Mercury 90 Service Manual

6A-0 - LOWER UNIT 90-830234R3 DECEMBER 1997
Table of Contents
Page
Specifications 6A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 6A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Drive Shaft) 6A-4. . . . . . . . . . . . . . . . . . . .
Gear Housing (Propeller Shaft) 6A-6. . . . . . . . . . . . . . . . .
Gear Case Identification 6A-8. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Housing
Lubricant 6A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft 6A-11. . . . . . . . .
Pinion Gear, Drive Shaft, and Forward Gear 6A-13.
Upper Drive Shaft Bearing 6A-15. . . . . . . . . . . . . . . . .
Oil Sleeve 6A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Drive Shaft Bearing Race 6A-16. . . . . . . . . . . .
Shift Shaft 6A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6A-17. . . . . . . . . . . . . . .
Trim Tab Adjustment and Replacement 6A-17. . . . . .
Page
Reassembly 6A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6A-18. . . . . . . . . . . . . . .
Shift Shaft 6A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier Reassembly 6A-19. . . . . . . . . . . . . . .
Forward Gear Reassembly 6A-21. . . . . . . . . . . . . . . .
Propeller Shaft Reassembly 6A-22. . . . . . . . . . . . . . .
Drive Shaft Wear Sleeve Installation 6A-22. . . . . . . .
Lower Drive Shaft Bearing Race Installation 6A-23.
Oil Sleeve Installation 6A-24. . . . . . . . . . . . . . . . . . . . .
Upper Drive Shaft Bearing Installation 6A-24. . . . . . .
Forward Gear, Lower Drive Shaft Bearing,
Pinion Gear, and Drive Shaft Installation 6A-25. . . . .
Pinion Gear Depth and Forward Gear
Backlash 6A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft
Installation 6A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Reassembly and Installation 6A-30. . .
Gear Housing Pressure Test 6A-32. . . . . . . . . . . . . . .
Filling Gear Housing With Lubricant 6A-33. . . . . . . . . . .
Gearcase Installation 6A-34. . . . . . . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 6A-36. . . . . . . . . . . . . . . . . . . . . .

Mercury 90 Specifications

General

Brand	Mercury
Model	90
Category	Outboard Motor
Language	English