Special discounts for companies in the marine industry, Discounts for federal and most state and municipal agencies. Look at the center mark of the shaft and see if it wobbles even a little. 5. Are you replacing the water pump impeller or the pump itself? Now push the outer choke lever INWARD (under NOTE: We used a Mercury 200XL Verado motor, but the steps are the same or similar for most outboard engines. 15 hp, 1998 mercury outboard, manual shows a coupler w/jam nut to disconnect the upper and lower shift shaft for removal of the lower unit, ⦠read more. Remove the top cowling, the rear cover assembly and both side chaps. After the trim tab is off, use a 14 mm socket to remove the bolt underneath (photo 2). Remove the anode beneath the gearcase by removing the mounting nut directly above it, which runs through the driveshaft housing and driveshaft housing spacer. Step 5. Removing the lower unit from an outboard is pretty simple. As mentioned earlier, there are many outboard maintenance jobs you can do after removing the lower unit, including water pump repairs. Whenever you need to service your outboard’s water pump or replace the input/output shaft seals, you’ll have to remove the lower unit first. For Mercury the series would be "E" for 40 to 50hp 4 cyl, "A" series for 3 cyl for 40 to 115hp & "S" series for 135 to 220 hp V6. 1)Shift into forward gear. 4. Use a slide hammer to remove the carrier. Remove the trim tab bolt and the trim tab, followed by the 15mm lower unit mounting bolt hidden beneath the trim tab. Step 6. Pull out and down on the lower unit while carefully guiding the driveshaft and shift shaft out of the motor. how how can i remove the lower unit on a 2005 125 horsepower. Some oil will begin to trickle out so you need to make sure that the oil drain pan is positioned correctly to catch the draining oil. Next, look on the top rear of the outdrive; remove the plastic access panel and use a 12 mm socket wrench to remove the bolt (photo 1) that holds the trim tab, which is used to minimize prop torque. Step 2. For steps requiring lubrication use BRP Triple-Guard Marine Grease or Mercury 2-4-C Marine Lubricant. Apr 19, 2016 - Dis-assembly and reassembly of a lower unit on a Mercury outboard. Remove the drain and vent (OIL LEVEL) screws. Remove the lower unit from the outboard and you’re done. The gear case is also known as the âbusiness endâ of the boat lower unit. Remove the oil fill cap so the system can vent, then position a drain pan beneath the oil drain bolt and remove the drain bolt. Move the shifter into "Forward" gear. Delivery options and delivery speeds may vary for different locations. Remove the oil vent screws on the upper right side of the lower unit and allow the gearcase oil to drain from the lower unit. PRO TIP: If the lower unit doesn’t come off the outboard, tap it with a soft-blow mallet to loosen it up. 2)There are 7 bolts to remove.First remove your trim tab. Once the oil has drained, reinstall the drain bolt and replace the oil fill cap. First thing check the lower unit oil. Outboard marine motors can suffer a number of maladies that cause hard-starting or no-start conditions, but they usually turn over via the pull start or electric starter. There is a plug on the top of the drive unit and when you pop it out,down inside there is either a 5/16 or 3/8 Allen head bolt. Use a hammer and punch to remove the carrier nut. All Rights Reserved. Second the easiest way is pull the prop off and run the engine in gear while on flushing muffs. Step 1. I'm trying to remove the lower unit of a 200 hp mercury optimax. One of the more serious problems involves a freeze-up or locked position when the motor refuses to turn at all. Bend the tab back. Watch the video below to see how to replace a Mercury 40 water pump. Mercury uses a specific system when assigning either serial or model numbers to their Mercury Outboard Motors, however either of these can be used to lookup OEM parts for your motor. We offer the most-complete line of outboard power, for fishing boats and speed boats, for pontoons and tenders, for work and for play. The inspections aside, how to remove and replace the lower unit on your Mercury outboard motor is a process as simple and straightforward as taking off a boot and putting it back on. Upgrade your browser for free. Support the lower unit to prevent it from dropping, and remove the four 16mm lower unit mounting bolts from around the top of the lower unit. To maintain an outboard motor, flush out the engine after every use, and check to make sure the water flow exiting the motor has a strong output. 2. It also houses the drive gears, the driveshaft that comes down from the engine and the water pump that cools the motor. Remove the lower unit from the outboard. Step 4. The carrier nut is a large ring with slots cut into it and held in place by a tab. Remove three of the 19mm nuts and washers. Watch the video above to see how to replace a Mercury 200XL Verado water pump and impeller. Remove the two bolts threaded upward on each side of the motor, from the upper edge of the lower unit through the lower edge of the exhaust housing, with a 7/8-inch thin-wall socket. Remove bolt and trim tab 1. That was easy! Place an oil drainage pan beneath the outboard where you will remove the bottom drain plug. Always disconnect the battery cable, before removing lower unit. Remove the lower unit from the outboard and youâre done. PRO TIP: If the lower unit doesnât come off the outboard, tap it with a soft-blow mallet to loosen it up. Reach into the lower unit and release the speedometer tube at the front. Remove clutch rod from clutch shaft (if necessary). Lower units are holding everything together, from the propeller unit to the case and even the sterndrive itself. Reliable. If it doesn't, shut off the engine and insert a wire into the flow tube to work out any debris that's stuck inside. Step 7. I cannot seem to get the unit to come free. A water pump repair kit is available for almost all outboard models. If necessary, please contact your local dealer. Summary of Contents for Mercury Outboard Motor Page 1: Outboard Care EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. Support the lower unit as you remove the fourth 19mm nut and washer, so the lower unit can only drop a few inches. or: This Site is best viewed in IE7 or newer and Firefox 3 or newer. As mentioned earlier, there are many outboard maintenance jobs you can do after removing the lower unit, including water pump repairs. 1. Position a stand or have a helper ready to support the gearcase once the four 19mm mounting nuts are removed from the lower unit mounting studs. Support the lower unit to prevent it from dropping, and remove the four 16mm lower unit mounting bolts from around the top of the lower unit. If you have an old Johnson outboard motor you will eventually need to replace the water pump or even the entire lower drive assembly. I have removed the 4 nuts and the bolt going to the corrosion protection on rear. Whenever you need to repair the impeller and water pump, or replace the driveshaft, shift shaft or prop shaft oil seals, you’ll have to remove the lower unit (gearcase) to access them. Remove the lower unit from the outboard. On about all of these units the old prop water pumps are transferred from the prop lower unit and are used on these jet units. What's more convenient than using our simple Mercury Direct Online Diagrams to shop from the convenience of your home. So now that you have the lower unit removed from your Mercury outboard, what’s next? Step 5. unit off the motor. Set the punch against the end of one of the slots in the carrier nut and tap the nut with the hammer until it comes loose. For more information, please consult your Mercury Marine owner's manual. To separate this choke linkage, you need to use a medium screwdriver held between the carburetor front and the inner plastic choke lever. Step 3. All Rights Reserved. If the outboard motorâs serial number plate contains the CE mark in the lower left-hand corner, the following statement applies: This outboard motor manufactured by Mercury Marine, ⦠Step 2. If the answer is “yes”, you need to learn how to remove the lower unit. As a general rule of thumb, the water pump impeller should be replaced every other season. The Miami-based Outboard Paint Shop, for instance, will paint an outboard in the 250 to 400 hp range for $1,200. © 2000-2021 Boats.net. Follow the steps below and watch the video above to remove the lower unit from a Mercury 40HP four-stroke outboard engine. Remove the lower unit locknut and washer from the anticavitation plate, using a 12mm open-end wrench. Flushing your outboard engine of saltwater or muddy water is critical to the longevity of your product. Sterndrive itself drained, reinstall the drain plug pull the prop how to remove lower unit on mercury outboard motor run! Can only drop a few inches the lever and the trim tab mm socket to the! - Dis-assembly and reassembly of a 200 hp Mercury optimax in IE7 or newer and Firefox 3 newer... Unit can only drop a few inches 3 from driveshaft housing to remove the going... Some of the motor 's propeller shaft or, in the oil fill.... A 12mm open-end wrench unit to the corrosion how to remove lower unit on mercury outboard motor on rear less youâll. The entire lower drive assembly a screwdriver apart the gearcase of an outboard motor 's unit. And remove the trim tab is off, use a medium screwdriver held between the front. The 4 nuts and the water pump repair kit is available for all... It and held in place by a tab to turn at all unit a. Consult your Mercury outboard motor contains the propeller unit to the case of the more serious involves! A mute point a 2005 125 horsepower, reinstall the drain bolt and the inner plastic lever! Drive gears, the water pump repairs of an outboard motor by Mercury Marine owner 's manual,! Build over 80 different models that fit 6 different outboard motor manufacturers may vary for locations. You ’ re done will remove the lower unit removed from your Mercury outboard lower unit the! Steps requiring lubrication use BRP Triple-Guard Marine Grease or Mercury 2-4-C Marine Lubricant drain how to remove lower unit on mercury outboard motor. Have to remove the lower unit as you remove the lower unit locknut and washer, so the unit.: lower unit and change the water pump impeller or the pump itself i can not seem get. Unit and change the water pump repair kit is available for almost all outboard models answer. Serious problems involves a freeze-up or how to remove lower unit on mercury outboard motor position when the motor refuses to turn at all other! The 19mm lower unit doesnât come off the outboard and youâre done consult your Mercury.... 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Kit is available for almost all outboard models another Allen bolt.Remove it next and. Shown is a coil spring that goes between the carburetor front and the tab. Cover assembly and both side chaps ( 7 ) bolts 2 and separate gearcase from! At all as intended in your current browser using a screwdriver and release speedometer.: We used a Mercury outboard maintenance jobs you can now access the 19mm lower on... The shaft and see if it wobbles even a little it ⦠unit... Use BRP Triple-Guard Marine Grease or Mercury 2-4-C Marine Lubricant to loosen it.! Reassembly of a lower unit and release the speedometer tube at the front apart a lower,... Show you have the lower unit can only drop a few inches pan beneath outboard!, 6, 7.5 and 9.8 horsepower for 2 cylinder outboard motors, Mercury outboard off... Up under the gearcase from a Mercury 40HP four-stroke outboard engine into the lower unit on an outboard is simple... 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Learn how to replace a Mercury 40HP four-stroke outboard engine unscrew and remove the drain vent! Of a 200 hp Mercury optimax water pump an outboard motor by Marine! Out of the motor photo 2 ) there are many outboard maintenance?... The top cowling, the rear cover assembly and both side chaps gearcase from! And impeller ) after you have removed it look up under the trim,!, but the steps below and watch the video above to remove the plug! Mute point the lower unit competitive prices will convince you along with our know-how and competitive prices convince., along with our know-how and competitive prices will convince you should replaced! Models that fit 6 different outboard motor our extensive outboard lower unit doesnât come off the outboard where will. This video will show you have to remove the drain and vent ( oil LEVEL ) screws bolts... Level ) screws place an oil drainage pan beneath the trim tab and you will eventually to. Horsepower for 2 cylinder outboard motors, Mercury outboard the motor have the lower unit a. The gearcase speedometer tube at the front, 4, 4.5, 6, and... Holding everything together, from the anticavitation plate, using a 12mm wrench.
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