NON-BIGFOOT GEAR HOUSING

LOWER UNIT
Section 6A - Non-Bigfoot Gear Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-1 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Forward Gear Bearing Race . . . . . . . . . . . 6A-28
Quicksilver Lubricants and Service Aids . . . . 6A-5 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-28
Gear Housing (Drive Shaft - 1.83:1) . . . . . . . 6A-6 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-31
Gear Housing (Prop Shaft - 1.83:1) . . . . . . . . 6A-8 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-32
General Service Recommendations . . . . . . . 6A-10 Lower Driveshaft Bearing Installation . . . 6A-33
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Upper Driveshaft Bearing Installation . . . 6A-34
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Forward Gear, Pinion Gear and
Draining and Inspecting Gear Lubricant . . . . 6A-11 Driveshaft Assembly Installation . . . . . . . 6A-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12 Pinion Gear Location and
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Forward Gear Backlash . . . . . . . . . . . . . . 6A-36
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Determining Pinion Gear Location . . . . . . 6A-36
Bearing Carrier and Propeller Shaft . . . . . 6A-15 Determining Forward Gear Backlash . . . . 6A-39
Propeller Shaft Disassembly . . . . . . . . . . . . . . 6A-18 Bearing Carrier and
Pinion Gear, Driveshaft and Forward Gear . . 6A-20 Propeller Shaft Installation . . . . . . . . . . . . 6A-41
Upper Driveshaft Bearing . . . . . . . . . . . . . . . . . 6A-21 Water Pump Re-Assembly/Installation . . 6A-42
Lower Driveshaft Bearing . . . . . . . . . . . . . .
Forward Gear Bearing Race . . . . . . . . . . .
6A-22
6A-22
Gear Housing Pressure Test . . . . . . . . . . . . . .
Gear Housing Installation . . . . . . . . . . . . . . . . .
6A-47
6A-48
6
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23 Filling Gear Housing with Lubricant . . . . . . . . 6A-50 A
Gear Housing Reassembly . . . . . . . . . . . . . . . 6A-25 Trim Tab Adjustment and Replacement . . . . 6A-51
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25

Specifications

Gear Ratio 1.83:1

Gearcase Capacity 11.5 fl oz (340 mL)
Lubricant Type Quicksilver Gear Lube-Premium Blend
Forward Gear
Number of Teeth 22 Spiral/Bevel
Pinion Gear
Number of Teeth 12 Spiral/Bevel
Pinion Height 0.025 in. (0.64 mm)
GEAR HOUSING Pinion Gear Locating Tool
(1.83:1) (91-817008A2)
Forward Gear Backlash 0.011-0.017 in. (0.28-0.43 mm)
Backlash Indicator Tool (91-19660--1)
MARK #4 or 0.366 in. (9.3 mm)
Water Pressure (Warm Engine)
@ 800 rpm 1-3 psi (7-21 kPa)
@ 6000 rpm (WOT) 12-25 psi (83-172 kPa)
Leak Test Pressure 10-12 psi (68-83 kPa)
for 5 Minutes

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NON-BIGFOOT GEAR HOUSING

Special Tools
1. Bearing Preload Tool 91-14311A2

2. Backlash Indicator Tool 91-19660--1

19660-1

3. Puller 91-27780

4. Universal Puller Plate 91-37241

5. Driver Head 91-37312.

6. Driver Rod (91-37323)

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 NON-BIGFOOT GEAR HOUSING

7. Bearing Retaining Tool 91-43506.

8. Puller Jaws (91-46086A1)

9. Dial Indicator (91-58222A1)

10. Dial Indicator Adaptor Kit (91-83155)

11. Puller Bolt (91-85716)

12. Forward Gear Bearing Installer 91-817005.

13. Water Pump Base Seal Installer 91-817006.

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NON-BIGFOOT GEAR HOUSING

14. Bearing Carrier Seal Installer 91-817007.

15. Pinion Gear Location Tool 91-817008A2.

16. Forward Gear Bearing Race Driver Cup 91-817009.

17. Needle Bearing Installer 91-817011.

18. Backlash Indicator Tool 91-817057A1.

d
a
c
51043

Ref. Description Qty.

a Plate 1
b Nut 1
c Stud 1
d Sleeve 1

91-817057A-1 Update Kit (Converts 91-14311A-1 Bearing Preload Kit Tool to a 91-14311A-2)

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 NON-BIGFOOT GEAR HOUSING

19. Lower Driveshaft Bearing Driver Assembly 91-817058A1.

20. Driveshaft Holding Tool 91-817070 55/60 (2–stroke).

21. Driveshaft Holding Tool 91-877840A1 50/60 (4–stroke).

Quicksilver Lubricants and Service Aids

Part No. Description
92-809820 Loctite “271”
92-90113--2 RTV Silicone Sealer
92-850737A1 Premium Blend Gear Lubricant
92-850735A1 Anti-Corrosion Grease
92-850736A1 2-4-C w/Teflon

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NON-BIGFOOT GEAR HOUSING

GEAR HOUSING (DRIVE SHAFT)(1.83:1 GEAR RATIO)

95
7 3.44 IN./87.37MM
36 TORPEDO DIA.
34

30 22

28 21
95
27 29 20
95 19
32 29
34
95
33

7 Loctite 271 (92-809820)

31 87 Premium Gear Lubricant (92-850737A1)
7 95 2-4-C With Teflon (92-825407A12)

23
95 18
24

26 7

25

95 10
87 95
6
7
7
17
7 9
15
8 16
5

1 14 95
4
3
35
13
11
12

3 4

7
4
2

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 NON-BIGFOOT GEAR HOUSING

GEAR HOUSING (DRIVE SHAFT)(1.83:1 GEAR RATIO)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 GEAR HOUSING
2 1 DRAIN SCREW 58 6.5
3 2 SCREW 58 6.5
4 3 WASHER-sealing
5 1 DOWEL PIN
6 1 DOWEL PIN
7 1 PIPE PLUG
8 1 ROLLER BEARING
9 1 SEAL KIT
10 1 FILLER PLATE
11 1 PINION GEAR (14 TEETH)
12 1 NUT 50 67.8
13 1 SHIFT SHAFT ASSEMBLY
14 1 RETAINING RING
15 1 BUSHING ASSEMBLY
16 1 O-RING
17 1 OIL SEAL
18 1 DRIVE SHAFT
19 AR SHIM SET (SIZES 006 THRU 038)
20 1 TAPERED ROLLER BEARING
21 1 CUP
22 1 NUT 75 101.7
23 1 WATER PUMP BASE
24 1 O-RING
25 1 OIL SEAL
26 1 OIL SEAL
27 1 IMPELLER
28 1 KEY
29 2 WASHER
30 1 WATER PUMP
31 1 GASKET (LOWER)
32 1 GASKET (UPPER)
33 1 FACE PLATE
34 6 SCREW (M6x16) 60 6.8
35 1 SHIFT CAM
36 1 COUPLER

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NON-BIGFOOT GEAR HOUSING

GEAR HOUSING (PROP SHAFT)(1.83:1 GEAR RATIO)

3.44 IN./87.37MM
TORPEDO DIA.

59

65
61
60

1
95 95

63 46
45
64 47
43
42 66
7 40
41 67
56 38
57
58 39
37

62
55
54
95 53 7

51
95

95 52
50
49

94 48

44

7 Loctite 271 (92-809820)

94 Anti-Corrosion Grease (92-78376A6)
95 2-4-C With Teflon (92-825407A12)

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 NON-BIGFOOT GEAR HOUSING

GEAR HOUSING (PROP SHAFT)(1.83:1 GEAR RATIO)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 GEAR HOUSING
37 AR SHIM SET (SIZES 006 THRU 048)
38 1 TAPERED ROLLER BEARING
39 1 CUP
40 1 FORWARD GEAR (23 TEETH)
41 1 ROLLER BEARING
42 1 CAM FOLLOWER
43 1 SLIDE
44 1 SPRING
45 1 CLUTCH
46 1 CROSS PIN
47 1 SPRING
48 1 PROPELLER SHAFT
49 1 REVERSE GEAR (23 TEETH)
50 1 BALL BEARING
51 1 BEARING CARRIER ASSEMBLY
52 1 O-RING
53 1 ROLLER BEARING
54 1 OIL SEAL
55 1 OIL SEAL
56 2 SCREW (M8x30) 225 18.8 25.5
57 2 WASHER
58 2 THREADED INSERT
59 1 TRIM TAB
60 1 SCREW (M10 x 30) 186 21.0
61 1 WASHER
62 1 THRUST HUB
63 1 PROPELLER NUT 55 74.6
64 1 TAB WASHER
65 1 DECAL- Gear Ratio
66 4 WASHER
67 4 SCREW (M10 x 45) 40 54

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NON-BIGFOOT GEAR HOUSING

General Service Recommendations

There may be more than one way to “disassemble” or “reassemble” a particular part(s),
therefore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more components.
Service procedure order in this section is a normal disassembly-reassembly sequence.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in air line.
Bearings
WARNING
To avoid personal injury, wear eye protection and regulate air pressure to not more
than 25 p.s.i. (172 kPa) when drying bearings with compressed air. Do not spin bear-
ings with compressed air as this may cause bearings to score from lack of lubrica-
tion.
All bearings must be cleaned and inspected. Clean bearings with solvent and dry with com-
pressed air. Air should be directed at the bearing so that it passes through the bearing. Do
not spin bearing with compressed air (see above warning). After cleaning, lubricate bear-
ings with Quicksilver Gear Lubricant. DO NOT lubricate tapered bearing cups until after in-
spection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bearing
race in-and-out, while holding outer race, to check for side wear. When inspecting tapered
bearings, determine condition of rollers and inner bearing race by inspecting bearing cup
for pitting, scoring, grooves, uneven wear, imbedded particles and/or discoloration from
over-heating. Always replace tapered bearing and race as a set.
Inspect gear housing for bearing races that have spun in their respective bores. If race(s)
have spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles, un-
even wear and/or discoloration from overheating. The shaft and bearing must be replaced
if such a condition exists.
Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to ap-
pearance. To prevent leakage around seals, apply Loctite 271 to outer diameter of all seals.
When using Loctite on seals or threads, surfaces must be clean and dry. Apply 2-4-C w/Te-
flon on all O-rings and on I.D. of oil seals. Apply 2-4-C w/Teflon to external surfaces of bear-
ing carrier.

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 NON-BIGFOOT GEAR HOUSING

Draining and Inspecting Gear Lubricant

WARNING
If gear housing is installed on engine, to avoid accidental starting, disconnect (and
isolate) spark plug leads from spark plugs before working near the propeller.
1. With gear housing in normal running position, place a clean pan under housing and re-
move the two vent screws and one fill/drain screw (with gaskets).

b
53922

a - Vent Plug
b - Fill/Drain Plug

2. Inspect gear lubricant for metal particles (lubricant will have a “metal flake” appearance).
Presence of fine metal particles (resembling powder) in the drain pan indicates normal
wear. The presence of metal chips in the drain pan indicates the need for gear housing
disassembly and component inspection.
3. Note color of gear lubricant. White or cream color MAY indicate presence of water in lu-
bricant. Gear lubricant which has been drained from a gear case recently in operation
will have a yellowish color due to lubricant agitation/aeration. Gear lube which is mixed
with assembly lubricant (Special Lube 101 or 2-4-C w/Teflon) will also be creamy white
in color. This is normal and should not be confused with the presence of water. If water
is suspected to be present in gearcase, a pressure check of gearcase should be made
(with no lubricant in gearcase). Gearcase should hold 10-12 psi of pressure for 5 min-
utes without leaking down. Pouring a portion of the gear lubricant into a glass jar and
allowing the lubricant to settle will allow any water in the lube to separate and settle to
the bottom of the jar.
4. Presence of water in gear lubricant indicates the need for disassembly and inspection
of oil seals, seal surfaces, O-rings, water pump gaskets, bearings and bearing surfaces,
as well as gear housing components. If gearcase is rebuilt, gearcase should be pressure
checked before filling with lubricant.

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NON-BIGFOOT GEAR HOUSING

Removal
WARNING
To prevent accidental engine starting, remove (and isolate) spark plug leads from
spark plugs before removing gear housing.
1. Remove (and isolate) spark plug leads from spark plugs.
2. Shift engine into forward gear.
3. Tilt engine to full “Up” position.
4. Remove 4 bolts and washers, two from each side.
5. Remove trim tab.
6. Remove locknut and washer in trim tab recess.
7. Remove gear housing.

a c
53992

a - Trim Tab
b - Locknut and Washer
c - Bolts(4) M10 x 45 and Washers(4)

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Disassembly
Water Pump
NOTE: If water tube seal stayed on water tube (inside of drive shaft housing) when gear
housing was removed, pull water tube seal from water tube.
1. Replace water tube seal, if damaged.
2. Remove 6 screws, washers, and isolators (Design 1).
3. Remove cover.
NOTE: Isolators from forward 2 screws are shorter than the other isolators. Retain these
for proper reassembly (Design 1).
NOTE: Design 1 included isolators on the water pump housing screws. Newer design ver-
sions did not use these isolators.

a
e

b
b

c
d

a - Water Tube Seal d - Isolators (6) If so equipped

b - Screw (6) M6x30 e - Cover
c - Washers (6)

IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting cover and plate, as the depth of the groove will not affect
water pump output.
4. Replace cover if thickness of steel at the discharge slots is 0.060 in. (1.524 mm) or less,
or if groove(s) (other than impeller sealing bead groove) in cover roof are more than
0.030 in. (0.762 mm) deep.
5. Lift impeller, drive key, and gasket from drive shaft.

c b

19220

a - Impeller
b - Drive Key
c - Gasket

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NON-BIGFOOT GEAR HOUSING

6. Inspect impeller. Replace impeller if any of the following conditions exist:

• Impeller blade(s) are cracked, torn, or worn.
• Impeller is glazed or melted (caused by operation without sufficient water sup-
ply).
• Rubber portion of impeller is not bonded to impeller hub.
7. Remove plate and gasket.
8. Replace plate if groove(s) (other than impeller sealing bead groove) in plate are more
than 0.030 in. (0.762 mm) deep.

a - Plate
b - Gasket
Old Style Base
9. Remove water pump base by lifting gently as shown. Inspect carefully for cracks.

51206

a - Water Pump Base

New Style Base
10. Remove water pump base by lifting gently as shown. Inspect carefully for cracks.

55874

a - Water Pump Base

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 NON-BIGFOOT GEAR HOUSING

11. Remove (and discard) seals, if damaged. Secure the base to a bench top or lightly
clamp base in vise when removing seals.

51205

a - Seals

12. Remove seal and plate if damaged or worn.

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
b

ÉÉÉÉÉÉÉ
a

51268

a - Seal
b - Plate
Bearing Carrier and Propeller Shaft
1. Remove fasteners.

a 51117

a - Fasteners

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NON-BIGFOOT GEAR HOUSING

2. With propeller shaft horizontal, use bearing puller to remove carrier from gear housing.
Remove propeller shaft components as an assembly, taking care not to lose cam follow-
er.

b
e
c a 91-46086A1 Puller Jaws
91–58716 Puller Bolt

d 51116

a - Bearing Carrier
b - Puller Jaws (91-46086A1)
c - Puller Bolt (91-85716)
d - Thrust Hub
e - Propeller Shaft

3. Replace reverse gear if gear teeth or clutch teeth on reverse gear are chipped or worn.
If reverse gear must be replaced, pinion and sliding clutch should also be inspected for
damage.
4. If reverse gear bearing is rusted or does not roll freely, replace bearing. Remove bearing
and reverse gear using bearing puller.

a
91-27780

a - Bearing Puller (91-27780)

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5. Remove ball bearing from reverse gear using Universal Puller Plate and mandrel.

a
d

91-37312 91-37241
b c
51269

a - Ball Bearing
b - Reverse Gear
c - Universal Puller Plate (91-37241)
d - Driver Head (91-37312)

6. If bearing is rusted or does not roll freely, replace bearing. Remove bearing and oil seals.
Discard oil seals.

91-37323
a

b 91-37312

a - Driver Rod (91-37323)

b - Driver Head (91-37312)
c - Propeller Shaft Needle Bearing
d - Oil Seals (2)

7. Remove propeller shaft seals and bearing carrier O-ring.

51263
a - O-ring

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NON-BIGFOOT GEAR HOUSING

Propeller Shaft Disassembly

1. Remove spring. Push out cross pin.

d
b

c
a

a - Spring
b - Cam Follower
c - Apply Pressure as Shown
d - Punch
e - Cross Pin

2. Replace cam follower if worn or pitted on either end.

3. Replace sliding clutch if jaws are rounded or chipped. Rounded jaws indicate the follow-
ing:
• Improper shift cable adjustment.
• Engine idle speed too high while shifting.
• Shifting too slowly.

a e c

b
d 51265

a - Cam Follower
b - Guide Block
c - Spring
d - Sliding Clutch
e - Jaws

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 NON-BIGFOOT GEAR HOUSING

4. Check bearing surfaces of propeller shaft. If shaft is worn/pitted, replace shaft and corre-
sponding bearing.
5. Replace propeller shaft if:
a. Splines are twisted or worn.
b. Bearing surfaces of propeller shaft are pitted or worn.
c. Oil seal surface is grooved in excess of 0.005 in. (0.12mm).
d. Shaft has a noticeable “wobble” or is bent more than 0.006 in. (.152 mm). Check with
a dial indicator and V-blocks.

c b

51139

a
a - V-Blocks
b - Bearing Surfaces
c - Check with Dial Indicator Here

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NON-BIGFOOT GEAR HOUSING

Pinion Gear, Driveshaft and Forward Gear

1. Hold driveshaft using Driveshaft Holding Tool. Remove (and discard) pinion nut.

Model Drive Shaft Holding Tool

40/50/60 (4-Stroke) 91-877840A1
55/60 Bigfoot (2–Stroke) 91-817070

2. Remove driveshaft, pinion gear, and forward gear.

3. Replace pinion gear if chipped or worn.
4. Replace lower driveshaft bearing if rusted or damaged; or does not roll freely. To re-
move, refer to “Lower Driveshaft Bearing”, following.
5. Replace forward gear if gear teeth are chipped or worn.

e
a d

a - Pinion Nut
b - Driveshaft
c - Pinion Gear
d - Bearing
e - Forward Gear
6. Replace forward gear needle bearing if rusted or does not roll freely after cleaning in
solvent. Remove as shown.

a - Needle Bearing

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 NON-BIGFOOT GEAR HOUSING

7. Replace forward gear tapered roller bearing and race if either bearing or race are rusted
or damaged; or if bearing does not roll freely after cleaning in solvent. Remove bearing
from gear using Universal Puller Plate and Mandrel. To remove race, refer to “Forward
Gear Bearing Race”, following.

a c

91-37241
b
51119

a - Bearing/Race
b - Puller Plate (91-37241)
c - Mandrel

Upper Driveshaft Bearing

1. Replace bearing and race if either bearing or race are rusted or damaged; or if bearing
does not roll freely after cleaning in solvent.

51271
a - Bearing

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NON-BIGFOOT GEAR HOUSING

Lower Driveshaft Bearing

1. Remove lower driveshaft bearing using tool (91-817058A1) with bushing installed.

c
a

91-817058A1

51260

a - Bearing
b - Removal Tool (91-817058A1)
c - Bushing

Forward Gear Bearing Race

IMPORTANT: Retain shim(s) for re-assembly.
1. Remove race and shim(s) using bearing puller.

91-27780
c b
a
a - Race
b - Shim(s)
c - Bearing Puller (91-27780)

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 NON-BIGFOOT GEAR HOUSING

Shift Shaft
1. Remove shift shaft coupler and spacer.

51271

a - Coupler
b - Spacer

2. Remove shift shaft bushing and shift shaft. Protect shift shaft to prevent spline damage.

51205

a - Shift Shaft Bushing

b - Shift Shaft

3. Remove shift shaft cam, replace if worn.

51117

a - Shift Shaft Cam (55/60 2–Stroke shown)

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NON-BIGFOOT GEAR HOUSING

NOTE: Remove any burrs or sharp edges on the shift shaft splines before removing the shift
shaft bushing.
4. Remove shift shaft bushing and “E” clip from shift shaft. Replace shift shaft if splines are
twisted or damaged on either end of shaft. Remove (and discard) O-ring if damaged.
d
b c
a

51264

a - Shift Shaft Bushing

b - “E” Clip
c - Shift Shaft
d - O-ring
5. Remove (and discard) seal if damaged.

51265
a - Seal

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 NON-BIGFOOT GEAR HOUSING

Gear Housing Reassembly

Shift Shaft
1. Apply Loctite 271 on O.D. of new seal. Install with seal lip up, as shown.
2. Press seal into shift shaft bushing until seal bottoms. Use a suitable tool.
3. Apply 2-4-C w/Teflon on O-ring and I.D. of seal.

95

a
7

51270
7 Loctite 271 (92-809820)
95 2-4-C With Teflon (92-825407A12)

a - Seal Lips Facing Up

b - Shift Shaft Bushing
c - Tool
4. Assemble components.
95 d
b
c
a

51264
95 2-4-C With Teflon (92-825407A12)
a - Shift Shaft
b - “E” Clip
c - Bushing
d - O-ring

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NON-BIGFOOT GEAR HOUSING

5. Install shift cam; align hole in shift cam with shift shaft pilot bore.

a a

b c
51117

a - Shift Shaft Pilot Bore

b - Shift Cam numbers up (2–Stroke)
c - Shift Shaft numbers down (4–Stroke)
6. Install shift shaft assembly; insert splines into shift cam.

51268

a - Shift Shaft Assembly

Propeller Shaft
1. Install components. Clutch should be installed with long end (non-ratcheting) toward
propshaft reverse shoulder.
d c a

95 e
b
95 2-4-C w/Teflon (92-850736A1)
a - Spring
b - Clutch (Align Hole with Slot in Prop Shaft)
c - Guide Block
d - Cam Follower (Hold in Place with 2-4-C w/Teflon)
e - Propshaft Shoulder

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 NON-BIGFOOT GEAR HOUSING

2. Install cross pin.

b
a 51268

a - Cross Pin
b - Cam Follower
c - Apply Pressure in This Direction

3. Install spring.
NOTE: Spring windings must lay flat in clutch groove. DO NOT allow spring coils to overlap
each other.
a

51265

a - Spring

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NON-BIGFOOT GEAR HOUSING

Forward Gear Bearing Race

1. Place shim(s), retained from disassembly, into housing. If shim(s) were lost or damaged,
or a new gearcase is being assembled, start with a .010 in. (.254mm) shim.
2. Drive bearing race into housing. Use a lead hammer to avoid damage to propshaft.

d c a
b 4

91-817009 51265

4 Needle Bearing Assy. Lub. (92-825265A1)

a - Shim(s)
b - Driver Cup (91-817009)
c - Propeller Shaft
d - Assembled Bearing Carrier

Bearing Carrier
1. Lubricate O.D. of needle bearing with 2-4-C w/Teflon.
2. Install needle bearing.
Installation Note: Push against numbered end of bearing.

b
a

91-817011

95

51269

95 2-4-C With Teflon (92-825407A12)

a - Needle Bearing
b - Installer (91-817011)

Page 6A-28 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

3. Apply Loctite 271 on O.D. of small diameter oil seal. Seal lip should face away from
shoulder on Installation Tool. Press seal in until Installer Tool bottoms out.

7 a
91-817007

58209
7 Loctite “271” (92-809819)
a - Small Diameter Seal
b - Installer Tool (91-817007)

4. Apply Loctite 271 on O.D. of larger diameter oil seal. Seal lip should face towards shoul-
der on installation tool. Press in until Installer tool bottoms out.

7
a 91-817007

51263
7 Loctite “271” (92-809819)
a - Large Diameter Seal
b - Installer Tool (91-817007)

90-883065 APRIL 2001 Page 6A-29

NON-BIGFOOT GEAR HOUSING

Installation Note: If service tools are not available, the following reference dimensions ap-
ply for installing bearing and seals to proper depths.
.82 in. (20mm)

a
51275

a - Bearing

.44 in. (11mm)

.04 in. (1mm)

b
a

51275

a - Oil Seal (Install with Lip Down)

b - Oil Seal (Install With Lip Up)

Page 6A-30 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

Reverse Gear
1. Lubricate I.D. of bearing with 2-4-C w/Teflon. Use suitable mandrel and press onto gear
until bearing bottoms.

b
a

95

51205
95 2-4-C With Teflon (92-825407A12)

a - Bearing
b - Suitable Mandrel

2. Lubricate O.D. of bearing with 2-4-c w/Teflon. Use suitable mandrel and press reverse
gear/bearing assembly into bearing carrier until bearing bottoms out.

c
95

51264
95 2-4-C With Teflon (92-825407A12)
a - Reverse Gear and Bearing Assembly
b - Suitable Mandrel
c - Bearing Carrier

90-883065 APRIL 2001 Page 6A-31

NON-BIGFOOT GEAR HOUSING

Forward Gear
1. Lubricate O.D. of bearing with 2-4-C w/Teflon. Press new propshaft bearing into gear
until Installer Tool bottoms.
Installation Note: Push against numbered end of bearing.
91-817005

95

95 2-4-C With Teflon (92-825407A12) 51291

a - Installer Tool (91-817005)

2. Lubricate I.D. of bearing with 2-4-C w/Teflon. Use suitable mandrel and press tapered
roller bearing onto gear until bearing bottoms on gear.

b
95
a

51272

95 2-4-C With Teflon (92-825407A12)

a - Bearing (Lubricate I.D. Before Assembly)
b - Suitable Mandrel

Page 6A-32 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

Lower Driveshaft Bearing Installation

1. Lubricate O.D. of bearing with 2-4-C w/Teflon.
2. Install bearing into housing. Press until Installer Tool bottoms out.
Installation Note: Push against numbered end of bearing.

7.05 in.
7.07 in. ( )
179.0mm
179.5mm
b

95

c
91-817058A1

51260
95 2-4-C With Teflon (92-825407A12)
a - Needle Bearing (Lubricate O.D. Before Assembly)
b - Bearing Installer Tool (91-817058A1)
c - Reference (Bearing Depth)

90-883065 APRIL 2001 Page 6A-33

NON-BIGFOOT GEAR HOUSING

Upper Driveshaft Bearing Installation

1. Lubricate I.D. of bearing with 2-4-C w/Teflon. Using suitable mandrel press upper drive-
shaft bearing onto driveshaft until bearing contacts driveshaft shoulder.

95 a

51268
95 2-4-C With Teflon (92-825407A12)

a - Upper Driveshaft Bearing (Lubricate I.D. Before Assembly)

Page 6A-34 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and
Driveshaft Installation
NOTE: If shim(s) were lost or are not reusable (damaged), start with approximately .015 in.
(0.361mm).
Install components in sequence shown.

g
91-43506
e

f
b
g a

51263

ASSEMBLY SEQUENCE
a - Forward Gear/Bearing: Apply Premium Blend Gear Lube to Bearing Rollers Be-
fore Installation
b - Pinion Gear
c - Driveshaft
d - Upper Driveshaft Bearing Race and Shim(s)
e - Upper Driveshaft Bearing Retainer. Tighten to Specified Torque using Tool
(91-43506)
f - Driveshaft Holding Tool
g - Pinion Nut (New) (See Note at “Pinion Gear Depth”, Following.) Recess in Nut
is Installed Toward Pinion Gear (See Inset).
Model Drive Shaft Holding Tool
40/50/60 (4-Stroke) 91-877840A1
55/60 (2-Stroke) 91-817070

Upper Driveshaft Bearing Retainer Torque

75 lb-ft (101.7 Nm)

90-883065 APRIL 2001 Page 6A-35

NON-BIGFOOT GEAR HOUSING

Pinion Gear Location and Forward Gear Backlash

DETERMINING PINION GEAR LOCATION
NOTE: Read entire procedure before attempting any change in shim thickness.
IMPORTANT: Forward gear assembly pilots the end of the pinion gage and must be
installed in gear housing when checking pinion gear depth. Without it an inaccurate
measurement will be obtained.
1. Clean the gear housing bearing carrier shoulder and diameter.
2. Position gear housing upright (driveshaft vertical). Install Bearing Preload Tool
(91–14311A2) in sequence shown.

h
3/4 in. (19mm) I.D.

i i

g
f
e

51270

INSTALLATION SEQUENCE: Bearing Preload Tool (91–14311A2)

a - Plate
b - Adaptor: Bearing surfaces clean and free of nicks
c - Thrust Bearing: Oiled and able to move freely
d - Thrust Washer: Clean and free of nicks and bends
e - Spring
f - Nut: Threaded all the way onto bolt
g - Bolt: Held snug against spring
h - Sleeve: Holes in sleeve must align with set screws
i - Set Screw (2): Tighten against drive shaft, bolt should not slide on driveshaft

Page 6A-36 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

3. Measure distance between top of nut and bottom of bolt head.

4. Increase distance by 1 in. (25.4mm).
5. Rotate driveshaft 10 revolutions. This properly seats upper driveshaft tapered roller
bearing.

c
a

19884

a - Distance, 1 in. (25.4 mm)

b - Nut
c - Bolt

6. Insert Pinion Location Tool. Position access hole as shown. Insert feeler gauge between
gauging surface and pinion gear.
a b c d

91-817008A2

51265

a - Pinion Location Tool (91-817008A2)

b - Access Hole
c - Gauging Surface
d - Pinion Gear

90-883065 APRIL 2001 Page 6A-37

NON-BIGFOOT GEAR HOUSING

7. The correct clearance between the gauging surface and the pinion gear is .025 in.
(0.64mm).
8. If clearance is more than .025 in. (0.64mm) remove shims from under the upper bearing
cup. If clearance is less than 0.25 in., add shims under the upper bearing race.
9. After final adjustment to pinion height, and forward gear backlash has been estab-
lished, apply Loctite 271 to threads and torque new pinion nut to specified torque.
NOTE: Clean driveshaft and pinion nut threads with Loctite Primer of suitable de-greaser
before applying Loctite.

51285

51263
7 Loctite “271” (92-809819)
a - Bearing Race
b - Shim(s)
c - Pinion Nut (Recessed Side Toward Pinion)
Pinion Nut Torque
50 lb-ft (67 Nm)

Page 6A-38 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

Determining Forward Gear Backlash

NOTE: Read entire procedure before attempting any change in shim thickness.
1. Obtain correct pinion gear location; refer to “Determining Pinion Gear Location”, preced-
ing.
2. Install Bearing Preload Tool on driveshaft; refer to “Determining Pinion Gear Location”,
preceding.
3. Install components as shown.
4. While holding the driveshaft, torque the puller bolt to 45 in-lb.
5. Rotate driveshaft 5-10 revolutions. This should properly seat the forward gear tapered
roller bearing. Repeat step 4.

91-46086A1 Puller Jaws

91–58716 Puller Bolt
d a b

51119

c
a - Propeller Shaft*
b - Bearing Carrier* (Assembled)
c - Puller Jaws (91-46086A1)
d - Puller Bolt (91-58716)
Puller Bolt Torque
45 lb-in. (5.1 Nm)

• *Refer to “Bearing Carrier and Propeller Shaft Installation”, following.

90-883065 APRIL 2001 Page 6A-39

NON-BIGFOOT GEAR HOUSING

6. Install components as shown.

e f

d c

91–83155 Dial Indicator Adapter Kit

a

91–58222A1 Dial Indicator

91–19660–1 Backlask Indicator

b c
51117
a - Threaded Rod (Obtain Locally) d - Dial Indicator Adaptor Kit (91-83155)
b - Washers e - Dial Indicator (91-58222A1)
c - Nuts f - Backlash Indicator Tool (91-19660-1)
7. Position Dial Indicator on appropriate line (from chart) marked on Backlash Indicator
Tool.
BACKLASH ALIGN POINTER OF DIAL INDI-
MODEL INDICATOR TOOL CATOR WITH MARK
40/50/60 (4-Stroke) 91-19660-1 4 OR 0.366 in. (9.3 mm)
55/60 (2-Stroke) 91-19660-1 3

8. Turn driveshaft back-and-forth (check for no rotation at the propeller shaft).

9. Dial Indicator registers amount of backlash, which must be between specifications
shown in chart.
MODEL DIAL INDICATOR MINIMUM DIAL INDICATOR MAXIMUM
40/50/60 (4-Stroke) 0.011 in. (0.28 mm) 0.017 in. (.43 mm)
55/60 (2-Stroke) 0.013 in. (0.33 mm) 0.019 in. (.48 mm)

10. If backlash is less than the minimum reading, remove shim(s) from in front of the forward
gear bearing race. If backlash is more than the maximum reading, add shim(s) in front
of the forward gear bearing race. When final measurement has been made, apply Loc-
tite 271 to threads of pinion nut.
NOTE: By adding or subtracting .001 in. (0.025mm) shim, the backlash will change 0.001
in. (0.032mm).

Page 6A-40 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

Bearing Carrier and Propeller Shaft Installation

1. Lubricate O-ring, bearing carrier and related gearcase housing bores, in areas shown,
with Quicksilver 2-4-C w/Teflon.
2. Insert propeller shaft assembly into bearing carrier.
3. Install bearing carrier and propeller shaft assembly into gear housing. Use care not to
displace cam follower.

a b
95 51271

95 2-4-C w/Teflon (92-850736A1)

a - O-ring
b - Cam Follower
4. Discard the thin 0.063 in. (1.60 mm) flat washers and the 25 mm long bolts on models
listed. Install thicker flat washers and longer bolts.
55/60 (3 Cylinder - 2 Stroke) Non Big Foot
USA 0G662097 and below
Belgium NA

a
b

a - Bolt 25 mm Long - Discard

b - Thin Flat Washer 0.063 in. (1.60 mm) thick - Discard

5. Install thicker flat washers and longer bolts.

a
b

a - Bolt (10-855940-30) 1.18 in. (30 mm) Long

b - Washer (12-855941) 0.090 in. (2.29 mm)

90-883065 APRIL 2001 Page 6A-41

NON-BIGFOOT GEAR HOUSING

6. Torque bolts to specified torque.

51117
7
7 Loctite “271” (92-809819)
a - Bolts (2) M8x30
Bearing Carrier Bolt Torque
225 lb-in. / 18.8 lb-ft. (25.5 Nm)

Water Pump Re-Assembly and Installation

1. Place seal on longer shoulder side of tool. Seal spring should face the shoulder of the
tool during installation. Apply Loctite 271 to O.D. of seal.
2. Press into water pump base until tool bottoms.

7
91-817006
a

55876
7 Loctite 271 (92-809820)

a - Seal
b - Seal Installation Tool (91-817006)

Page 6A-42 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

3. Place seal on shorter shoulder side of tool. Seal spring should face the shoulder of the
tool during installation. Apply Loctite 271 to O.D. of seal.
4. Press into water pump base until tool bottoms.

b 91-817006
a

55877

7 Loctite 271 (92-809820)

a - Seal
b - Shorter Side of Tool
c - Seal Installation Tool (91-817006)
NOTE: If installation tool is not available, press seals in as shown to depths indicated.

0.04 in. (1.02 mm)

a

55878

a - Seal (Install with spring visible when installed.)

b - Seal (Install with spring visible when installed.)
c - Seal Bottom

90-883065 APRIL 2001 Page 6A-43

NON-BIGFOOT GEAR HOUSING

5. Install O-ring. Apply Quicksilver 2-4-C w/Teflon to o-ring,seal lips and gear housing bore.
6. Install water pump base into gear case.

95

55879
95 2-4-C w/Teflon (92-850736A1)

a - O-ring
b - Water Pump Base
c - Gear Case
7. If removed previously, re-install seal and filler plate.

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
b

a
ÉÉÉÉÉÉÉ

51268

a - Seal
b - Filler Plate

Page 6A-44 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

8. Install gasket and face plate.

51293

a - Gasket
b - Face Plate

IMPORTANT: If the old impeller is re-used, install in the original (clockwise) direction
of rotation.
9. Install drive key and impeller.

51292

a - Drive Key
b - Impeller
10. Lubricate I.D. of cover with Quicksilver 2-4-C w/Teflon. Install gasket with bead facing up.

95
b
a

51290

95 2-4-C With Teflon (92-825407A12)

a - Gasket
b - Bead Toward Cover

90-883065 APRIL 2001 Page 6A-45

NON-BIGFOOT GEAR HOUSING

11. Rotate driveshaft clockwise and push water pump housing down.

12. Apply Loctite 271 on threads and tighten screws to specified torque (in sequence
shown).

c d
d d
c

b b c 51275

a - Water Pump Housing Assembly

b - Isolators, (Design 1) Note: 2 isolators for forward screws are different from
remaining 4 isolators
c - Washers (6)
d - Screw (6) M6x16

NOTE: Torque cover screws as shown.

1 3

4 2

51271

Cover Screw Torque

60 lb-in. (6.8 Nm)

Page 6A-46 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

13. If water tube seal stayed on water tube (in driveshaft housing), pull seal from water tube.
14. Lubricate I.D. of water tube seal with Quicksilver 2-4-C w/Teflon and install.

51206

a - Water Tube Seal

Gear Housing Pressure Test

1. Remove vent plug and install pressure test gauge. Tighten securely.

2. Pressurize housing to 10-12 PSI (69-83 kPa) and observe gauge for 5 minutes.
3. Rotate driveshaft, prop shaft and move shift rod while housing is pressurized to check
for leaks.

4. If pressure drop is noted, immerse housing in water.

5. Re-pressurize to 10-12 PSI (69-83 kPa) and check for air bubbles.
6. Replace leaking seals as necessary. Retest housing.
NOTE: Gearcase assembly should hold 10-12 PSI (69-83 kPa) for 5 minutes.
7. Remove tester from housing. Install vent plug and new sealing washers.

90-883065 APRIL 2001 Page 6A-47

NON-BIGFOOT GEAR HOUSING

Gear Housing Installation

WARNING
Disconnect (and isolate) spark plug leads before installing gear housing onto drive-
shaft housing.
1. Position shift linkage into forward gear position.
Remote Control Model Shown

b
a

c
a - Shift Lever 40/50/60 EFI (4-Stroke)
b - Shift Lever 40/50/60 Carb (4-Stroke)
c - Shift Lever 60 Carb (2-Stroke)
2. Tilt engine to full “Up” position. Engage tilt lock lever.
3. Shift gear housing into neutral. Propeller shaft will rotate freely in either direction.
4. Install water tube seal, spacer and shift shaft coupler.
95

a c

51206
95 2-4-C w/Teflon (92-850736A1)
a - Water Tube Seal
b - Spacer
c - Shift Shaft Coupler

Page 6A-48 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

CAUTION
Do not lubricate top of driveshaft. Excess lubricant will not allow driveshaft to fully
engage crankshaft. Tightening the gear housing fasteners (if excess lubricant is on
top of driveshaft) will load the driveshaft/crankshaft and may damage either or both
powerhead and gear housing. Wipe the top of driveshaft free of lubricant.
5. Lightly apply Quicksilver 2-4-C w/Teflon onto the driveshaft splines.
6. Shift gear housing into forward gear. Gear housing will not engage when propeller shaft
is turned clockwise.
7. Position driveshaft into driveshaft housing. Move gear housing towards driveshaft hous-
ing while aligning shift shaft coupler, water tube seal and driveshaft splines.
NOTE: If the driveshaft splines will not align with the crankshaft splines, install a propeller
and turn the propeller shaft counterclockwise while pushing gear housing onto driveshaft
housing. It may also be necessary to move the shift block (on the powerhead) to align the
shift shaft splines for proper re-assembly.
8. Install 4 bolts and washers, (two each side). Apply Loctite 271 on bottom half of bolt
threads prior to installation.
9. Install locknut and washer.
10. Torque bolts and locknut to specified torque.

7 a
b

50551

7 Loctite “271” (92-809819)

a - Bolts and Washers (4) M10x45
b - Locknut and Washer
Bolts and Locknut Torque
40 lb-ft (54 Nm)

11. Check shift operation.

a. Propeller shaft will not rotate in counterclockwise direction when in forward gear.
Clutch will ratchet (clicking noise) when rotated clockwise.
b. Propeller shaft will rotate freely in either direction when gearcase is in neutral.
c. Propeller shaft will not rotate in either direction when gearcase is in reverse.
IMPORTANT: If shift operation is not as described, remove the gear housing and cor-
rect the shift operation.

90-883065 APRIL 2001 Page 6A-49

NON-BIGFOOT GEAR HOUSING

Filling Gear Housing with Lubricant

NOTE: Gear housing lubricant capacity is approximately 11.5 fl. oz. (340 ml).

WARNING
If gear housing is installed on outboard, disconnect (and isolate) spark plug leads
from spark plugs before working near the propeller.
CAUTION
Do not use automotive grease in the gear housing. Use only Quicksilver Gear Lube.
1. Remove any gasket material from “Fill/Drain” and “Vent” plugs and gear housing. Install
new sealing washers on “Fill/Drain” and “Vent” plugs.
IMPORTANT: Never add lubricant without removing “Vent” plugs. Gear housing can-
not be filled because of trapped air. Fill gear housing when driveshaft is in a vertical
position.
2. Remove “Fill/Drain” plug and sealing washer.
3. Insert lubricant tube in “Fill/Drain” hole, then remove “Vent” plugs and sealing washer.
4. Fill until excess lubricant flows out of left “Vent” hole.
5. Replace left “Vent” plug and sealing washer and continue to fill until lubricant flows from
right “Vent” hole.
6. Replace right “Vent” plug and sealing washer.
7. Install “Fill/Drain” plug and sealing washer.
8. Torque screws to specified torque.

b
c

50558
a
a - “Fill/Drain” Plug
b - “Vent” Plug
c - “Vent” Plug
Screw Torque
58 lb-in. (6.5 Nm)

Page 6A-50 90-883065 APRIL 2001

 NON-BIGFOOT GEAR HOUSING

Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is made of a special alloy to aid in protecting the drive shaft
housing and gear housing from galvanic corrosion (corrosion and pitting of metal
surfaces). Do not paint or place protective coating on the trim tab, or trim tab corro-
sion protection function will be lost.
1. Replace trim tab if 50% (or more) corroded. Mark location of old trim tab on anti-ventila-
tion plate before removal; install new trim tab in same location.
2. The trim tab will offset (balance) some of the “steering load” that is caused by “propeller
torque” at higher speeds. If at higher speeds the boat turns more easily to the left, loosen
screw, move the trim tab (trailing edge) to the left (when viewed from behind); re-tighten
screw. Turn trim tab (trailing edge) to the right if the boat turns more easily to the right.

a
c

50553

a - Trim Tab
b - Anti-Ventilation Plate
c - Retaining Screw (M10x30) and Washer
Retaining Screw Torque
22 lb-ft (29.8 Nm)

90-883065 APRIL 2001 Page 6A-51