Mariner Mercury 105/140 JET, Service Manual

Page: 547 / 797

90-824052R3 JUNE 2002 LOWER UNIT - 6A-51
2. On PRODUCTION MODEL GEAR CASES,
position sliding clutch onto propeller shaft with
GROOVED RINGS (ON SLIDING CLUTCH)
TOWARD PROPELLER END OF PROPELLER
SHAFT. Cross pin hole and detent holes (in
sliding clutch) must line up with cross pin slot and
detent notches on propeller shaft.
IMPORTANT: On high performance gearcases –
CLE, Sport Master and Torque Master – sliding
clutch MUST BE INSTALLED with GROOVED
RINGS FACING FORWARD GEAR or full engage-
ment of reverse gear clutch dogs will not occur.
d
c
b
e
f
51864
a
a - Sliding Clutch
b - Grooved Rings
c - Cross Pin Hole
d - Detent Hole (Behind Finger and Thumb)
e - Detent Notch (One on Each Side)
f - Cross Pin Slot
3. Insert Cross Pin Tool (91-86642) thru sliding
clutch, propeller shaft and actuator rod. (Be sure
that cross pin tool is between compression
springs.)
4. Insert cross pin thru sliding clutch, propeller shaft
and actuator rod, forcing cross pin tool out. Be
sure that flat sides of cross pin are toward
compression springs. Cross pin must be flush on
both ends with sliding clutch.
b
a
51864
a - Cross Pin Tool (91-86642)
b - Cross Pin
NOTE: Pro Max and Super Magnum models use a
slotted cross pin 91-86642-1 and Cross Pin Handle
91-86642-2 to assemble clutch onto propshaft. Turn
handle COUNTERCLOCKWISE to install cross pin.
c
b
a
a
a - Cross Pin
b - Cross Pin Tang
c - Cross Pin Tool 91-86642-2
5. Apply a small amount of 2-4-C w/Teflon Marine
Lubricant on each detent pin. Position a detent
pin in each detent pin hole of sliding clutch with
rounded end of pins toward propeller shaft.
a
b
c
51864
a - Detent Pins
b - Cross Pin
c - Sliding Clutch
6. Install cross pin retaining springs onto sliding
clutch as follows:
IMPORTANT: DO NOT over-stretch retaining
springs
when installing them onto sliding clutch.
a. Installing first spring
(1.) Insert tang end of spring into a detent pin.
(2.) Spirally wrap spring into groove on sliding
clutch.
(3.) Position spring in groove so that straight
end of spring is against the side of groove.
b. Installing second spring
(1.) Insert tang end of spring into the opposite
detent pin that was used in Step a-1.
(2.) Spirally wrap spring into groove on sliding
clutch in the opposite direction that the
first spring was wound.