Mercury 40 Service Manual

6
B
BIGFOOT GEAR HOUSING
90-828631R3 MARCH 1999 Page 6B-1
LOWER UNIT
Section 6B - Bigfoot Gear Housing
Table of Contents
Specifications 6B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricants and Service Aids 6B-5. . . . . .
Gear Housing (Driveshaft)
(2.31:1 Gear Ratio) 6B-6. . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Prop Shaft)
(2.31:1 Gear Ratio) 6B-8. . . . . . . . . . . . . . . . . . . . . . . .
General Service Recommendations 6B-10. . . . . . . .
Bearings 6B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seals 6B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Lubricant 6B-11. . . . .
Removal 6B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6B-13. . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft 6B-16. . . . . .
Pinion Gear, Driveshaft, and
Forward Gear 6B-21. . . . . . . . . . . . . . . . . . . . . . . . .
Upper Driveshaft Bearing 6B-24. . . . . . . . . . . . . . .
Oil Sleeve 6B-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Driveshaft Bearing Race 6B-26. . . . . . . . .
Shift Shaft 6B-27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6B-29. . . . . . . . . . . .
Trim Tab Adjustment and Replacement 6B-29. . .
Reassembly 6B-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6B-30. . . . . . . . . . . .
Shift Shaft 6B-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier Reassembly 6B-33. . . . . . . . . . . .
Forward Gear Reassembly 6B-37. . . . . . . . . . . . .
Propeller Shaft Reassembly 6B-39. . . . . . . . . . . .
Driveshaft Wear Sleeve Installation 6B-40. . . . . .
Lower Driveshaft Bearing
Race Installation 6B-42. . . . . . . . . . . . . . . . . . . . . .
Oil Sleeve Installation 6B-43. . . . . . . . . . . . . . . . . .
Upper Driveshaft Bearing Installation 6B-43. . . .
Forward Gear, Lower Driveshaft Bearing,
Pinion Gear, and Driveshaft Installation 6B-45. .
Pinion Gear Depth and Forward
Gear Backlash 6B-46. . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft
Installation 6B-51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Reassembly and Installation 6B-53
Gear Housing Pressure Test 6B-56. . . . . . . . . . . .
Filling Gear Housing With Lubricant 6B-57. . . . . . . .
Gearcase Installation 6B-58. . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 6B-62. . . . . . . . . . . . . . . . . . .
Specifications
GEAR HOUSING
BIGFOOT
(2.3:1)
Gear Ratio
Gearcase Capacity
Lubricant Type
Forward Gear
Number of Teeth
Pinion Gear
Number of Teeth
Pinion Height
Pinion Gear Locating Tool
Flat Number
Disc Number
Forward Gear Backlash
Backlash Indicating Tool
Mark Number
Water Pressure
@ 800 rpm (Idle)
@ 6000 rpm (WOT)
2.31:1
22.5 fl oz (655 mL)
Quicksilver Gear Lube-Premium Blend
30 Spiral/Bevel
13 Spiral/Bevel
0.025 in. (0.64 mm)
91-12349A2
#8
#3
0.012-0.019 in. (0.30-0.48 mm)
91-78473
#4
2-4 psi (14-28 kPa)
10-15 psi (69-103 kPa)

Mercury 40 Specifications

General

Brand	Mercury
Model	40
Category	Outboard Motor
Language	English