Mariner Mercury 105/140 JET, Service Manual

Page: 610 / 797

6B-54 - LOWER UNIT 90-824052R3 JUNE 2002
IMPORTANT: Prior to installation of shift shaft,
verify that the round retaining ring and “E” ring
(if equipped) are in position and secure.
51867
a
c
b
d
a - Shift Shaft Bushing
b - Shift Shaft
c - “E” Ring (if equipped)
d - Round Retaining Ring (if equipped)
14. Apply a light coat of 2-4-C w/Teflon to the threads
of the shift shaft bushing.
15. Insert shift shaft down shift shaft hole in gear
housing and into shift cam. It may be necessary
to rotate shift shaft back-and-forth slightly in
order for splines of shift shaft to match up with
splines of shift cam. Thread bushing into position,
but do not tighten down at this time.
16. Verify bearing carrier key way is aligned with gear
housing key way and install bearing carrier key.
17. Place tab washer against bearing carrier.
51885
a
a - Tab Washer
IMPORTANT: Ensure that the “V” shaped tab on
cover nut tab washer locates in the “V” slot of the
bearing carrier.
18. Apply 2-4-C w/Teflon to threads of cover nut and
install cover nut in gear housing. Verify that the
word “OFF” and arrow are visible.
CAUTION
Before torquing bearing carrier cover nut, gear
case should either be mounted in a stand specifi-
cally designed for holding gear cases or bolted to
a driveshaft housing to avoid possible damage to
the gear case.
19. Using Cover Nut Tool (91-61069), torque cover
nut to 210 Ib. ft. (284.5 N·m) for production
models and 250 lb. ft. (339.0 N·m) for high
performance Pro Max and Super Magnum
models.
a
b
51911
a - Cover Nut Tool (91-61069)
b - Cover Nut
20. Bend one lock tab of tab washer into cover nut
(only one will align).