Rear Engine Mounts - Check torque to 30-40 ft. lb.
(47-54 N·m).
Gimbal Bearing - Lubricate.
Cooling System - Clean and inspect.
Steering System - Lubricate and inspect for loose, End of first boating season and thereafter, every 100
damaged or missing parts. hours of operation or once yearly, whichever occurs
first.
Electrical System - Check for loose or damaged
wiring.
Closed Cooling System Pressure Cap - Clean,
inspect and test .
Cooling System Hoses and Clamps - Inspect for
damage and deterioration. Check clamps for
tightness.
Continuity Circuit - Check components for loose
connections, broken or frayed wires.
Shift and Throttle Cable and Linkage - Lubricate and
inspect for loose, damaged or missing parts.
Engine Exhaust System - Inspect externally for
damage, deterioration and restrictions. Check for
tightness.
Ignition System - Check timing and adjust as needed.
Task Interval
Steering Head and Remote Control - Inspect and End of first boating season and thereafter, every 100
lubricate. hours of operation or once yearly,
y y, whichever occurs
Carburetor - Inspect and adjust. first.
50308
Early Models
Lubricating Propeller Shaft
1. Lubricate with Special Lubricant 101, 2-4-C Ma-
rine Lubricant With Teflon or Perfect Seal (listed
in order of effectiveness).
22265
Later Models
22074
a - Lubrication Point
! WARNING
Transom end of steering cable MUST BE fully re-
tracted into cable housing when lubricating
cable. If cable is lubricated while extended, hy-
draulic lock of cable could occur.
1. Lubricate following points with specified lubri- a - Steering Cable Grease Fitting - 2-4-C Marine Lubricant
cant. With Teflon
b - Steering - Cable End And Exposed Portion - Special Lubri-
cant 101
c - Pivot Points - SAE 20 Or 30 Engine Oil
d - Pivot Bolts - Special Lubricant 101
e - Lubricating Tie Bar Pivot Points
22023
22079
a - Steering Cable Grease Fitting - 2-4-C Marine Lubricant
With Teflon (See Previous Warning)
b - Control Valve Grease Fitting - 2-4-C Marine Lubricant With
Teflon
c - Steering Cable End - Special Lubricant 101
Starboard Engine
d - Pivot Point - SAE 20 Or 30 Engine Oil
e - Pivot Bolts - Special Lubricant 101
22079
Port Engine
a - Pivot Points
23254
22079
Port Engine
22079 23258
a - Swivel Shaft (Later Models May Not Be Equipped With
Fitting) [2-4-C Marine Lubricant With Teflon]
Starboard Engine b - Hinge Pin (One Each Side) [2-4-C Marine Lubricant With
a - Pivot Points Teflon]
c - Gimbal Bearing (U-Joint And Gimbal Bearing Grease)
d - Swivel Pin (2-4-C Marine Lubricant With Teflon)
! CAUTION
DO NOT attempt to fill drive unit through oil vent
hole, as air will be trapped in drive unit and unit
will be damaged from lack of lubricant.
23264
23254
! CAUTION
If more than 2 fl. oz. (60 ml) of oil is required to fill
drive unit, an oil leak may exist. Find and correct 23266
cause of leak before unit is placed in operation.
a - Oil Fill/Drain Screw
b - Sealing Washer
4. If oil level is low, reinstall oil vent screw and seal-
ing washer. Remove oil fill/drain screw and insert
lubricant pump into oil fill/drain hole.
5. Remove oil vent screw. Fill drive unit (through oil
fill/drain hole) with oil until an an air-free stream
of oil flows out of oil vent hole.
b
70115
a 22101
a - Fill/Drain Plug
b - Sealing Washer Or O-ring
22161
a - Oil Reservoir
b - Cap
b
70115
a 22101
23266
23253
a - Adapter and Seal
23266 b - Hose
23253
a - Adapter
b - Hose Fitting
23253
a - Vent Hole
22161
23266
b - Fill/Drain Screw c - Oil Reservoir
c - Sealing Washer d - Cap
90-12934--2 3-194
1097 MAINTENANCE - 1B-11
General Maintenance 2. Remove plug from drive shaft housing to gain ac-
cess to trim tab attaching screw (not shown in
photo).
Maintaining Power Package Exterior
3. Use a 3/8 in. alIen wrench and unthread trim tab
Surfaces attaching screw from trim tab - DO NOT attempt
Entire Power Package should be sprayed at recom- to remove trim tab attaching screw.
mended intervals with Quicksilver Corrosion and
Rust Preventive Type II. Follow instructions on can ! CAUTION
for proper application.
To be effective, new trim tab MUST make good
At least once each year, entire Power Package electrical contact with gear housing.
should be cleaned and external surfaces, which have
become bare, should be repainted with Quicksilver 4. Scrape trim tab mounting surface on gear hous-
Primer and Spray Paint. ing down to bare metal.
5. Install trim tab, aligning trailing edge with index
Steering Head and Remote Control mark made in Step 1. Tighten screw securely.
Maintenance 6. Reinstall plug in drive shaft housing.
Lubricate steering head and remote control with 7. If power package is equipped with manual steer-
2-4-C Marine Lubricant. Inspect steering head and ing, adjust trim tab.
remote control for ease of operation.
22090
Engine
Refer to appropriate Engine Service Manual.
Sterndrive
1. Lubricate steering system. Refer to SECTION
1-B.
2. Lubricate transom gimbal housing assembly
swivel shaft and pin, hinge pins, gimbal bearing
and propeller shaft. Refer to SECTION 1-B.
3. Lubricate sterndrive unit U-Joint shaft splines
71176 and cross bearings. Refer to SECTION 3-A.
4. Inspect U-Joint bellows for cracks or other signs
Paint the drive unit and transom assembly with a of deterioration. Check bellows clamps for tight-
good quality marine paint or anti-fouling paint that ness. Refer to SECTION 4.
DOES NOT contain copper, tin, or any other material
that could conduct electrical current. Do not paint 5. Check engine alignment. Refer to Engine
drain holes, anodes, MerCathode system, or items Service Manual.
specified by the boat manufacturer. 6. Change sterndrive unit oil.
Spray power package components inside the boat
every 2 - 3 weeks with Quicksilver Corrosion Guard ! CAUTION
to protect the finish from dulling and corrosion. Exter-
Water drain holes in sterndrive unit MUST BE
nal power package components may also be
open to allow water to drain, or trapped water
sprayed.
may freeze and cause severe damage to
All lubrication points, especially steering system, housings.
shift and throttle linkages should be kept well lubri-
cated. Flush the cooling system periodically, prefer-
ably after each use.
! CAUTION
A discharged battery can be damaged by freez-
ing.
U-Joint bellows may develop a “set” if unit is 2. Install fully-charged battery. Clean battery cable
stored in raised position and may fail when unit clamps and terminals and reconnect cables. Be
is returned to service. Store sterndrive unit in the sure to tighten clamps securely. Apply a thin coat
full trim IN/DOWN position. of petroleum base grease to clamps and termi-
nals to help retard corrosion.
3. After recommissioning and starting engine,
check steering system and shift control for proper
operation.
3
B
23146
GEAR HOUSINGS
MR/ALPHA ONE/ALPHA ONE SS
Table of Contents
Page Page
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .
3B-1 Propeller Shaft, Forward Gear And
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
3B-1 Bearing And Shift Spool Assembly
Torque Specifications . . . . . . . . . . . . . . . . 3B-1 Inspection And Cleaning . . . . . . . . . . 3B-30
Shimming Specifications . . . . . . . . . . . . . . 3B-1 Lathe And Dial Indicator . . . . . . . . . . . 3B-30
Lubricants/Sealers/Adhesives . . . . . . . . . . . . 3B-1 V-blocks And Dial Indicator . . . . . . . . . 3B-30
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
3B-1 Propeller Shaft, Forward Gear And Shift
Special Information . . . . . . . . . . . . . . . . . . . . . 3B-2 Spool Reassembly . . . . . . . . . . . . . . . 3B-31
Shift Spool Assembly . . . . . . . . . . . . . . . . 3B-2 Shift Shaft Disassembly . . . . . . . . . . . . 3B-32
Forward Gear Bearing Bore . . . . . . . . . . . 3B-3 Shift Shaft Inspection And Cleaning . 3B-32
MR/Alpha One Gear Housing . . . . . . . . . . . . 3B-8 Shift Shaft Reassembly . . . . . . . . . . . . 3B-32
Pre-Disassembly Inspection . . . . . . . . . . . . . 3B-12 Gear Housing Cleaning And
Inspection . . . . . . . . . . . . . . . . . . . . . . . 3B-33
Separate Drive Shaft Housing From
Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 Gear Housing Reassembly And
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . 3B-33
Gear Housing Disassembly . . . . . . . . . . . . . . 3B-14
Shift Shaft Installation . . . . . . . . . . . . . 3B-33
Component Servicing . . . . . . . . . . . . . . . . 3B-19
Drive Shaft And Pinion Gear
Water Pump Inspection . . . . . . . . . . . . 3B-19 Installation (Without Propeller
Water Pump Reassembly . . . . . . . . . . 3B-21 Shaft In Place) . . . . . . . . . . . . . . . . . . . 3B-34
Drive Shaft Disassembly . . . . . . . . . . . 3B-22 Checking Pinion Gear Height . . . . . . . 3B-35
Pinion Bearing Removal . . . . . . . . . . . 3B-22 Forward Gear Bearing Cup
Pinion Bearing Installation . . . . . . . . . . 3B-23 Installation . . . . . . . . . . . . . . . . . . . . . . 3B-38
Drive Shaft Reassembly . . . . . . . . . . . 3B-23 Propeller Shaft, Forward Gear And
Bearing Carrier, Reverse Gear And Shift Spool Installation . . . . . . . . . . . . 3B-39
Retainer Inspection . . . . . . . . . . . . . . . . 3B-23 Drive Shaft And Pinion Gear Installation
Bearing Carrier And Reverse Gear (With Propeller Shaft In Place) . . . . . 3B-40
Disassembly . . . . . . . . . . . . . . . . . . . . . 3B-24 Bearing Carrier And Reverse Gear
Bearing Carrier And Reverse Gear Installation . . . . . . . . . . . . . . . . . . . . . . 3B-41
Reassembly . . . . . . . . . . . . . . . . . . . . . 3B-26 Checking Forward Gear Backlash . . . 3B-43
Propeller Shaft, Forward Gear And Shift Checking Reverse Gear Backlash . . . 3B-47
Spool Disassembly . . . . . . . . . . . . . . . 3B-28 Water Pump Installation . . . . . . . . . . . . 3B-51
Shift Spool Assembly Inspection . . . . 3B-29 Gear Housing Installation . . . . . . . . . . . . . 3B-53
3.2635
to
3.2650
75248
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
plete assembly for replacement of the original lower unit.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Complete Supersession Listing
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
Models ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Ratio
(Original)
ÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Assy Superseded by Serial No. Range
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
Complete
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
120 1.98:1 1623-5356A20 1623-8951A43 4893635 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
140 1.98:1 1623-5356A20 1623-8951A43 4893635 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
165 1.65:1 1623-5356A20 1623-8951A43 4890460 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A20 1623-8951A43 4893835 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
485 1.84:1 1623-5356A20 1623-8951A43 4893835 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
225 - S 1.50:1 1623-5356A3 1623-8951A43 3856268 thru 4200499
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A3 1623-8951A43 4782330 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
233 1.32:1 1623-8951A2 1623-8951A43 4200500 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A3 1623-8951A43 4791300 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-8951A2 1623-8951A43 4791300 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
260 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A6 1623-8951A43 3784374 and below
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A13 1623-8951A43 3784375 thru 3909577
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-5356A3 1623-8951A43 3909578 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-8951A2 1623-8951A43 4782330 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A3 1623-8951A43 4208730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-8951A2 1623-8951A43 4208730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
R ALL 1623-5356A20 1623-8951A43 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
MR ALL 1623-5356A20 1623-8951A43 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
Alpha
ALL 1623-8951A23 1623-8951A43 6225577 and up
One
ÁÁÁÁÁ
ÁÁÁÁÁ
Alpha
ÁÁÁÁÁ
One ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ALL
ÁÁÁÁÁÁÁÁÁÁÁ
1623-8951A14 1623-8951A43 6225577 and up
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
lower unit.
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Only Supersession List
ÁÁÁÁ
ÁÁÁÁÁÁ
Models
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Ratio
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
(Original)
ÁÁÁÁÁÁÁÁÁÁ
Gear Housing Only
Superseded by Serial No. Range
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
120 1.98:1 1623-5356A4 None Required 4893635 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
140 1.98:1 1623-5356A4 None Required 4893635 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
165 1.65:1 1623-5356A4 None Required 4890460 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4893835 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4208730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4208730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
485 1.84:1 1623-5356A4 None Required 4893835 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
225 - S 1.50:1 1623-5356A4 None Required 3856268 thru 4200499
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A4 None Required 4782330 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
233 1.32:1 1623-5356A4 None Required 4200500 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A4 None Required 4791300 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A4 None Required 4791300 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
260 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A3 1623-5356A4 3784374 and below
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A3 1623-5356A4 3784375 thru 3909577
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-5356A4 None Required 3909578 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A4 None Required 4782330 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
R ALL 1623-5356A4 None Required 6225577 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
MR ALL 1623-8951A15 1623-8951A37 6225577 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha 1623-8951A27
ALL 1623-8951A37 6225577 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
One (Black)
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha 1623-8951A14
ALL 1623-8951A37 6225577 and up
One (Oyster)
75256B
FWD. Gear
When Ordering
Bearing Current Part Number:
Gear Housing:
Supersedes To:
1623-8951A27 1623-8951A37
3.4895-3.5000 in. O.D. 3.2635-3.2650 in. O.D.
(88.86-88.90 mm) (82.89-82.93 mm)
Fwd. Gr. Brg. Fwd. Gr. Brg.
1623-815822A6 1623-815822A30
3.4895-3.5000 in. O.D. 3.2635-3.2650 in. O.D.
(88.86-88.90 mm) (82.89-82.93 mm)
Fwd. Gr. Brg. Fwd. Gr. Brg.
40 15
36 42 39 16
Torque Specifications 38 17 40 32
a 60-80 lb. ft. (81-108 N·m)
21
b 30-lb. in. (3-5 N·m)
41 34 50
c 60-80 lb. in. (6.8-9 N·m)
37
d 28 lb. ft. (38 N·m) 49
e 35 lb. ft. (47 N·m) 33 48
f 23 lb. ft. (31 N·m) 47
g 50 lb. ft. (68 N·m) 20 14 46
31
h 210 lb. ft. (285 N·m)
35 45
i 30-50 lb. in. (3.39-5.65 N·m)
30 44
J 100 lb. ft. (130 N·m)
29 43
Lubricants/Sealers/Adhesives
27
A Quicksilver 2-4-C Marine Lubricant . . . 92-825407A2 6
28 5
B 3M Brand Adhesive . . . . . . . . . . . . . . . . . 92-86166-1
7
C Quicksilver Needle Bearing Assembly 4 2
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . 92-825265A1
D Quicksilver Perfect Seal . . . . . . . . . . . . . 92-34227-1 24
3
26
E Quicksilver Special Lubricant 101 . . . . . 92-13872A1
13
22
8 52 51
10
1
12
18
19
75743
3
7
6
8
9
10
12 11
13
15 14
17
16 18
24
19
20
21
22
23
25
26
27
28
29
30
31
32
33
75744
23263
22086
23266
a - Fill/Drain Screw
b - Sealing Washer
22074
a - Propeller Nut
b - Tab Washer
c - Spline Washer 23263
d - Continuity Washer
a - Allen Screw (In Trim Tab Cavity)
e - Propeller
b - Locknuts
f - Thrust Hub
3. Mark trim tab position with a piece of tape; then b. Remove locknut from front side of drive shaft
remove trim tab. housing.
23253
a - Trim Tab
b - Plastic Plug (From Access Hole)
c - 3/8 in. Allen Wrench 23261
NOTE: If O-ring remains lodged between upper drive NOTE: It may be necessary to use a punch and
shaft seals (in drive shaft housing), be sure to remove hammer to drive impeller upward on drive shaft. In
O-ring or reassembly will be impaired. extreme cases, it may be necessary to split hub of
impeller with hammer and chisel.
1. Remove components shown.
23356
a - O-ring
b - Water Tube
c - Rubber Centrifugal Slinger
d - Self-Tapping Screw
23356
23349
50312
23347
70492
23347
a - Bearing Retainer
b - Bearing Retainer Wrench (91-43506)
50313
73868
a - Pinion Gear
b - Anti-Galling Washer (Hidden)
73069
a - Drive Shaft
b - Bearing Cup
c - Bearing Retainer
d - Pinion Nut
a - Propeller Shaft
b - Shift Spool
c - Shift Crank
23354
50312
23351
23355
23348
a - O-ring
b - Gasket
23355
METHOD “B”
a
23347
23351
23343
a - Gasket
b - O-ring
23139
23351
a - Oil Seal
b - Oil Seal Driver (91-44110) a - Water Pump Body
c - Water Pump Base b - Insert
c - Tab
! CAUTION
Water pump base gasket MUST BE installed cor-
rectly. A gasket incorrectly installed will block
water pump base water passage. A blocked water
passage will result in subsequent engine over-
heating damage.
23351
73875
a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)
x
x x
x x
x
23351
a - Shipping Sleeve
23350 23355
50314
23356
a - Bearing Carrier
b - Mating Surfaces
a - Bearing Carrier Retainer
3. Inspect reverse gear for pitting, chipped or
broken teeth, hairline fractures, excessive wear BEARING CARRIER AND REVERSE GEAR
or uneven wear. DISASSEMBLY
4. Inspect clutch jaws for damage. Jaws must not 1. Remove O-ring from bearing carrier.
be chipped or rounded off.
23354
a - Bearing Carrier
23355 b - O-ring
! CAUTION
a - Reverse Gear Teeth
b - Clutch Jaws Clamp on reinforcing rib of bearing carrier ONLY,
or damage to carrier may result.
23352
23351
23351
50315
a - Needle Bearing
23140 b - Bearing Carrier
c - Bearing Driver (91-15755)
a - Needle Bearing
b - Oil Seals
c - Puller Head (91-36569)
2. Apply Loctite 27131 or Type “A” to outside
d - Bearing Driver Rod (91-37323) diameter of first propeller shaft oil seal. Install
seal with lip facing needle bearing. Press oil seal
b. If Replacing Seals Only: Remove oil seals. with tool until tool bottoms on bearing carrier.
Be careful not to damage bore.
50315
a - Oil Seal
23140 b - Oil Seal Driver (91-31108)
a - Oil Seals c - Bearing Carrier
b - Pry Bar
50315 23349
a - Oil Seal a - Bearing Carrier
b - Oil Seal Driver (91-31108) b - Reverse Gear And Bearing Assembly
c - Bearing Carrier c - Pilot Washer (P/N 91-36571)
4. Install thrust washer and ball bearing on reverse 6. Install O-ring on bearing carrier.
gear. Press ball bearing using pilot washer until
bearing bottoms on gear.
23354
a - O-ring
b - Bearing Carrier
23346
a - Ball Bearing
b - Thrust Washer
c - Reverse Gear
d - Pilot Washer (91-36571)
a - Spring
b - Pin 23350
c - Shift Spool Assembly
d - Forward Gear Assembly
e - Sliding Clutch
74008
23356
a - Contact Area
b
c
75219 a
a - Earlier Style Shift Spool Assembly
b - Later Style Shift Spool Assembly
c - Measure End Play Here At Gap
2. Check forward gear clutch jaws for damage. b. Mount dial indicator just forward of propeller
Jaws must not be chipped or rounded off. shaft splines.
c. Rotate shaft and observe dial indicator
movement. Movement of more than .005 in.
(0.013 mm) is reason for replacement.
23355
23355
23353
a - Forward Gear
b - Tapered Roller Bearing
c - Suitable Mandrel
23350
a - Sliding Clutch
b - Grooves In Clutch
c - Forward Gear Assembly
d - Cross Pin
e - Propeller Shaft
f - Spool And Actuating Shaft Assembly
g - Cross Pin Retainer Spring
a - Forward Gear
b - Needle Bearing (Not Seen)
c - Needle Bearing Driver (91-33491)
23354
23349
23354
a - Shift Shaft
b - Clip
c - Washer
d - O-ring
23355 e - Shift Shaft Bushing (Seal Inside)
a - Seal Surface
b - Splines
SHIFT SHAFT INSTALLATION 3. Thread shift shaft bushing into gear housing.
Torque to 50 lb. ft. (68 N·m) using shift shaft
1. Place shift crank on locating pin in forward bushing tool.
section of gear housing. Ensure shift crank faces
toward left (port) side of gear housing.
73883
73870
a - Shift Shaft Bushing Tool (91-31107)
a - Shift Crank
b - Locating Pin
23354
23351
a - Stainless Steel Washer (Rubber Washer Beneath)
a - Shim(s)
DRIVE SHAFT AND PINION GEAR INSTALLATION NOTE: For ease of installation, glue washer to pinion
(WITHOUT PROPELLER SHAFT IN PLACE) gear, using 3M Adhesive (92-86166-1) or equivalent.
IMPORTANT: If unit does not require reshimming 3. Install drive shaft and pinion gear as follows:
(no parts were replaced), proceed to Propeller a. Place pinion gear and washer in gear
Shaft and Forward Gear Installation. If pinion housing.
height must be checked, proceed as follows. b. Insert drive shaft into gear housing bore.
1. If pinion bearing was not replaced, but needle Rotate drive shaft to engage drive shaft
bearings have fallen out during disassembly, splines with pinion gear splines.
install 18 needles in needle bearing outer race. c. Hand thread nut onto drive shaft. DO NOT
Use needle bearing assembly lubricant to help tighten further at this time. if the pinion gear
hold needles in place. nut has a machined shoulder on one side,
install the shouldered side against the pinion
gear. If both sides of the nut are shouldered,
then either side of the nut may rest against
the pinion gear.
23142
a - Rollers (18)
b - Roller Bearing Outer Race
23353
23352
a - Bearing Cup
b - Retainer
73884
5. Torque retainer using Drive Shaft Bearing
Retainer Tool (91-43506) to 100 lb. ft. (130 N·m). a - Drive Shaft Nut Wrench (91-56775)
b - Torque Wrench
c - Socket
d - Breaker Bar
e - Bearing Carrier Retainer
23348
75733
a - Allen Screws
23144
71591
a - Bottom Nut
23144
a - Nuts
23146
23145
a - Nuts
a - Collar b - Drive Shaft
b - Set Screw
c - Flat On Drive Shaft 6. Measure pinion height as follows:
a. Place pinion gear shimming tool in gear
4. Pull up on drive shaft, push down on collar and
housing.
tighten set screw.
NOTE: Take the following measurements at 3
locations, rotating drive shaft and pinion gear 120
degrees at a time.
b. Insert a .025 in. (0.64 mm) feeler gauge
between one tooth of pinion gear and high
point of shimming tool. Take 2 or more
readings, rotating drive shaft and pinion gear
120 degrees at a time. Clearance should be
exactly .025 in. (0.64 mm).
c. If clearance is not correct, add or subtract
shims from beneath drive shaft tapered roller
bearing cup to obtain proper pinion gear
height.
23145
a - Drive Shaft
b - Collar
c - Set Screw
26410
75241
23353
a - Drive Shaft
b - Pinion Gear
b 75256
74009
a - Hex-Head Screw
b - Bearing Adaptor Installation Tool (91-18605A1)
c - Cup Driver (Earlier 91-36577 )
d - Bearing Cup
e - Shims
23356
50317
a - Shims
23343
23346
50313
50312
a - Key
23355
4. Install tab washer. Ensure “V” shaped tab aligns
a - Bearing Carrier Retainer Wrench (91-61069)
with “V” notch in bearing carrier.
IMPORTANT: Do not secure bearing carrier re-
tainer by bending tab on tab washer until forward
and reverse gear backlash have been checked
and corrected as explained following.
50314
a - Tab Washer
b - “V” Tab
23137
a - Bearing Carrier
b - Tab Washer
75733
a - Allen Screws
73885
3. Screw the bottom nut of the bearing preload tool
down until it is one inch further down the threaded
rod than it was previously.
a - Top Nut With Threaded Pipe
b - Nut
c - Spring
d - Thrust Washer
e - Thrust Bearing
f - Thrust Washer
71591
23145
a - Collar
b - Set Screw
c - Flat On Drive Shaft
23144
a - Spring
b - Plate
c - Washer
d - Bearing
e - Washer
f - Spacers (3)
23145
a - Drive Shaft
b - Collar
c - Set Screw
23144
23146
a - Nuts (3)
b - Drive Shaft 23352
23146
23146
a - Drive Shaft
b - Dial Indicator
c - Indicator Rod
d - Indicator Pointer
23352
a - Puller Jaws
b - Puller Bolt
73885
23144
a - Spring
b - Plate
c - Washer
d - Bearing
e - Washer
f - Spacers (3)
23144 23145
23145
23146
a - Collar
b - Set Screw a - Nuts (3)
c - Flat on Drive Shaft b - Drive Shaft
23146
a - Drive Shaft
7. Apply backward pressure on propeller shaft as b - Dial Indicator
follows: c - Indicator Rod
d - Indicator Pointer
a. Install pinion nut adaptor tool, washer and
propeller nut as shown.
9. Perform step a, b or c following.
b. Torque propeller nut to 45 lb. in. (5 N·m).
a. If Backlash is Less than Required, add
appropriate thickness shims (from Shim Pack
P/N 15- 31535A1) between gear housing and
bearing carrier.
b. If Backlash is More than Required, check
for improper installation of bearing carrier. If
carrier is installed properly, it will be
necessary to replace gear housing.
c. If Backlash is Within Specifications,
proceed to next step.
23355
! CAUTION
Before loosening collar set screw, tighten pre-
load tool nuts until they bottom on spacers.
71185
a - Alpha One Old Style (With O-ring Groove)
b - Alpha One New Style (Without O-ring Groove)
23145
a - Collar
b - Set Screw
c - Nuts (3)
23343
50312
a - Impeller
b - Counterclockwise Direction
23343
23350
23147
23266
a - Water Tube
a - Trim Tab Allen Screw 23138
b - Drive Shaft Splines - DO NOT Lubricate Top Of Drive Shaft
b - Oil Seal
c - Alignment Pins
2. Install trim tab allen screw. d - Centrifugal Slinger
e - O-ring (If O-ring Groove Is Present)
3. Install oil seal and apply Special Lubricant 101,
f - Shift Shaft
2-4-C Marine Lubricant, or Perfect Seal to oil
seal. 6. Place drive shaft housing shift shaft in the full
4. Check that alignment pins, centrifugal slinger forward position.
and drive shaft O-ring are in place (if O-ring and
O-ring groove are present).
5. Move gear housing shift shaft clockwise to shift
gear housing into forward gear.
23265
a - Shift Shaft
23253
a - Trim Tab
b - Allen Wrench
c - Plastic Plug
23263
4
B
23292
71415
23156
71414
New Style Shift Cable
New Style Trim Position Sender a - Shift Cable Retaining Nut
23169
22160
Old Style Shift Cable
Older Style Trim Position Sender a - Shift Cable Retaining Nut
The new style cable can be used on all MerCruiser
models.
OLD 50485
50485
OLD
Core Wires
Shift Cable Conduit
a - New Pre-Cut Core Wire Dimension 72-1/8 in. (1832 mm)
b - Front Edge of Anchor
NEW OLD
50485
Cable Anchors
26408
26409
a - Plastic Plugs (2)
b - Nut Swivel Shaft Nut
26409
22183
a - Anchor Screws (2)
b - End Guide
22183
a - Jam Nut
b - Threaded Tube
22091
a - Trim Limit Switch 23153
b - Screws (2) a - Safety Wire - Cut
c - Retainers (2) b - Set Screw
c - Shift Slide
23262 23154
NOTE: On units with old style shift cable, pull bellows 10. Remove shift cable wrapping from shift cable on
away from bell housing after crimp clamp is loos- inner transom.
ened.
22030
a - Inner Transom
b - Shift Cable
c - Wrapping
23364
a - Water Tube Cover
b - Screws
c - Water Tube 22755
d - Rubber Grommet (Beneath Cover) a - Port Side Continuity Wire
73892
a - Continuity Wire
23292
a - Hinge Pins
b - Hinge Pin Tool
c - Apply Heat Here
23254
a - Swivel Shaft Grease Fitting (Not Present On Later Models)
! CAUTION
Be sure to position template correctly when
marking access hole drilling locations. If holes
are not located properly, it will not be possible to
23158 remove upper swivel shaft without complete
transom assembly removal.
a - U-joint Bellows Front Hose Clamp
b - Exhaust Bellows Rear Hose Clamp
c - Bell Housing 3. Position templates on gimbal housing and mark
d - Shift Cable Bellows drilling locations (port and starboard) using a
center punch.
Access Plug Kit Installation
NOTE: If steering lever cavity is not accessible, it will
be necessary to drill access holes in the gimbal
housing. This procedure requires the following:
Access Plug Kit 22-88847A1
1-1/8 in. Hole Saw (Obtain Locally)
1 in. Npt Pipe Tap (Obtain Locally)
23363
22756 a - Template (Port Side Shown)
a - Access Hole Plugs
50540
50540
a - Drill Pilot Hole
50540
a - Hole Saw
50541
23254
a - Screws (2)
Washers (4) With Engine and Transom Assembly Installed
Nuts (2) a - Clamping Screw (Turn Through Access Hole)
b - Gimbal Ring b - Nut
50541
a - Cotter Pin
b - Lower Swivel Pin
c - Washer
d - Continuity Wire
50541
a - Nut 23293
b - Washer (Small I.D.)
c - Steering Lever
d - Washer (Large I.D.)
e - Upper Swivel Shaft
50541
U-JOINT BELLOWS
1. Loosen hose clamp and remove U-joint bellows
from bell housing.
50543
a - Bell Housing
b - U-joint Bellows
23361
c - Hose Clamp
a - Bell Housing
2. Remove old adhesive from U-joint bellows b - Mounting Flange
mounting surface, using lacquer thinner.
! WARNING
b Be sure to read and follow package label direc-
tions when using bellows adhesive.
a
c
23364
a - U-joint Bellows
b - Mounting Surface
c - Clamp
d - Grounding Clip
23364
a - U-joint Bellows
b - Mounting Surface
WATER HOSE
1. Loosen hose clamp and remove water hose from
connector.
50542
a - U-joint Bellows
b - Ground Clips
23361
a - Water Hose
b - Hose Clamp
23294
a - Water Hose
b - Water Tube
c - Hose Clamp
50543
a - Bell Housing
b - Water Hose Connector
50543
a - Bell Housing
b - Water Hose Connector
23294
a - Water Hose
b - Water Tube
c - Hose Clamp
23156
a - Water Hose
b - Hose Clamp
23169
23-805041A2
71227
23169
70181
23362
a - Bushing 70982
a - Upper Bushing
b - Bushing Installation Tool (90-805057A2)
70141 50543
a - Upper Shift Shaft Lever Screw a - O-ring
b - Upper Shift Shaft Lever b - Rubber Gasket
c - Washer (Beneath Lever)
d - Upper Shift Shaft Gimbal Ring
GASKET AND O-RING BEARING AND SEALS (EARLIER STYLE)
1. Remove bearing, seals and spacer using bearing
1. Remove U-joint bore rubber gasket and water
and seal driver.
passage O-ring.
50543
a - O-ring 50544
b - Rubber Gasket a - Bearing and Seal Driver (P/N 91-33492)
50542
a - Spacer
b - Stake Mark
50544
50540
a - Seals
b - Bearing 22440
c - Spacer
d - Bearing And Seal Driver (91-33492) a - Bushing
b - Bearing And Seal Driver (91-43578)
22454
a - Bushing
b - Bearing And Seal Driver (91-43578)
22454
a - Gimbal Ring
b - Synthane Washer (Port And Starboard)
26370
Transom Assembly with Square-Square Upper
Swivel Shaft
a - Bushing
b - Oil Seal
26370
26370
22081
a - Exhaust Bellows
b - Clamp
22450
a - Exhaust Bellows
b - Mounting Surface
26370
73986
a - Exhaust Bellows
b - Hose Clamp
50542
a - Mounting Flange
73987
73987
70197
a - Screw
23296 23293
b - Trim Harness Clamp - Remove
c - Trim Limit Switch Wires a - Square/Spline Swivel Shaft
d - Trim Position Sender Wires b - Square/Square Swivel Shaft
2. Install trim limit switch wires and trim position IMPORTANT: Square/Spline Swivel Shaft must be
sender wires. DO NOT pinch wires. installed with flat on splines forward.
70198
a - Trim Limit Switch Wires
b - Trim Position Sender Wires
3. Apply Perfect Seal to threads of screw and install
trim harness clamp and screw.
23364
23361
a - Gimbal Ring
b - Swivel Shaft
22461
22261
a - Continuity Wire
22445
a - Lower Swivel Pin
b - Washer
c - Cotter Pin
d - Gimbal Ring
23293
a - Screw
b - Nut
23362
a - Swivel Shaft
b - Nut
c - Steering Lever (Washer On Top And Bottom)
23293
a - Nut
b - Swivel Shaft
50541
23293
a - Steering Lever
b - Nut
c - Small I.D. Washer
d - Large I.D. Washer
50541
23254
22461
50541
50541
23254 22948
a - Grease Fitting (Not Present On Later Models) a - Forward Anchor Pin (Longer) - Coat with 2-4-C Marine
Lubricant
b - Washers (2) - Large I.D.
c - Rubber Bushings (4)
d - Washers (2) - Small I.D.
e - Nuts
f - Plastic Caps (2)
22550
23363
a - Plastic Plug - 3/8 in. (9 mm)
of plug protrudes a - Bell Housing
! WARNING
Be sure to read and follow package label direc-
tions when using bellows adhesive.
23158
a - U-joint Bellows
b - Hose Clamp
22161
a - Expander Tool
23292
a - Bell Housing
b - Gimbal Ring
c - Hinge Pin Tool (P/N 91-78310)
d - Torque Wrench (lb. ft.)
23154
a - Expander Tool
b - Bell Housing Flange
22079
a - Exhaust Bellows
b - Mounting Surface
c - Ground Clip
23158
a - Exhaust Bellows
b - Bell Housing Flange
c - Hose Clamp
23155
a - Shift Cable
b - Shift Cable Bellows
c - Crimp Clamp
22030
23262
50544
a - Core Wire
a - Water Tube
b - Shift Slide
b - Rubber Grommet
11. Install inner core wire through shift cable. Be sure
9. Install water tube cover and tighten screws
and position shift lever roller between slot on shift
securely.
slide.
23364
a - Water Tube Cover
b - Screws
23262
22183
a - Core Wire
b - 1-3/8 in. (35 mm)
c - Cut Here
22183
a - Threaded Tube
b - Core Wire a - Core Wire Tip
c - Jam Nut
18. (If using older style shift cable that has core wire
14. Install sterndrive unit. (Refer to Section 2A). with support tube). Position support tube so that
1/2 in. (13 mm) of core wire extends from edge of
15. Shift drive unit into forward gear by pushing in on
support tube. Crimp end of support tube.
core wire with a pair of pliers, while rotating pro-
peller shaft counterclockwise. Ensure clutch is
fully engaged.
a - Support Tube
b - Core Wire 22183
19. Install shift cable end guide over core wire and in-
22183 sert core wire through cable anchor. Tighten
screws securely.
22183
22092
a - Index Marks
50484
22091
22160
22092
73892
a - Continuity Wire
22091
a - Trim Position Sender
b - Screws (2)
c - Retainer (2)
5
B
26349
Torque Specification
TORQUE
DESCRIPTION
lb. in. lb. ft. N⋅m
Pump to Adaptor Screws 75 8
Electrical Specification
115 Amps at
Pump Amperage Draw 2200 - 2600 P.S.l.
(15173 - 17932 kPa)
Lubricants/Sealers/
50494
Adhesives
Oildyne Power Trim Pump
2-4-C Marine Lubricant 92-825407A2
Liquid Neoprene 92-25711-2
Needle Bearing Assembly
92-825265A1
Lubricant
Special Tools
Test Gauge Kit 91-52915A6
Multi-Meter (Ohmmeter) 91-99750A1
Torx Socket Obtain Locally
! CAUTION
Due to differences in internal valving, the Oildyne
trim pump cannot be used to replace an earlier
high pressure Prestolite pump, or vice-versa.
Use of incorrect pump will affect trim operation
and may cause damage to trim system.
Special Information
Trail-Out Valve Removal
Early production Oildyne pumps were equipped with
a trailout valve. This valve was eliminated on later
pumps. If this valve should fail on one of the early
production pumps, the valve can be removed and
replaced with plug 19-11005A1.
26348
Older Production
a - Manual Release Valve Has Been Removed From This
Location
50472
a - Trail-Out Valve - Replaced with Plug 19-11005
! WARNING
Before loosening manual release valve, make
sure all persons are clear of sterndrive unit as
unit may drop to the full IN/DOWN position if
valve is opened too quickly.
In the case of a Power Trim system malfunction, the
sterndrive unit can be raised and lowered manually
by turning the manual release valve (if equipped)
counterclockwise approximately 3 turns and moving
drive unit to desired position by hand. After drive unit
has been placed in the desired position, close valve
NEW ADAPTOR OLD ADAPTOR COMPLETELY. Power Trim system will not function
50474 properly and damage to valve O-rings may result,
a - Adaptor Fitting - Used with Old Adaptor unless valve is completely closed.
22089
50473
a - OUT/UP Trim Hose
a - Fill/Vent Screw b - Front Connection on Trim Cylinder
b - “FILL-ADD” Dipstick Markings Oildyne Power Trim Pump
26349
22089
Reading NOT OK
22126
Reading NOT OK
Reading NOT OK
22090
Reading NOT OK
3. Run pump IN/DOWN until gauge reading
reaches 400 - 600 psi (2759 - 4138 kPa). Stop
Install Trim Pump Rebuild
Reading OK
Up Pressure pumping IN/DOWN. Pressure should not fall
Kit and Retest (5)* Test Completed
below 350 psi (2414 kPa).
Reading NOT OK • Gauge Reading Above 350 PSI (2414 kPa),
Replace Adaptor (3)*
DOWN Pressure Test completed.
• Gauge Reading Below 350 PSI (2414 kPa),
IN/DOWN Pressure Test perform the following:
Check for External Oil Leaks; Down Pressure
1. Close Valve “A” and open Valve “B.” Correct and Retest (6)*
Reading OK Test Completed
ceed to step 3.
• Gauge Reading NOT Within Specifica- Reading NOT OK
tions, perform the following. Replace Trail-Out Valve (if Down Pressure
equipped) with Plug Reading OK Test Completed
19-11005 and Retest (7)*
Reading NOT OK
Reading NOT OK
73890
22126
22090
Gauge Connected to Hydraulic Connector
a - UP Hose a - Test Gauge
b - DOWN Hose b - Coupling (Supplied with Gauge)
c - Hydraulic Connector c - Front Hydraulic Connector Port
2. Connect gauge at most convenient location. 3. Open Valve “A” and “B” and run pump OUT/UP
and IN/DOWN; several times (to purge air).
4. Run pump OUT/UP until trim cylinders are fully
extended. Observe gauge while pumping. Pres-
sure should be 2200 - 2600 psi (15173 - 17932
kPa).
5. Stop pumping OUT/UP. Pressure should not fall
below 1900 psi (13104 kPa).
If readings are not within specifications, an in-
ternal trim cylinder leak is indicated. Use the fol-
lowing procedure to locate faulty cylinder.
a. If gauge is connected at pump, reconnect
gauge at gimbal housing hydraulic connec-
tor. Repeat Step 2. Run pump in OUT/UP
direction until trim cylinder are fully extended.
b. Close Valve “B” on test gauge and repeat
Steps 3 and 4.
26350
If Readings Are Now Within Specifications: Trim
cylinder on the same side that test gauge is con-
Gauge Connected at Pump nected, is faulty.
a - Hydraulic Test Gauge (91-52915 A3) If Readings Are Still Not Within Specifications:
b - Fitting (22-77366) Trim cylinder on the opposite side from where the test
c - Fittings (Supplied with Gauge)
gauge is connected, is faulty.
d - Black Hydraulic Hose (from Gimbal Housing)
e - Gray Hydraulic Hose (from Gimbal Housing)
1. OUT/UP Operation:
a. Connect a jumper wire between positive (+)
solenoid terminal and BLUE/WHITE motor
lead terminal.
b. Motor should run.
22562
a - Trailering Clip
22089 50493
a - UP Trim Hose a - OUT/UP Solenoid
b - Front Connection b - Positive Terminal (+)
c - Blue-White Motor Lead Terminal
4. Run pump in IN/DOWN direction. If oil flows from
d - Jumper Wire
UP port on trim cylinder, shock piston is leaking
and must be replaced.
50494
a - OUT/UP Solenoid
b - 12 Volt Positive (+) Supply Lead
c - Negative (-) Supply Lead
4. IN/DOWN Operation:
a. Connect a 12 volt positive (+) supply lead to
50493 green-white motor lead terminal.
a - IN/DOWN Solenoid b. Connect the negative (-) supply lead to a
b - Positive Terminal (+) good ground on pump.
c - Green-White Motor Lead Terminal
d - Jumper Wire c. Motor should run.
! CAUTION
Remain clear of drive unit when performing pow-
er trim pump motor tests with pump in boat and
hydraulic hose connected.
1. UP/“Out” Solenoid:
a. Connect jumper wire between positive (+)
solenoid terminal and BLUE/WHITE harness
wire terminal.
b. Motor should run.
50494
a - IN/DOWN Solenoid
b - POSITIVE (+) Terminal
c - GREEN/WHITE Harness Wire Terminal
d - Jumper Wire
50495
a - OUT/UP Solenoid
b - POSITIVE (+) Terminal
c - BLUE/WHITE Harness Wire Terminal
d - Jumper Wire
50495
a - IN/DOWN Solenoid
b - 12 Volt Positive (+) Supply Lead
c - Negative (-) Supply Lead
d - Ohmmeter Leads
50493
a - 110 Amp Fuse
50495 b - Ohmmeter Leads
50494
a - Volt Meter Negative (-) Lead
b - Volt Meter Positive (+) Lead
c - Fuse
50492
a - Fuse Holder
22497
a - 20 Amp Fuse
b - Ohmmeter Leads
50476
Disassembly
! CAUTION
Work area must be dirt-and-lint free. The slight-
est amount of dirt in hydraulic system can cause
pump malfunction.
1. Disconnect trim motor wires.
50511
a - UP Solenoid
b - DOWN Solenoid
c - Mounting Bolts (2 on Each Solenoid)
50512
4. Remove pump reservoir.
a - Blue/White Motor Wire
b - Green/White Motor Wire
c - Black Ground Wire
50509
a - Pump Reservoir
b - Bolt and O-ring
50509
a - Trim Pump
b - Floor Bracket
c - Mounting Bolts
! WARNING
Before loosening the manual release valve, make
sure all people are clear of drive unit as drive unit
will drop to full IN/DOWN position when valve is
loosened.
50472
50473 a - Filters
a - O-rings (3) b - 5/8 In. Socket
50474 50396
NEW ADAPTOR OLD ADAPTOR a - UP Pressure Relief Valve
50474 b - Jam Nut
a - O-ring c - Replacement UP Pressure Relief Valve (Blue)
b - UP Pressure Relief Valve d - O-ring
50396
50396
50396
50474
a - DOWN Pressure Relief Valve
b - Jam Nut
c - Replacement Valve (Green)
d - O-ring
50474
a - O-rings
b - Adaptor Seal
50472
4. Install pump and torque screws to 70 lb. in. (8
a - Trail-Out Valve Assembly N·m) using a hex lobular socket or standard 3/16
b - Replacement Plug And O-ring in. socket.
Pump Replacement
NOTE: The pump is not rebuildable. If pump is defec-
tive, replace as an assembly.
1. Remove pump attaching screws with a hex lobu-
lar socket or standard 3/16 in. socket. Do NOT
loosen pump assembly screws. Remove pump.
70870
a - Screws
Adaptor Replacement
NOTE: Adaptor is rebuildable (Refer to “Adaptor Re-
pair”). Order “Trim Pump Adaptor Kit” (99073A1).
70870
1. Remove hydraulic lines from the adaptor and cap
off the lines.
a - Screws
b - Pump Assembly Screws
22498
a - Adaptor
b - Vent Screw (Dipstick)
50511 c - O-ring
a - Solenoid Plate d - Coupling - (Shallow Slot Toward Reservoir)
b - Locknuts
c - Bolts 10. Remove studs from old adaptor and install in new
adaptor.
3. Remove 2 locknuts (a) shown in illustration. Re- 11. Align motor shaft with coupling and install motor
move motor assembly. onto adaptor. Be sure wires are positioned as
shown below. Motor assembly will be flush with
adaptor.
73885
a - Remove Locknuts (Studs May Turn Out)
b - DO NOT Loosen
50476
a - Poppet Valves (2)
! CAUTION
50511
Use care in removing check valve bodies from
a - Solenoid Plate adaptor, so as not to damage poppet valve seat
b - Locknuts surface on valve body.
c - Bolt
14. Uncap hydraulic lines and reconnect to adaptor. 3. Remove check valve bodies and spool.
Adaptor Repair
INTERNAL O-RING and POPPET VALVE
REPLACEMENT
1. Remove hex plug retainers and springs (one on
each side).
50475
50474
a - Hex Plug Retainers (2)
b - Springs (2)
70867
a - O-rings
b - Hex Plug Retainers
c - Springs
d - Poppet Valves
e - Check Valve Bodies
f - Spool
! CAUTION
50509
DO NOT force check valve bodies into adaptor as
damage to O-rings may result.
50472
a - Spool
b - Check Valve Body (2)
c - Poppet Valve (2)
d - Check Valve Body O-ring (2)
70870
50474 a - Screws
a - Spring (2) b - Pump Assembly Screws
b - O-ring (2)
c - Hex Plug Retainer (2) 3. Remove oil seal by prying out with a screwdriver.
! CAUTION
Hex plug retainers MUST BE turned into adaptor
exactly as outlined or damage to check valve
body O-rings may result.
13. Tighten hex plug retainer 1/4 turn, then back off
1/8 turn. Repeat until hex plug is tightened
securely.
50474
a - Oil Seal
50476
a - Hex Plug Retainer (2)
50474
50511
a - Oil Seal - Lip Toward Pump
b - O-rings a - BLUE/WHITE Motor Wire
c - Pump b - GREEN/WHITE Motor Wire
c - BLACK Ground Wire
7. Install pump and torque screws to 75 lb. in. (8
N·m) using a hex lobular socket or a standard 2. Remove solenoid plate.
3/16 in. socket.
70870
a - Screws
50511
a - Solenoid Plate
b - Locknuts
c - Screw
50511
50512
50476 d - Armature
e - Thrust Washer
a - Locknuts (Studs May Turn Out)
b - DO NOT Loosen
Armature Tests
4. Disassemble motor as follows: CONTINUITY TEST
a. Remove end frame caps. 1. Check armature for continuity. Set ohmmeter on
Rx1 scale. Place leads on armature shaft and on
b. Remove thrust washer (if equipped).
each commutator bar one at a time.
c. Remove armature from field and frame
Continuity Indicated: Armature is grounded (re-
assembly. place armature).
Continuity Not Indicated: Armature is not
grounded.
50475
a - Locknuts 50509
b - End Frame Caps a - Ohmmeter
c - Field And Frame Assembly b - Meter Lead
c - Meter Lead
50510
50510
a - Ohmmeter Lead - Connected to Brush Lead
b - Ohmmeter Lead - Connected to GREEN/WHITE Lead
50510
a - Field Frame
b - Field Brush Lead
50475
a - Brushes
50471
a - Plastic Casing
50475 50473
50471
a - Locknuts
b - Upper End Cap 50475
c - Longer Stud
d - End Cap Motor Lead Recess
50471
a - Coupling (Shallow Slot Toward Oil Reservoir)
b - O-ring 50511
a - Solenoid Plate
12. Install motor assembly. b - Locknuts
c - Bolt
50471
50511
a - BLUE/WHITE Motor Wire
b - GREEN/WHITE Motor Wire
c - BLACK Ground Wire
50512
a - Solenoid Terminal Cover
b - Screw
50494
a - Positive Battery Lead
b - Negative Battery Lead
c - Harness Connector
d - Black Hydraulic Hose (UP Hose)
e - Gray Hydraulic Hose (DOWN Hose)
50509
a - Trim Pump
b - Floor Bracket
c - Screws And Lock Washers
26351
6
B
22945
MANUAL STEERING
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1
Torque Specifications . . . . . . . . . . . . . . . . . . 6B-1
Lubricants/Sealers/Adhesives . . . . . . . . . . . . . . 6B-1
Steering Cable Selection, Removal, and Installa-
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3
Manual Steering Swivel Ring Component
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
21435
21436
22055
a - Cotter Pin
b - Clevis Pin
c - Locking Sleeve 50478
d - Cable Coupler Nut a - Steering Cable End
e - Steering Cable b - Clevis Assembly
c - Clevis Pin
Installation d - Cotter Pin
! WARNING
Steering cable outer casing MUST BE free to
move back and forth for steering to function
properly. DO NOT fasten any wires, cables or oth-
er items to steering cable, as this may prevent it
from moving.
50483
a - Clevis Assembly
b - Steering Lever
c - Tie Bar
d - Clevis Pin
e - Cotter Pin
22055
a - Steering Cable
b - Cotter Pin
c - Locking Sleeve
d - Cable Coupler Nut
e - Steering Cable Guide Tube
f - Steering Cable End
g - Cotter Pin
h - Clevis Pin
i - Steering Lever
23256
22946
a - Bushings 50478
50478
a - Bushings
22944
a - Pivot Bolts
50478
22946
a - Bushings
22944
a - Pivot Bolts
b - Tab Washer
c - Swivel Ring
a - Swivel Ring
b - Cotter Pins
c - Pivot Pins (Hidden)
22944
a - Pivot Bolts
b - Washer Tabs
TROUBLESHOOTING
Table of Contents
Page Page
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Trim System Completely Inoperative In
Sterndrive Unit Troubleshooting . . . . . . . . . . . . 1C-1 Manual Mode . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Sterndrive Unit Will Not Slide Into Trim In/Down Switch Inoperative In
Bell Housing . . . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Manual Trim Control . . . . . . . . . . . . . . . . . 1C-23
Drive Unit Does Not Shift Into Gear; Remote Trim Out/Up Switch And Trailer Switch
Control Shift Handle Moves . . . . . . . . . . . . . 1C-1 Inoperative In Manual Trim Control . . . . 1C-23
Drive Unit Does Not Shift Into Gear; Remote Trim Out/Up Switch Inoperative In
Control Shift Handle Does Not Move . . . . . 1C-2 Manual Trim Control . . . . . . . . . . . . . . . . . 1C-23
Drive Unit Shifts Hard . . . . . . . . . . . . . . . . . . 1C-2 Boat Is On Plane Well Before Drive
Drive Unit In Gear, Will Not Shift Out Of Unit Begins To Trim Out . . . . . . . . . . . . . . 1C-24
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Boat Is Not On Plane Before Drive
Drive Unit Jumps Out Of Gear . . . . . . . . . . . 1C-3 Unit Begins To Plane Out . . . . . . . . . . . . . 1C-24
Gear Housing Noise . . . . . . . . . . . . . . . . . . . 1C-3 Auto Trim II System Wiring Diagram . . . . . 1C-25
Drive Shaft Housing Noise . . . . . . . . . . . . . . 1C-4 Power Trim System Troubleshooting -
Performance Troubleshooting . . . . . . . . . . . . . . 1C-7 Hydraulic System on Oildyne Trim Pump . . 1C-26
Low Full-Throttle Engine RPM . . . . . . . . . . . 1C-7 Drive Unit Cannot Be Trimmed Out/Up . . 1C-26
High Full-Throttle Engine RPM . . . . . . . . . . 1C-7 Drive Unit Cannot Be Lowered From
Up Position . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Propeller Ventilating/Cavitating . . . . . . . . . . 1C-7
Drive Unit Will Not Stay In Full Up Position
Poor Boat Performance And/Or Poor For Extended Periods . . . . . . . . . . . . . . . . 1C-28
Maneuverability-Bow Too Low . . . . . . . . . . 1C-8
Drive Will Not Stay In The Trimmed Out/Up
Poor Boat Performance And/Or Poor Position When Underway . . . . . . . . . . . . . 1C-28
Maneuverability-Bow Too High . . . . . . . . . 1C-8
Drive Unit Trails Out/Up On Deceleration Or
Steering System Troubleshooting . . . . . . . . . . 1C-9 When Shifting Into Reverse . . . . . . . . . . 1C-28
Hard Steering - Ride Guide Steering Oil Foams Out Of Pump Fill/Vent Screw . 1C-29
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-9
The Trim Pump Motor Runs But Does
Hard Steering Power Steering System . . . . 1C-9 Not Pump Oil . . . . . . . . . . . . . . . . . . . . . . . 1C-29
Power Steering System External Fluid Power Trim Hydraulic Schematic . . . . . . . 1C-30
Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10
Power Trim System Troubleshooting - Hydraulic
Power Trim Electrical System . . . . . . . . . . . . . 1C-11 System on Prestolite Trim Pump . . . . . . . . . 1C-31
Power Trim Pump Motor Will Not Run In Drive Unit Cannot Be Trimmed Out/Up . . 1C-31
The Out/Up Or In/Down Direction . . . . . 1C-11
Drive Unit Cannot Be Lowered From
Power Trim Motor Runs In The Out/Up OUT/UP Position . . . . . . . . . . . . . . . . . . . . 1C-31
Direction, Not In The In/Down Direction 1C-12
Drive Unit Will Not Stay In Full Out/Up
Power Trim Pump Motor Runs In/Down, But Position For Extended Periods . . . . . . . . 1C-32
Not In The Out/Up Direction - . . . . . . . . . 1C-13
Drive Unit Will Not Stay In Trimmed Out/Up
Trim Control Out/Up Switch Inoperative . . 1C-14 Position When Underway . . . . . . . . . . . . . 1C-32
Trim Control Trailer Switch Inoperative . . 1C-14 Drive Unit Trails OUT/UP on Deceleration or
Trim System Functions While When Shifting into Reverse . . . . . . . . . . 1C-32
Unattended . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14 Oil Foams Out of Pump “Vent” Screw . . . 1C-32
Auto Trim Electrical System . . . . . . . . . . . . . . 1C-18 Prestolite Trim System Diagram . . . . . . . . 1C-33
Pump Motor Will Not Run Up Or Down In Corrosion Protection . . . . . . . . . . . . . . . . . . . . . 1C-34
Either Manual Or Auto Mode . . . . . . . . . . 1C-18
Corrosion Of Underwater Parts, Without Merca-
Pump Motor Will Run Up, But Not Down In thode Or Current Protection . . . . . . . . . . . . 1C-34
Both Manual And Auto Modes . . . . . . . . . 1C-19
Corrosion On Underwater Parts, With Merca-
Pump Motor Runs Down, But Not Up In Both thode Or Current Protection . . . . . . . . . . . 1C-34
The Manual And Auto Modes . . . . . . . . . 1C-20
Corrosion Troubleshooting Procedures . . 1C-37
Pump Motor Will Not Stop Running Down
In Auto Mode . . . . . . . . . . . . . . . . . . . . . . . 1C-21 Shift System Troubleshooting . . . . . . . . . . . . . 1C-38
Pump Motor Will Not Run Up Or Down In Checking for Excessive Play . . . . . . . . . . . 1C-38
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21 Isolating Excessive Play . . . . . . . . . . . . . . . 1C-41
Pump Motor Will Run Down, But Not Up In Checking Remote Control Shift Cable
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-42
Pump Motor Will Run Up, But Not Down In Checking Cutout Switch Timing . . . . . . . . . 1C-44
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22 Checking Operation . . . . . . . . . . . . . . . . . . . 1C-45
Cause Remedy
1. U-joint shaft splines not aligned with engine 1. Rotate propeller shaft COUNTERCLOCKWISE
coupler splines. to align splines.
4. Damaged u-joint shaft splines and/or engine 4. Inspect and replace if necessary.
coupler splines.
5. Lower shift shaft not in forward gear position. 5. Properly align shift shafts.
Bell Housing shift shaft not lined up.
6. Bell housing shift shaft coupler not aligned. 6. Place coupler in forward gear position.
Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Moves
Cause Remedy
3. Inner core wire broken or loose. 3. Reconnect or replace inner core wire.
Cause Remedy
4. Shift shaft or shift shaft lever jammed. 4. Install shift crank properly.
5. Shift cable not installed deep enough into bell 5. Install cable further into bell housing.
housing.
Cause Remedy
2. Damaged remote control or drive unit shift cable. 2. Replace cable(s) and adjust.
4. Corroded shift cables. 4. Replace, adjust, and check for water leakage.
11. Shift crank and/or clutch actuating spool worn. 11. Replace crank and spool.
12. Damaged shift shaft bushing. 12. Replace shift shaft bushing.
13. Bent upper, intermediate, or lower shift shaft(s). 13. Inspect and replace.
Cause Remedy
2. Cable end not connected in drive unit. 2. Remove and reinstall drive unit.
Cause Remedy
Cause Remedy
Cause Remedy
Cause Remedy
14. Gimbal bearing not fully seated in gimbal 14. Drive bearing assembly into place.
housing. Yoke moves back and forth when
turning and may hammer against bearing if not IMPORTANT: Gimbal bearing must be pressed in
fully seated. past lead-in chamfer in bearing bore.
Cause Remedy
23. Engine mounting holes drilled off-center in inner 23. Make sure the holes are equally spaced fore
transom plate engine supports or engine and aft and are equal distance from the
flywheel housing centerline.
1. Improper drive unit trim angle. 1. Properly adjust drive unit trim angle.
3. Improper propeller pitch. 3. Water test boat using a lower pitch propeller.
6. Permanent “hook” in boat bottom. 6. Check for a “hook” in the boat bottom by placing
a straight edge, at least 6ft. (2m) long, under the
NOTE: Some boats are built with a slight “hook” for bottom edge of the transom. If a “hook” is
correct boat performance. found, contact the boat manufacturer.
Cause Remedy
1. Improper propeller pitch. 1. Water test boat using a higher pitch propeller.
Propeller Ventilating/Cavitating
Cause Remedy
Cause Remedy
1. Improper drive unit trim angle. 1. Properly adjust drive unit trim angle.
4. Permanent “hook” in boat bottom. 4. Check for a “hook” in the boat bottom by placing
NOTE: Some boats are built with a slight “hook” for a straight edge, at least 6ft. (2m) long, under
correct boat performance. the bottom edge of the transom. If a “hook” is
found, contact the boat manufacturer.
5. Power hook or weak boat bottom. 5. Water test boat. Boat will perform normally until
hook develops at high speed: then loss of RPM
and speed will occur. Contact boat
manufacturer.
Cause Remedy
1. Improper drive unit trim angle. 1. Properly adjust drive unit trim angle.
3. Propeller pitch too high. 3. Water test the boat using a lower pitch propeller.
4. Permanent “rocker” in boat bottom. 4. Check for a “rocker” in the boat bottom by
placing a straight edge, at least 6 ft. (2m) long,
NOTE: Some boats are built with a slight “rocker” under the bottom edge of the transom. If a
for correct boat performance. “rocker” is found, contact the boat manufacturer.
Cause Remedy
4. Ride Guide rack or rotary head not lubricated. 4. Disassemble and lubricate.
Cause Remedy
Cause Remedy
Power Trim Pump Motor Will Not Run In The Out/Up Or In/Down Direction
(Solenoids Do Not Click)
IMPORTANT: Refer to wiring diagram at end of this section for assistance in electrical system trouble-
shooting.
Cause Remedy
1. Thermal circuit breaker in pump motor broken. 1. Replace commutator end plate assembly.
3. Power trim pump battery cables or wiring 3. Clean and or tighten connections “1”, “2,” “4,”
harness connections corroded or lose. “10,” “11,” “12,” and “18,” as necessary.
Cause Remedy
6. Pump gears froze. 6. Replace pump valve body and gear assembly.
Power Trim Motor Runs In The Out/Up Direction, But Not In The In/Down
Direction (In/Down Solenoid Does Not Click)
Cause Remedy
Cause Remedy
Power Trim Pump Motor Runs In The Out/Up But Not In The In/Down Direction -
In/Down Solenoid Clicks
Cause Remedy
Power Trim Pump Motor Runs In The In/Down Direction, But Not In The Out/Up
Direction - Both Trim And Trailer Switches Inoperative - (Out/Up Solenoid
Clicks)
Cause Remedy
Cause Remedy
1. Trim limit switch lead bullet connectors loose or 1. Clean and/or tighten connections “14,” “15,” “16”
corroded. and “17” (in wiring diagram), as necessary.
Cause Remedy
Cause Remedy
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LIT = LIGHT
DRK = DARK
22252
Power Trim Electrical System Wiring Diagram (with 3-Button Trim Control)
Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode
(Solenoids Click)
Cause Remedy
Cause Remedy
1. Pump negative battery cable loose, corroded or 1. Check cable “13” for a loose or corroded
damaged connection, or damage.
Pump Motor Will Run Up, But Not Down In Both Manual And Auto Modes
(Down Solenoid Does Not Click)
Cause Remedy
1. Loose or Dirty solenoid connections. 1. Check connections “4,” “7,” and “12.”
Cause Remedy
Pump Motor Runs Down, But Not Up In Both The Manual And Auto Modes
(Up Solenoid Clicks)
Cause Remedy
Pump Motor Runs Down, But Not Up In Both the Manual and Auto Mode -
(Up Solenoid Does Not Click)
1. Faulty solenoid 1. Replace solenoid
Cause Remedy
Pump Motor Will Not Run Up Or Down In Auto Mode (Manual Mode Functions
Properly)
Cause Remedy
1. Open circuit in control module sense lead. 1. Check lead “17” (in Figure 12) for loose or
corroded connections or damage.
Pump Motor Will Run Up, But Not Down In Auto Mode (Manual Mode Functions
Properly)
Cause Remedy
Cause Remedy
Trim Out/Up Switch And Trailer Switch Inoperative In Manual Trim Control -
Trim In/Down Switch Operates (Auto Mode Functions Properly)
Cause Remedy
1. Trim control 20 amp fuse (if so equipped) - “43” 1. Determine cause for blown fuse and correct
blown. before replacing fuse.
2. Open in power supply lead to trim and trailer 2. Check voltage at terminal “44.” If no voltage is
switch. indicated, check lead “45” for a poor connection
or damage.
3. Faulty trim OUT/UP switch (applies only to trim 3. Check for voltage at terminal “40” while
controls where it is necessary to actuate trim actuating trim OUT/UP switch. Replace
UP switch in order for trailer switch to function). switch if no voltage is indicated.
Cause Remedy
1. Faulty trim OUT/UP switch (applies only to 1. While actuating switch, check for voltage at
trim controls where it is not necessary to actuate output terminal. Replace switch if voltage is
trim UP switch in order for trailer switch to not indicated.
function - not shown).
2. Open circuit in wiring harness 2. Check leads “31” and “37” for loose or corroded
connections or damage.
Cause Remedy
Cause Remedy
Cause Remedy
7 8
6
2
5
9
13
10
12
47
4 11
46 15
43 21 19
41 24
42
22
25 16
44
40 23
26
39
29
45
30
38 34
36 37
33
31 17
32
35
22178
Drive Unit Cannot Be Trimmed Out/Up, Trims Slowly Or Trims With Jerky
Movements
Cause Remedy
5. Hoses reversed on one cylinder only. 5. Connect hoses “7” and “8” correctly.
11. Check the condition of the oil, it may be 11. Remove the reservoir and clean out the
contaminated and thick like honey. contaminated oil.
12. A possible tight adaptor pump gear, or water or 12. Replace the pump assembly in the adaptor, or
oil in the motor. replace the electric motor assembly.
Cause Remedy
5. Trim cylinder(s) block leaking internally. 5. Test. Rebuild or replace cylinder as necessary.
9. Drive unit binding in gimbal ring. 9. Check for cause of binding and replace.
11. Foreign material under down pressure relief 11. Replace the down pressure relief valve
valve. assembly
12. Dirt or foreign material under the down 12. Replace the down pressure relief valve
pressure relief valve assembly
13. Check the condition of the oil, it may be 13. Remove the reservoir and clean out the
contaminated and thick like honey contaminated oil
14. A possible tight adaptor pump gear, or water or 14. Replace the pump assembly in the adaptor, or
oil in the motor replace the electric motor assembly
Cause Remedy
Drive Will Not Stay In The Trimmed Out/Up Position When Underway
NOTE: Use the following in conjunction with items mentioned under “Drive Unit Will Not Stay In Full ‘Up’ Position
For Extended Periods”
Cause Remedy
1. Air in trim system. 1. Check for cause of entry. Fill and bleed system.
2. Leaky shuttle poppet valve “1.” 2. Install repair kit for shuttle valve “1.”
Drive Unit Trails Out/Up On Deceleration Or When Shifting Into Reverse (Unit
Thumps When Shifting)
Cause Remedy
Cause Remedy
The Trim Pump Motor Runs But Does Not Pump Oil
Cause Remedy
1. Broken coupler between the pump and the 1. Replace the coupler.
motor.
8
7
11
5
10
73552
Cause Remedy
1. Check for cause of low oil level and correct.
1. Power trim pump oil level low (1).
Add oil.
2. Check for cause of entry and correct. Add oil to
2. Air in trim system.
pump and bleed trim system.
3. Manual release valve (2) not completely closed. 3. Close valve (2) completely.
4. Insufficient pump pressure or pump shuttle valve 4. Test, as explained following. Replace valve body
(3) stuck. and gear assembly.
5. Hoses (5) (6) reversed on one cylinder only. 5. Connect hoses (5) (6) correctly.
6. Check for cause of binding (bent piston rod (8),
6. Trim cylinder(s) (7) binding.
etc.). Repair or replace, as necessary.
7. Gimbal housing-to-trim pump hydraulic hoses
7. Replace hose (4) (9).
(4) (9) pinched.
Drive Unit Cannot Be Lowered From OUT/UP Position or Lowers with Jerky
Movements
Cause Remedy
1. Check for cause of entry. Fill and bleed trim
1. Air in trim system.
system.
2. Insufficient pump IN/DOWN pressure or shuttle 2. Test, as explained following. Replace valve body
valve (3) stuck. and gear assembly.
3. Test, as explained following. Rebuild or replace
3. Trim cylinder(s) (7) leaking internally.
cylinder (7) as necessary.
4. Check for cause of binding (bent piston rod (8),
4. Trim cylinder(s) (7) binding.
etc.). Repair or replace, as necessary.
5. Gimbal housing-to-trim pump hydraulic hose (4)
5. Replace hoses (4) (9).
(9) pinched.
6. Hoses (5) (6) reversed on one trim cylinder only. 6. Reconnect hoses (5) (6) correctly.
7. Check for cause of binding (bent gimbal ring,
7. Drive unit binding in gimbal ring.
drive shaft housing, etc.) and replace.
Drive Unit Will Not Stay In Trimmed OUT/UP Position When Underway
Cause Remedy
1. Air in trim system. 1. Check for cause of entry. Fill and bleed system.
2. Check for cause and correct. Add oil to pump
2. External leakage.
and bleed trim system.
3. Pump OUT/UP circuit leaking internally (3) (4) 3. Test as explained following. Replace valve body
(5). and gear assembly.
Drive Unit Trails OUT/UP on Deceleration or When Shifting into Reverse (Unit
Thumps When Shifting)
Cause Remedy
1. Determine cause for air entry and correct. Add
1. Air in trim system.
oil to pump and bleed trim system.
2. Trim cylinder(s) (7) leaking internally. 2. Test as explained following. Replace or rebuild
cylinder(s) (7), as necessary.
3. Trim pump IN/DOWN circuit (3) (6) (9) leaking 3. Test as explained following.
internally.
Cause Remedy
5. Shore power causing overload of anode(s) and/ 5. Disconnect shore power or install Quicksilver
or Mercathode. isolator.
Cause Remedy
5. Loss of continuity between drive components 5. Ensure continuity (check continuity wires and
and ground. washers).
b. Check battery.
9. Mercathode system not functioning. c. Check for loose connections at controller and
battery.
Cause Remedy
b. Check battery.
5. Mercathode system not functioning. c. Check for loose connections at controller and
battery.
READINGS
Potential Diagnosis1
Potential Diagnosis
CORROSION SYMPTOMS
50308
22267
IMPORTANT: If boat is equipped with A REMOTE Later Models (With Plastic Shift Lever)
CONTROL THAT HAS SEPARATE SHIFT AND
a - Remote Control Shift Cable
THROTTLE LEVERS, this shift assist assembly b - Plastic Shift Lever
should NOT be used. The use of the shift assist c - Clevis Pin and Cotter Pin
assembly with this type of remote control can d - Locknut and Washer
cause the shift lever to move out of gear unex-
pectedly.
22911
71339
a - Shift Lever
b - Throttle Lever
22058
b 22266
50499
22062
a - Throttle Cable End Guide
b - Carburetor Throttle Lever
22058
22267
50499
50498
50497
a - 9/16 in. (14 mm) Or Less
50498
50499
50368
50499
a - Lever
b - Roller
c - Special Tool
50499
a - BLACK Wires
b - WHITE/GREEN Wires
50497
a - Special Tool
b - 1/8 in. (3 mm)
50309
22058
a - Adjustable Stud
b - Shift Cutout Switch Roller
3
C
b 75256
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
plete assembly for replacement of the original lower unit.
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Complete Supersession Listing
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
Models ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Ratio
(Original)
ÁÁÁÁÁÁÁÁÁÁ
Gear Housing Assy Superseded by Serial No. Range
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Complete
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
120 1.98:1 1623-5356A20 1623-8951A43 4893635 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
140 1.98:1 1623-5356A20 1623-8951A43 4893635 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
165 1.65:1 1623-5356A20 1623-8951A43 4890460 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A20 1623-8951A43 4893835 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
485 1.84:1 1623-5356A20 1623-8951A43 4893835 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
225 - S 1.50:1 1623-5356A3 1623-8951A43 3856268 thru 4200499
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A3 1623-8951A43 4782330 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
233 1.32:1 1623-8951A2 1623-8951A43 4200500 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A3 1623-8951A43 4791300 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-8951A2 1623-8951A43 4791300 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
260 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A6 1623-8951A43 3784374 and below
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A13 1623-8951A43 3784375 thru 3909577
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-5356A3 1623-8951A43 3909578 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-8951A2 1623-8951A43 4782330 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A3 1623-8951A43 4208730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-8951A2 1623-8951A43 4208730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
R ALL 1623-5356A20 1623-8951A43 6225577 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
MR ALL 1623-5356A20 1623-8951A43 6225577 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha
ALL 1623-8951A23 1623-8951A43 6225577 and up
One
ÁÁÁÁ
ÁÁÁÁÁÁ
Alpha
ÁÁÁÁ
One ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ALL
ÁÁÁÁÁÁÁÁÁÁ
1623-8951A14 1623-8951A43 6225577 and up
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
lower unit.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Only Supersession List
ÁÁÁÁÁ
ÁÁÁÁÁ
Models
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Ratio
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
(Original)
ÁÁÁÁÁÁÁÁÁÁ
Gear Housing Only
Superseded by Serial No. Range
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
120 1.98:1 1623-5356A4 None Required 4893635 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
140 1.98:1 1623-5356A4 None Required 4893635 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
165 1.65:1 1623-5356A4 None Required 4890460 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4893835 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4208730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4208730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
485 1.84:1 1623-5356A4 None Required 4893835 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
225 - S 1.50:1 1623-5356A4 None Required 3856268 thru 4200499
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A4 None Required 4782330 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
233 1.32:1 1623-5356A4 None Required 4200500 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A4 None Required 4791300 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A4 None Required 4791300 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
260 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A3 1623-5356A4 3784374 and below
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A3 1623-5356A4 3784375 thru 3909577
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-5356A4 None Required 3909578 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A4 None Required 4782330 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
R ALL 1623-5356A4 None Required 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
MR ALL 1623-8951A15 1623-8951A37 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha 1623-8951A27
ALL 1623-8951A37 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
One (Black)
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha 1623-8951A14
ALL 1623-8951A37 6225577 and up
One (Oyster)
75256B
FWD. Gear
When Ordering
Bearing Current Part Number:
Gear Housing:
Supersedes To:
1623-8951A27 1623-8951A37
3.4895-3.5000 in. O.D. 3.2635-3.2650 in. O.D.
(88.86-88.90 mm) (82.89-82.93 mm)
Fwd. Gr. Brg. Fwd. Gr. Brg.
1623-815822A6 1623-815822A30
3.4895-3.5000 in. O.D. 3.2635-3.2650 in. O.D.
(88.86-88.90 mm) (82.89-82.93 mm)
Fwd. Gr. Brg. Fwd. Gr. Brg.
21
41 34 50
37
49
Torque Specifications 33 48
a 60 - 80 lb. ft. (81 - 108 N·m) 47
b 30 lb. in. (3 N·m) 20 14 46
31
c 60 - 80 lb. in. (6-9 N·m) 45
35
d 28 lb. ft. (38 N·m)
30 44
e 35 lb. ft. (47 N·m)
f 23 lb. ft. (31 N·m)
24
3
26
Lubricants/Sealers/Adhesives
25
A Quicksilver 2-4-C Marine Lubricant . . . . 92-825407A2 11
3M Brand Adhesive . . . . . . . . . . . . . . . . . 92-86166-1 23
B
Quicksilver Needle Bearing Assembly
C 13
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . 92-825265A1 22
D Quicksilver Perfect Seal . . . . . . . . . . . . . 92-34227-1
8 52 51
E Quicksilver Special Lubricant 101 . . . . . 92-13872A1
10
1
12
18 75743
19
3
7
6
8
9
10
12 11
13
15 14
17
16 18
24
19
20
21
22
23
25
26
27
28
29
30
31
32
33
75744
22086
23266
a - Fill/Drain Screw
b - Vent Screw
22074
a - Propeller Nut
b - Tab Washer
c - Spline Washer
d - Continuity Washer 23263
e - Propeller
f - Thrust Hub a - Allen Screw (In Trim Tab Cavity)
b - Locknuts
23253
a - Trim Tab
b - Plastic Plug (From Access Hole)
c - 3/8 in. Allen Wrench 23261
23356
23356
23349
50312
a - Drilled Holes
6. Remove bearing carrier retainer following step
“a” or “b” as follows: FOR EARLY STYLE UNITS:
23347
! CAUTION
DO NOT drill into gear housing retainer threads
if using following procedure for removing retain-
er. 70934
70492
50500
50455
8. Remove pinion gear, drive shaft and tapered a - Slide Hammer Puller 91-34569A1
roller bearing. b - Bearing Cup
c - Shims
50502
73993
50312
23351
73990
23348
a - O-ring
b - Gasket
23355
METHOD “B”
Drill two 3/16 in. (5 mm) holes through water pump
body - DO NOT drill through insert. Drive insert out
of body, using punch and hammer.
23347
23351
23139
a - Oil Seal
b - Oil Seal Driver (91-44110)
c - Water Pump Base
23343
23139
a - Oil Seal
b - Oil Seal Driver (91-44110)
c - Water Pump Base
23351
23351
50317
a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)
x
x x
x x
x
23351
a - Shipping Sleeve
23355
50314
50454
50455
a - Reverse Gear Teeth
b - Clutch Jaws a - O-ring
b - Bearing Carrier
50454
23351
50315
23140
a - Needle Bearing
b - Bearing Carrier
a - Needle Bearing c - Bearing Driver (91-15755)
b - Oil Seals
c - Puller Head (91-36569)
2. Apply Loctite 27131 or Type “A” to outside diame-
d - Bearing Driver Rod (91-37323)
ter of first propeller shaft oil seal. Install seal with
lip facing needle bearing. Press oil seal with tool
b. If Replacing Seals Only: Remove oil seals. until tool bottoms on bearing carrier.
Be careful not to damage bore.
23140 50315
50315 50454
4. Install thrust washer and ball bearing on reverse 6. Install O-ring on bearing carrier.
gear. Press ball bearing using pilot washer until
bearing bottoms on gear. install the thrust washer
so that the tapered end of the thrust washer faces
toward the gear.
50455
a - O-ring
b - Bearing Carrier
50455
a - Ball Bearing
b - Thrust Washer
c - Reverse Gear
d - Pilot Washer (91-36571)
23141
74008
23356
a - Contact Area
c b
75219
a
a - Earlier Style Shift Spool Assembly
b - Later Style Shift Spool Assembly
c - Measure End Play Here At Gap
a - Shift Shaft
b - Spool
c - Gap Has Increased-End Play Measurement: .002-.010 in.
(0.05-0.25 mm) Is Same As Earlier Models
23355
23350
50455
a - Forward Gear
b - Tapered Roller Bearing
c - Suitable Mandrel (91-36571 Shown) 50501
a - Sliding Clutch
2. Press needle bearing into forward gear with b - Groove In Clutch
lettered side up - away from gear teeth. DO NOT c - Forward Gear Assembly
use excessive force. d - Cross Pin
e - Propeller Shaft
f - Spool And Actuating Shaft Assembly
g - Cross Pin Retainer Spring
50455
a - Forward Gear
b - Needle Bearing - Lettered Side Up-Away From Gear Teeth
c - Needle Bearing Driver 91-33491
23354
23349
23354
a - Shift Shaft
b - Clip
c - Washer
d - O-ring
23355
e - Shift Shaft Bushing (Seal Inside)
a - Seal Surface
b - Splines
SHIFT SHAFT INSTALLATION 3. Thread shift shaft bushing into gear housing.
Torque to 50 lb. ft. (68 N·m) using shift shaft
1. Place shift crank on locating pin in forward sec- bushing tool.
tion of gear housing. Ensure shift crank faces to-
ward left (port) side of gear housing.
73991
73870
a - Shift Shaft Bushing Tool (P/N 91-31107)
a - Shift Crank
b - Locating Pin
23354
IMPORTANT: If unit does not require reshimming 3. Place shim(s) in drive shaft housing bore. Install
(no parts were replaced), proceed to Propeller drive shaft tapered roller bearing cup.
Shaft and Forward Gear Installation. if pinion
height must be checked, proceed as follows.
1. If pinion bearing was not replaced, but needle
bearings have fallen out during disassembly,
install 18 needles in needle bearing outer race.
Use needle bearing assembly lubricant to help
hold needles in place.
50454
a - Shim(s)
b - Bearing Cup
c - Driver Cup 91-36577
d - Adaptor 91-36569
e - Driver Rod 91-37323
23142
73997
26410
50502
23351
a - Shims
50501
50500
50312
a - Key
50500
a - Shim Spacer
b - Shim(s)
c - Bearing Carrier Assembly
50314
a - Tab Washer
b - “V” Tab
23355
23352
23137
a - Bearing Carrier
b - Tab Washer
50456
a - Drive Shaft
b - Dial Indicator
c - Indicator Rod
d - Indicator Pointer
23355
71185
a - Drive Shaft
b - Dial Indicator
c - Indicator Rod
d - Indicator Pointer
50456
50456
a - Tape On O-ring Groove (If O-ring Groove Is Present)
a - Tape On O-ring Groove (If O-ring Groove is Present)
50312
23343
a - Impeller
a - Water Pump Base b - Counterclockwise Direction
b - Gasket
b
c
23350
23356
a - Water Pump Body
b - Water Pump Impeller
b c - Drive Shaft
23147
a - Water Pump Impeller
b - Key
c - Water Pump Face Plate And Gaskets (One On Each Side)
23266
a - Flat Washers and Nuts (3)
b - Screw
c - Water Tube (Plastic)
d - Centrifugal Slinger
e - O-ring (If O-ring Groove Is Present)
73989
23261
23265
23253
a - Trim Tab
b - Allen Wrench
c - Plastic Plug
5
C
26345
Electrical Specifications
115 Amps at
Pump Amperage Draw 2200 - 2600 PSl
(15173 - 17932 kPa)
Lubricants/Sealers/
Adhesives
Description Part No.
Power Trim and Steering
92-90100A12
Fluid
2-4-C Marine Lubricant 92-825407A2
Liquid Neoprene 92-25711-2
50524
22089
22089 a - IN/DOWN Trim Hose
a - OUT/UP Trim Hose b - Hydraulic Connector
b - Front Connection on Trim Cylinder c - Plug (22-38609)
22090
Gauge Connected at Pump 4. Open Valve “A” and “B” and run pump UP and
a - Hydraulic Test Gauge 91-52915A6 DOWN several times (to purge air).
b - Extension Hoses 91-52915A6
c - Fittings 22-77366
22126
22126
1. OUT/UP Operation:
a. Connect a jumper wire between positive (+)
solenoid terminal and BLUE/WHITE motor
lead terminal.
b. Motor should run.
22562
a - Trailering Clip
50523
a - OUT/UP Solenoid
b - POSITIVE Terminal (+)
c - BLUE/WHITE Motor Lead Terminal
d - Jumper Wire
22089
a - UP Trim Hose
b - Front Connection
50523
a - IN/DOWN Solenoid
b - POSITIVE Terminal (+) 50523
c - GREEN/WHITE Motor Lead Terminal a - OUT/UP Solenoid
d - Jumper Wire b - 12 Volt POSITIVE (+) Supply Lead
c - NEGATIVE (-) Supply Lead
3. If motor does not run, refer to “Motor Repair.” See
Table of Contents.
! CAUTION
Remain clear of drive unit when performing pow-
er trim pump motor tests with pump in boat and
hydraulic hose connected.
1. UP/OUT Solenoid:
a. Connect jumper wire between positive (+) so-
lenoid terminal and BLUE/WHITE harness
wire terminal.
b. Motor should run.
50524
a - IN/DOWN Solenoid
b - 12 Volt POSITIVE (+) Supply Lead
c - NEGATIVE (-) Supply Lead
50521
a - OUT/UP Solenoid
b - Positive (+) Terminal
c - BLUE/WHITE Harness Wire Terminal
d - Jumper Wire
50521
a - IN/DOWN Solenoid
b - Positive (+) Terminal
c - GREEN/WHITE Harness Wire Terminal
d - Jumper Wire
50521
a - OUT/UP Solenoid
b - 12 Volt Positive (+) Supply Lead
c - Negative (-) Supply Lead
d - Ohmmeter Leads
50523
50521
a - Fuse Holder
22497
a - 20 Amp Fuse
b - Ohmmeter Leads
50461
a - O-ring
b - Rubber Seal
Disassembly
! CAUTION
50524 Work area must be dirt and lint free. The slightest
a - Positive Battery Lead amount of dirt in hydraulic system can cause
b - Negative Battery Lead pump malfunction.
c - Harness Connector
d - Black Hydraulic Hose (UP Hose) 1. Disconnect trim motor wires.
e - Gray Hydraulic Hose (DOWN Hose)
50520
a - BLUE/WHITE Motor Wire
b - GREEN/WHITE Motor Wire
c - BLACK Ground Wires
50522
50460
a - Screws (8)
b - Valve Body And Gear Assembly
50522
a - Trim Pump
b - Floor Bracket
c - Mounting Bolts
50520
c - Seal
50520
a - UP Solenoid
b - DOWN Solenoid
c - Mounting Bolts (2 On Each Solenoid)
50520
a - Seal
a - Screws (8)
b - Valve Body And Gear Assembly
c - New Seal (Not Seen)
Motor Repair
Disassembly
1. Disconnect trim pump motor leads.
50522
a - Motor Shaft
b - Gear Assembly
50459
a - Trim Pump Motor Leads
b - Solenoids
50459
a - Solenoid Plate
b - Nut
c - Screws
d - Solenoids
e - Spacer
f - Connector and Harness
26506
3. Remove valve body and gear assembly. a - Nut And Washer (2)
b - End Plate Assembly
c - Field and Frame Assembly
d - Armature
e - Small Thrust Washer(s)
f - Large Thrust Washer
g - Spacer (1)
h - Studs (2)
i - Reservoir
50460
a - Screws (8)
b - Valve Body And Gear Assembly
c - Seal (Not Seen)
50520
a - Commutator
b - Gap
50461
Field Test
a - Ohmmeter
b - Meter Lead - Place On Armature Shaft TEST FOR OPEN CIRCUIT
c - Meter Lead - Place On All Commutator Bars (One At A Time)
1. Set ohmmeter to Rx1 scale and connect meter
TEST FOR SHORTS leads between field leads.
Zero Ohms Indicated (Full Continuity): Field OK.
1. Check armature on a growler (follow growler
manufacturers instructions). Indication of a short Zero Ohms Not Indicated (No Continuity):
requires replacement. Replace field assembly.
CLEANING COMMUTATOR
50461
a - Ohmmeter
b - Meter Leads - Connect Between Field Leads
c - Field Leads
50461
a - Ohmmeter
b - Meter Lead - Place On Positive Brush Holder Lead 50460
c - Meter Lead - Place On Frame
a - Ohmmeter
d - Field Lead
b - Meter Lead - Place On Positive Brush Lead
c - Meter Lead - Place On End Cap
Thermal Switch Test
2. Set ohmmeter on rx1 scale. Connect leads as
CONTINUITY TEST shown. Test negative brush lead for an open
condition.
1. Test thermal circuit breaker for continuity, using
ohmmeter set on Rx1 scale. Continuity Indicated: Brush lead OK.
Zero Ohms Indicated (Full Continuity): Thermal Continuity NOT Indicated: Inspect lead for a poor
switch OK. connection.
26507
BRUSH REPLACEMENT
1. Cut brush leads off as close to brush holders as
possible.
2. Using 70-30 tin-lead alloy rosin core solder, sol-
der new brushes to brush holders.
50459
a - Field Lead
b - Positive Brush Holder
c - End Cap
26507
a - Brush Leads
b - Brush Holders
26507
26506
a - Large Washer
b - Small Washer(s)
c - Armature
d - Reservoir
e - Long Stud
f - Sleeve (1)
g - Small Stud 26507
h - Connector And Harness Holder
50459
50520
a - Index Marks - Align a - Seal
b - Field And Frame Assembly
c - Reservoir
50459
a - Solenoid Plate
b - Nut
c - Screws
50522 d - Solenoids
a - Motor Shaft e - Spacer
b - Gear Assembly f - Connector And Harness
6. Install valve body and gear assembly. 8. Secure trim pump motor leads to solenoids.
50460
a - Screws (8)
b - Valve Body and Gear Assembly 50459
c - New Seal (Not Seen) a - Blue Lead - Connect to OUT/UP Solenoid
b - Green Lead - Connect to IN/DOWN Solenoid
c - OUT/UP Solenoid
d - IN/DOWN Solenoid
50522
a - Trim Pump
b - Floor Bracket
c - Screws and Lock Washers
50524
a - Positive Battery Lead
b - Negative Battery Lead
c - Harness Connector
d - Black Hydraulic Hose (UP Hose)
e - Gray Hydraulic Hose (DOWN Hose)
26347
3
D
50883
a
Shift Spool Assembly
The later style shift spool assembly has a larger gap
than the earlier style. This later style shift spool is sold
as a whole assembly and can be used when
replacing the earlier style. The end play for the spool
will remain the same as the earlier models [.002-.010
in. (0.05-0.25 mm)].
c 75241
74877
b a
75248
c
75219
Later Style Forward Gear Bore
a - Earlier Style Shift Spool Assembly (Prior to S/N 0K041000) a - 3.2635-3.2650 in.
b - Later Style Shift Spool Assembly (S/N 0K041000 And
Above)
c - Measure End Play Here at Gap
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
plete assembly for replacement of the original lower unit.
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Complete Supersession Listing
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
Models ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Ratio
(Original)
ÁÁÁÁÁÁÁÁÁÁ
Gear Housing Assy Superseded by Serial No. Range
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Complete
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
120 1.98:1 1623-5356A20 1623-8951A43 4893635 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
140 1.98:1 1623-5356A20 1623-8951A43 4893635 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
165 1.65:1 1623-5356A20 1623-8951A43 4890460 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A20 1623-8951A43 4893835 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
485 1.84:1 1623-5356A20 1623-8951A43 4893835 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
225 - S 1.50:1 1623-5356A3 1623-8951A43 3856268 thru 4200499
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A3 1623-8951A43 4782330 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
233 1.32:1 1623-8951A2 1623-8951A43 4200500 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A3 1623-8951A43 4791300 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-8951A2 1623-8951A43 4791300 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
260 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A6 1623-8951A43 3784374 and below
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A13 1623-8951A43 3784375 thru 3909577
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-5356A3 1623-8951A43 3909578 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-8951A2 1623-8951A43 4782330 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A20 1623-8951A43 4898730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A3 1623-8951A43 4208730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-8951A2 1623-8951A43 4208730 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
R ALL 1623-5356A20 1623-8951A43 6225577 and up
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ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
MR ALL 1623-5356A20 1623-8951A43 6225577 and up
ÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha
ALL 1623-8951A23 1623-8951A43 6225577 and up
One
ÁÁÁÁ
ÁÁÁÁÁÁ
Alpha
ÁÁÁÁ
One ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ALL
ÁÁÁÁÁÁÁÁÁÁ
1623-8951A14 1623-8951A43 6225577 and up
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
lower unit.
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Gear Housing Only Supersession List
ÁÁÁÁÁ
ÁÁÁÁÁ
Models
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Ratio
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
(Original)
ÁÁÁÁÁÁÁÁÁÁ
Gear Housing Only
Superseded by Serial No. Range
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
120 1.98:1 1623-5356A4 None Required 4893635 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
140 1.98:1 1623-5356A4 None Required 4893635 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
165 1.65:1 1623-5356A4 None Required 4890460 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4893835 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4208730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
470 1.84:1 1623-5356A4 None Required 4208730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
485 1.84:1 1623-5356A4 None Required 4893835 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
225 - S 1.50:1 1623-5356A4 None Required 3856268 thru 4200499
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A4 None Required 4782330 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
228 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
233 1.32:1 1623-5356A4 None Required 4200500 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A4 None Required 4791300 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
250 1.32:1 1623-5356A4 None Required 4791300 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
260 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A3 1623-5356A4 3784374 and below
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-4110A3 1623-5356A4 3784375 thru 3909577
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
888 1.50:1 1623-5356A4 None Required 3909578 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A4 None Required 4782330 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
898 1.50:1 1623-5356A4 None Required 4898730 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
R ALL 1623-5356A4 None Required 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
MR ALL 1623-8951A15 1623-8951A37 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha 1623-8951A27
ALL 1623-8951A37 6225577 and up
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
One (Black)
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
Alpha 1623-8951A14
ALL 1623-8951A37 6225577 and up
One (Oyster)
75256B
FWD. Gear
When Ordering
Bearing Current Part Number:
Gear Housing:
Supersedes To:
1623-8951A27 1623-8951A37
3.4895-3.5000 in. O.D. 3.2635-3.2650 in. O.D.
(88.86-88.90 mm) (82.89-82.93 mm)
Fwd. Gr. Brg. Fwd. Gr. Brg.
1623-815822A6 1623-815822A30
3.4895-3.5000 in. O.D. 3.2635-3.2650 in. O.D.
(88.86-88.90 mm) (82.89-82.93 mm)
Fwd. Gr. Brg. Fwd. Gr. Brg.
37 42 17
35
34 16
32
15
52
30
51
50
31 36
49
48
29 47
46
24 45
14
28 4
5
27 3
26 6
25
11
8
7
13
22
23
1
10
12
9
19
20
21
23135
2
40
43 2
42
3
4
5
6
14
7
13
9 8
15
10
11 16
12 17
18
19
20
21 28
29
22
23
24
25 30
26 31
32
27
33
34
35
36
37
38
39
23263
23253
a - Trim Tab
b - Plastic Plug (From Access Hole)
c - 3/8 in. Allen Wrench
2. Remove propeller.
23263
a - Allen Screw (In Trim Tab Cavity)
22074 b - Locknuts
a - Propeller Nut
b - Tab Washer
c - Spline Washer
d - Continuity Washer
e - Propeller
f - Thrust Hub
23261 23266
c - Locknut (Top Front) a - O-ring (If O-ring Groove Is Present)
d - Locknuts (One Each Side) b - Water Tube
c - Rubber Centrifugal Slinger
ALPHA I and MC I DRIVE SHAFT CHANGES d - Locknuts
e - Self-Tapping Screw
The service drive shaft for the lower unit will no longer
have an O-ring groove at the top of the shaft under
2. Carefully lift water pump body from gear housing.
the splines on all Alpha One 1990 and prior and also
MC I through 1976. All present production units con-
tain the New Style shaft without an O-ring groove
also.
23349
a - Water Pump Body
b - Pry Bars
71185
a - Alpha One Old Style (With O-ring Groove)
b - MC l New Style (Without O-ring Groove)
23356 50784
a - Water Pump Impeller a - Tab On Tab Washer
b - Drive Key
c - Water Pump Face Plate And Gaskets (One On Each Side
Of Face Plate) 6. Remove bearing carrier retainer following Step a
or b as follows:
4. Remove water pump base from gear housing. a. Remove bearing carrier retainer using bear-
ing carrier retainer wrench (91-61069).
23356 23347
a - Water Pump Base a - Bearing Carrier Retainer Wrench
b - Pry Bars
23356
a - Drilled Holes
50779
a - Thrust Washer
50786
a - Puller Bolt (91-85716)
b - Puller Jaws (91-46086A1)
c - Bearing Carrier Hub
50786
a - Thrust Bearing
50778
50787
a - Thrust Collar
50826
a - Thrust Collar
b - Keepers (2)
50784
a - Thrust Collar
50783
a - Thrust Bearing
23347
a - Bearing Retainer
b - Bearing Retainer Wrench (91-43506)
50783
a - Special Tool
b - Thrust Race
c - Forward Gear
d - Shim
73873
a - Pinion Nut Adaptor
50881 b - Drive Shaft Adaptor
a - Pinion Nut Adaptor (91-61067A2) c - Bearing Carrier
b - Tube I.D. - 1.27 in. (32.38 mm)
c - Cut Off 5/8 in. (16 mm)
d - Drill Hole - 1/2 in. (14 mm)
23352
a - Bearing Retainer
73874
a - Reverse Gear
b - Propeller Shaft Tool
c - Pinion Nut Adaptor
d - Shift Handle Tool
23351
b - Shims
50884
a - Propeller Shaft
b - Pinion Gear
c - Wire
50887
a - Propeller Shaft Assembly
50780
a - Puller Shaft (91-31229)
50887 b - Guide Plate (91-816243)
c - Nut (11-24156)
b - Thrust Bearing And Race
d - Jaws (91-816242)
e - Puller Head (From Slide Hammer Puller Kit 90-34569A1)
23354
a - Metal Washer and Rubber Washer (under metal washer)
23354
a - Shift Shaft Bushing Tool (91-31107)
50312
23355
a - Shift Shaft Assembly
b - Shift Shaft Bushing
23351
23343
a - O-ring
b - Gasket
23355
a - Water Pump Body
b - Insert
c - Hard Surface (Wood Block)
METHOD “B”
Drill two 3/16 in. (5 mm) holes through water pump
body. DO NOT drill through insert. Drive insert out
of body, using punch and hammer.
23347
a - Water Pump Base
b - Screw Driver
c - Oil Seals (2) - Drive Out One At A Time
23349
a - 3/16in. (5 mm) Holes
23139
a - Oil Seal
b - Oil Seal Driver (P/N 91-44110) 23343
c - Water Pump Base a - Gasket
b - O-ring
NOTE: The O.D. of the large seal is coated with rub-
ber. DO NOT use Loctite on this surface. Install this 4. Install water pump insert into water pump as
seal in a clean, dry bore. follows:
2. Press large seal into water pump base from bot- a. Lubricate water pump insert outside diameter
tom, with lip of seal facing bottom of water pump with Special Lubricant 101, 2-4-C Marine
base, using Oil Seal Driver (91-44110). Fill area Lubricant.
between two seals with 2-4-C Marine Lubricant.
b. Install insert into water pump body. Make
sure that tab on insert enters locating recess
in pump body.
23139
23351
a - Oil Seal
b - Oil Seal Driver (P/N 91-44110) a - Water Pump Body
c - Water Pump Base b - Insert
c - Tab
23351
a - Water Tube Seal
73875
a - Pinion Bearing
b - Bearing Driver (91-36569)
c - Pilot Washer (91-36571)
d - Driver Rod (91-37323)
23351
a - Shipping Sleeve
50314
a - Universal Puller Plate (91-37241)
b - Tapered Roller Bearing
c - Suitable Mandrel
50698
23350 a - Propeller Shaft Bearing Contact Area
a - Drive Shaft Pinion Bearing
b - Bearing Installation Tool (91-38628)
c - Puller Rod (91-31229)
d - Washer (12-34961)
e - Nut (11-24156)
f - Pilot Washer (91-36571)
g - Plate (91-29310)
50818
a - Bearing Carrier
b - Mating Surfaces
a - Needle Bearing
b - Oil Seals
c - Puller Head (91-36569)
d - Bearing Driver Rod (91-37323)
23356
a - Bearing Carrier Retainer
23140
a - Oil Seals
b - Pry Bar
50788
50788
a - Oil Seal (Fishing Line Cutter)
a - Needle Bearing b - Oil Seal Driver (91-31108)
b - Bearing Carrier c - Bearing Carrier
c - Bearing Driver (91-15755)
NOTE: If first oil seal has a rubber covered O.D., DO Forward Gear Inspection
NOT apply Loctite in the following step. Seal must be 1. Inspect forward gear for pitting, chipped or bro-
installed in a clean, dry bore. ken teeth, fracturing and excessive or uneven
2. Apply Loctite 27131 or Type “A” to outside diame- wear.
ter of first propeller shaft oil seal. Install seal with 2. Check forward gear clutch jaws for damage.
lip facing needle bearing. Press oil seal with tool Jaws must not be chipped or rounded off.
until tool bottoms on bearing carrier.
23351
a - Forward Gear Teeth
b - Clutch Jaws
50788
a - Oil Seal
b - Oil Seal Driver (91-31108)
c - Bearing Carrier
50783
a - Bearing Adaptor
b - Mandrel
50874
a - Forward Gear Bearing Adaptor
b - Special Tool
c - Pins
d - Universal Puller Plate
50885
a - Spring
b - Clutch 50778
a - Needle Bearing
2. Remove pin from clutch, slide spool assembly
out of propeller shaft, remove reverse gear and Propeller Shaft, Reverse Gear and
slide clutch off of propeller shaft. Bearing and Shift Spool Assembly
Inspection and Cleaning
1. Inspect reverse gear for pitting, chipped or bro-
ken teeth, fracturing and excessive or uneven
wear.
2. Check reverse gear clutch jaws for damage.
Jaws must not be chipped or rounded-off.
50885
23351
a - Gear Teeth
b - Clutch Jaws
a - Spool Assembly
50881
b - Reverse Gear
c - Clutch
d - Pin
50698
a - Propeller Shaft Centers
b - Mount Dial Indicator Here
c
74877
50698
a - Shift Shaft
a - Propeller Shaft Splines b - Spool
b - Oil Seal Contact Area c - Gap Has Increased - End Play Measurement:
.002 - .010 in. (0.051 - 0.254 mm) Is Same As
7. Clean all component parts (except new bearings) Earlier Models
with cleaning solvent. Dry components thorough- NOTE: The later style shift spool assembly for the
ly with compressed air, being careful not to spin counter rotation has a larger gap than the earlier
bearings. style. This later style shift spool, beginning with serial
number OF726586, is sold as a whole assembly and
8. Clean the shift spool assembly with a suitable must be used when replacing the earlier style (Prior
solvent and dry the parts thoroughly using to S/N OF726586).
compressed air.
c
9. Inspect the shift spool assembly for damage.
Small nicks and burrs may be smoothed. If any
parts are damaged or worn beyond repair, it will
be necessary to replace the complete shift spool
assembly. Individual parts are not available for 74877
the assembly. b
10. Inspect the shift spool for wear in the area where a
the shift crank comes into contact.
a
c
75219
a - Contact Area
REVERSE FORWARD
50885
a - Shorter Hub
b - Groove
50885
50789
a - Bearing Driver
b - Needle Bearing
c - Hub
50885
a - Sliding Clutch
b - Grooves In Clutch
c - Reverse Gear Assembly
d - Cross Pin
e - Propeller Shaft
f - Spool And Actuating Shaft Assembly
g - Cross Pin Retainer Spring
23354
a - Shift Shaft Bushing 23350
b - O-ring
c - Washer a - Contact Area
d - Clip b - Shift Crank
e - Shift Shaft
Shift Shaft Reassembly
Shift Shaft Inspection and Cleaning 1. Reassemble shift shaft components in order
NOTE: If oil seal in shift shaft bushing is found to be shown.
defective, oil seal and shift shaft bushing must be
replaced as an assembly.
1. Inspect shift shaft bushing for corrosion in seal
area. Replace if damaged.
23349 23354
a - Shift Shaft Bushing a - Shift Shaft
b - Clip
c - Washer
2. Inspect shift shaft splines and seal surface for
d - O-ring
corrosion. Ensure splines are not twisted. e - Shift Shaft Bushing (Seal Inside)
23355
a - Seal Surface
b - Splines
50887
a - Shift Crank
b - Locating Pin
50317
a - Shift Shaft Bushing Tool (91-31107)
! WARNING
Failure to install the stainless steel washer over
shift shaft bushing could allow intermediate shift
shaft to drop down during operation and prevent 50781
shifting of the drive unit.
a - Shims
b - Bearing Adaptor
4. Install rubber washer over shift shaft and seat in
3. Place reverse gear (without thrust race or thrust
bushing. Apply Special Lubricant 101 to stainless
bearing) into bearing adaptor.
steel washer to stick it in place over rubber
washer.
23354
a - Stainless Steel Washer (Rubber Washer Beneath)
23142
a - Rollers (18) - Hold In Place Using Needle Bearing Assem-
bly Lubricant (92-42649A1)
b - Roller Bearing Outer Race
50791
a - Installation Tool
b - Reverse Gear
74001
23348
a - Drive Shaft Bearing Retainer Tool (P/N 91-43506)
b - Retainer
50882
23352
a - Drive Shaft Nut Wrench (91-56775)
a - Bearing Cup
b - Torque Wrench
b - Retainer
c - Socket
d - Breaker Bar
e - Bearing Carrier Retainer
71591
23144
a - Spring
75733 b - Plate
a - Allen Screws c - Washer
d - Bearing
e - Washer
f - Spacers(3)
23144
a - Nuts (3) 23145
a - Drive Shaft
3. Place collar from Bearing Preload Tool b - Collar
(91-14311A2) over drive shaft with set screw c - Set Screw
down. Align set screw with flat on drive shaft.
5. Loosen nuts 3-4 turns and then rotate drive shaft
clockwise 2 or more turns to seat bearings.
23145
23146
a - Collar
a - Nuts
b - Set Screw
b - Drive Shaft
c - Flat on Drive Shaft
23146
a - Stud Adaptor (91-13948)
b - Backlash Indicator Rod (91-53459)
c - Dial Indicator Holding Tool (91-89897)
d - Dial Indicator (91-58222A1)
a - Shim 50882
50785
a - Thrust Bearing
50883
a - Thrust Collar
50785
a - Thrust Race
50880
a - Propeller Shaft
b - Shift Crank
50880
a - Installation Tool 50889
a - Bearing Adaptor
8. Lower forward gear with thrust bearing and race b - Thrust Race
down over propeller shaft. Ensure thrust race is c - Hook Tool
seated against shim by tapping it down with a soft 10. Remove forward gear installation tool while hold-
punch. Do not nick surface. ing down on forward gear bearing adaptor.
50889
a - Shim
b - Thrust Race
50889
a - Installation Tool
50881
23146
a - Drive Shaft
b - Dial Indicator
c - Indicator Rod
d - Indicator Pointer
23145
a - Collar
b - Set Screw
c - Nuts (3)
50888
a - Pinion Nut Adaptor
b - Bearing Carrier
c - Forward Gear Bearing Adaptor
d - Shim
! CAUTION
Before loosening collar set screw, tighten pre-
load tool nuts until they bottom on spacers.
50883
a - Pinion Gear And Nut
b - Bearing Carrier Retainer
23352
a - Retainer
50884
Checking Reverse Gear Backlash
a - Reverse Gear
1. Ensure bearing adaptor race surface is clean.
Coat thrust bearing with gear lube and install 3. If pinion bearing was not replaced, but needle
thrust race and bearing as shown. bearings have fallen out during disassembly,
install 18 needles in needle bearing outer race.
Use needle bearing assembly lubricant
(91-825265A1) to help hold needles in place.
50882 23142
a - Rollers (18)
a - Thrust Race
b - Roller Bearing Outer Race
b - Thrust Bearing
23351
a - Shim(s)
23348
a - Drive Shaft Bearing Retainer Tool (91-43506)
b - Retainer
23353
a - Pinion Gear, Nut And Washer
75750
23144
23144
a - Nuts (3)
23145
a - Drive Shaft
13. Place collar (from Bearing Preload Tool
b - Collar
91-14311A2) over drive shaft with set screw c - Set Screw
down. Align set screw with flat on drive shaft.
15. Loosen nuts 3-4 turns and turn drive shaft clock-
wise 2 or more turns to seat bearings.
23145
a - Collar
b - Set Screw
23146
c - Flat on Drive Shaft
a - Nuts (3)
b - Drive Shaft
23146
a - Stud Adaptor ( 91-13948)
b - Backlash Indicator Rod (91-53459)
c - Dial Indicator Holding Tool ( 91-89897)
d - Dial Indicator (91-58222A1)
50791
NOTE: Reverse Gear Bearing Adaptor Installation a - Bearing Adaptor Installation Tool
Tool (91-18605A2) is used to apply a light preload of b - Driver Bolt
reverse gear in the following steps.
18. Take backlash readings at 4 locations, rotating
17. Apply a light preload to reverse gear using Bear- drive shaft 90 degrees at a time, as follows:
ing Adaptor Installation Tool (91-18605A2) to
hold gear against thrust bearing as follows: a. Lightly turn drive shaft back and forth, so as
to feel backlash between gears (no move-
a. Install tool in gear housing and tighten until ment should be noticed at propeller shaft).
one or two threads are showing in gear hous-
ing bore. b. Observe dial indicator. Reading must fall
between .020-.030 in. (0.50-0.76 mm).
b. Turn driver bolt in by hand until a slight resis-
tance is felt (driver head contacts reverse
gear).
23145
a - Nuts (3)
b - Spacers
c - Collar
23146 d - Set Screw
a - Drive Shaft
b - Dial Indicator 23. Remove pinion nut and pinion gear. Install bear-
c - Indicator Rod ing carrier retainer to protect gear housing
d - Indicator Pointer threads.
! CAUTION
Before loosening collar set screw, tighten bear-
ing preload tool nuts until they bottom on
spacers.
22. Remove bearing preload tool as follows: 50884
a - Pinion Gear and Nut
a. Tighten 3 nuts until they bottom on spacers.
b. Loosen collar set screw and remove collar.
c. Remove remaining bearing preload tool com-
ponents.
23352
a - Retainer
50885
a - Shift Crank
25. Remove reverse gear. Thrust bearing and thrust b - Bearing Adaptor
race should be left in gear housing.
2. Tilt aft end of propeller shaft assembly toward left
(port) side of gear housing and begin to lower it
into gear housing.
50884
a - Reverse Gear
50888
a - Propeller Shaft
50886
a - Shift Handle Tool
b - Sliding Clutch
50888
a - Reverse Gear Hub
b - Bearing Adaptor
23351
a - Shims
50885
a - Reverse Gear
b - Bearing Adaptor
c - Shift Spool
d - Shift Crank
50787
a - Pinion Nut Adaptor (91-61067A3)
b - Drive Shaft
c - Bearing Carrier
50886 23352
a - Pinion Nut Adaptor a - Bearing Cup
b - Drive Shaft b - Retainer
c - Pinion Gear
50782
a - Shim
23343
8. Apply gear lube to thrust bearing and place on
forward gear. Place thrust race on top of thrust
a - Drive Shaft Bearing Retainer Tool (P/N 91-43506)
bearing with stepped side up as shown.
i. Torque pinion nut by turning drive shaft using
pinion nut wrench and torque wrench with
appropriate socket, to 60-80 lb. ft. (81-108
N·m).
73873
a - Pinion Nut Adaptor
b - Drive Shaft Adaptor
c - Bearing Carrier
50880
50783
a - Forward Gear Installation Tool
b - Forward Gear a - Thrust Race
10. Install forward gear bearing adaptor using a hook 12. Apply gear lube to thrust bearing and install on
tool as shown (Refer to end of this section to top of thrust race.
fabricate this tool). Ensure adaptor seats evenly
(Orientation does not matter, as bearing is the
against thrust race. Remove hook tool and
same on both sides.)
forward gear installation tool.
50881
a - Forward Gear Bearing Adaptor
b - Thrust Race
c - Hook Tool 50783
d - Forward Gear Installation Tool a - Thrust Bearing
50784
a - Thrust Collar 50778
b - Keepers
14. Pull up lightly on propeller shaft to expose groove
for keepers. Install two keepers in groove and 15. Install second thrust collar with stepped side up.
lower propeller shaft to hold them in place.
50787
a - Thrust Collar
50826
a - Groove
b - Keepers
50779
a - Thrust Race
50786 b - Bearing Carrier
a - Thrust Bearing
19. Install bearing carrier as follows:
17. Lubricate O-ring with gear lube and install in gear a. Coat gear housing contact surfaces with
housing as shown. Push down in groove. Special Lubricant 101.
b. Lubricate needle bearing with gear lube.
c. Fill area between seals with 2-4-C Marine
Lubricant.
d. Lower carrier into housing until fully seated.
50886
50826
a - O-ring
a - Bearing Carrier
50779
a - Tab Washer
50790
a - Bearing Carrier Retainer
50784
a - Tab
23343
a - O-ring Groove (Not Found On Service Parts)
50312
23343
a - Water Pump Base
b - Gasket
23356 23350
a - Water Pump Body
b - Water Pump Impeller
c - Drive Shaft
23147
a - Water Pump Impeller
b - Key
c - Water Pump Face Plate And Gaskets (One On Each Side)
23266
23266
a - Water Tube 23138
b - Drive Shaft Splines
a - Trim Tab Allen Screw
b - Oil Seal
2. Install trim tab allen screw. c - Alignment Pins
3. Install oil seal and apply Special Lubricant 101, d - Centrifugal Slinger
e - O-ring (If O-ring Groove Is Present)
2-4-C Marine Lubricant, or Perfect Seal to oil
f - Shift Shaft
seal.
4. Check that alignment pins, centrifugal slinger 6. Align intermediate shift shaft straight forward
and drive shaft O-ring are in place. (parallel with propeller shaft).
5. Move gear housing shift shaft clockwise to shift
gear housing into reverse.
23265
a - Shift Shaft
23253
a - Trim Tab
b - Allen Wrench
c - Plastic Plug
23263
5
D
22131
TRIM CYLINDERS
Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1
Torque Specifications . . . . . . . . . . . . . . . . . . 5D-1
Lubricants/Sealers/Adhesives . . . . . . . . . . . . . . 5D-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1
Trim Cylinder Internal Leak Test . . . . . . . . . . . . 5D-1
Trim Cylinder Shock Piston Test . . . . . . . . . . . . 5D-1
Trim Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . 5D-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5D-3
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D-8
Lubricants/Sealers/
Adhesives
NOTE: Prior to reassembly of trim cylinder(s), lubri-
cate all internal parts with Quicksilver Power Trim
and Steering Fluid or (if not available) 10W-30 or
10W-40 motor oil.
Special Tools
Description Part Number
Spanner Nut Wrench 91-821709
Large Pin Set 91-811907
Medium Pin Set 91-811908
Small Pin Set 91-811909
22060
22133
22441
a - Rear Anchor Pin
b - Large I.D. Washers (Port And Starboard)
c - Rubber Bushings (2) (Port And Starboard)
d - Small I.D. Washers (Port And Starboard)
e - Locknuts (Port And Starboard)
f - Plastic Caps (Port And Starboard)
22133
a - End Cap
71233 b - Cylinder
c - Piston Rod Assembly
22134
22131 22133
a - Floating Piston
a - End Cap
b - Trim Cylinder
b - Piston Rod
c - O-Ring
c - Large O-Ring
d - Small O-Ring (2)
4. Remove and disassemble shock piston assem-
e - Continuity Spring
bly. Be careful not to loose check balls. f - Rod Scraper
g - Plain Washer
h - Retaining Ring
22133
22132
22131 22132
! CAUTION
Ensure work area and all components are clean
before reassembling trim cylinders. Power Trim
components can become damaged if dirt gets
into system.
22132
22136
22133
22132
22132
s
u l
v t r n m o
x w y q k
J
22136
! CAUTION
DO NOT clamp center section of trim cylinder
during reassembly. If clamping of cylinder is nec-
essary, clamp cylinder on front mounting flange.
! CAUTION
Use only 2-4-C Marine Lubricant on end cap
threads. Other substances may act as an insula-
tor and cause poor electrical continuity between
cap and cylinder which could cause a corrosion
problem.
22133
22130
22133 22441
5
E
22129
When testing this Dual Power Trim system, take spe- a. Test for continuity between terminals 13 and
cial note of the following: 9.
• Continuity Indicated: proceed to “b.”
1. Control box harness connectors must be discon-
• No Continuity Indicated: replace relay.
nected and key switch must be “OFF.”
b. Connect a jumper wire between terminals 3
2. Make certain that the jumper lead used between and 5. Test for continuity between terminals
terminal 3 and 5 is used only when specified. 13 and 9.
The tests, listed following, are in a sequence accord- • No Continuity Indicated: relay ok.
ing to probability of component failure. It is recom-
• Continuity Indicated: replace relay.
mended, however, that all tests be performed even
if a faulty component is detected early in the se-
quence. This precaution will guard against repeat
failure if there is more than one failed component.
Diode Module Test
Perform the following diode tests using an ohmmeter
set on Rx1 scale. When testing diodes, take 2 read-
Testing Dual Power Trim ings. Note first reading; then, reverse meter leads
again noting reading.
System
If diode is good, meter should indicate a high or infi-
nite resistance (no meter movement) when con-
nected one way and a low reading (below 60 ohms)
when connected the other way.
If both readings are high or infinite, diode is open. Re-
place diode module.
If both readings are low, diode is shorted. Replace
diode module.
Diode No. 1
Connect a jumper wire between terminals 3 and 5.
22129 Test diode between terminals 9 and 10.
Dual Trim Control Panel Wiring Diagram Diode No. 2
a - Relay No. 1
Connect a jumper between terminals 3 and 5. Test
b - Relay No. 2
c - Diode Module diode between terminals 10 and 13.
d - Terminal Block
e - Control Panel ! CAUTION
Before proceeding with further diode testing, re-
Relay Test move fuse from red/purple harness lead so that
1. Testing Relay No. 1 it will not be possible to short either control box
or VOA meter.
a. Test for 12 volts at terminal 2, using only ter-
minal 4 as a ground. Diode No. 3
Test diode between terminals 6 and 12.
• Voltage Indicated: proceed to “b.”
Diode No. 4
• No Voltage Indicated: replace relay. Test diode between terminals 12 and 7.
b. Connect a jumper wire between terminals 3 Diode No. 5
and 5. Test for 12 volts at terminal 2, using Test diode between terminals 8 and 11.
only terminal 4 as a ground. Diode No. 6
• No Voltage Indicated: relay ok. Test diode between terminals 14 and 15.
Diode No. 7
• Voltage Indicated: replace relay. Test diode between terminals 8 and 5.
Diode No. 8
Test diode between terminals 5 and 15.
22216
a - Relay No. 1
b - Relay No. 2
c - Terminal Block 22086
a - Diode Module
7. Install control box cover. b - Nuts
c - Screws
22086
a - Screws
b - Cover
22086
22086
a - Bezel Nut (1 Per Switch)
b - Switch (1 Per Switch)
BLK BLACK
BLU BLUE
BRN BROWN
GRY GRAY
GRN GREEN
ORN ORANGE
PNK PINK
PUR PURPLE
RED RED
TAN TAN
WHT WHITE
YEL YELLOW
LIT LIGHT
DRK DARK
22123
5
F
22217
POWER TRIM
BLK Black
BLU Blue
BRN Brown
GRY Gray
GRN Green
ORN Orange
PNK Pink
PUR Purple
RED Red
TAN Tan
WHT White
YEL Yellow
LIT Light
DRK Dark
22212
22174
Quicksilver “Commander” Panel Trim Control
a - “Trailer” Switch – Press Until Drive Unit Reaches Desired
Height or End of Upward Travel
! CAUTION
DO NOT run engine above idle RPM with unit
raised for shallow water operation, as drive unit
is out beyond gimbal ring support flanges and
has no side support. USE EXTREME CAUTION
WHEN OPERATING BOAT WITH DRIVE UNIT
RAISED.
22212
22212
! WARNING
When adjusting trim limit, following, use extreme
care that engine is not accidentally started and
keep clear of area near propeller. Also, use care 22217
to prevent placing hands in an area where they a - Mode Switch – Place in “MANUAL” Mode
could be injured by drive unit movement.
4. With the assistance of another person actuate
! CAUTION
manual trim control switch used to trim drive unit
Trim limit switch MUST BE adjusted exactly as “Out” (DO NOT use “Trailer” switch) and turn trim
stated following. If switch is adjusted incorrectly, limit switch SLOWLY counterclockwise until trim
drive unit may move out beyond the gimbal ring cylinders extend to dimension shown. Retighten
support flanges (when making test run follow- trim limit switch retaining screws.
ing), and severe damage to stern drive unit may
result.
If more trim “Out” capability is desired, perform the
following.
1. Place drive unit in the full “In”/“Down” position.
50464
2. Turn trim limit switch clockwise to end of slots.
a - 21-3/4 in. 1/4 in. (554mm 6mm)
22091
22091
! WARNING
Difficulties in handling and operational control
may result if drive unit is adjusted “Out” too far.
If difficulties are encountered, drive unit trim
angle MUST BE moved “In” the amount
necessary to eliminate the problem and avoid a
possible safety hazard.
22175
a - Needle at Bottom of Scale – Drive Unit in Fully “In” Position
22091
a - Retaining Screws
b - Turn to Adjust