Mercury 200 OptiMax Jet Drive, Service Manual, Page: 378 / 391

Pump Unit
90-8M0050731 MAY 2011 Page 5A-29
4. Support the pump.
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5. Remove the remaining four nuts from the drive housing cover. Remove the drive housing cover and gasket.
a - Nut (4)
b - Gasket
6. Lower the drive housing while sliding the cables out. Place on a bench or suitable workstand for disassembly/repair.
Drive Housing Disassembly and Assembly
Draining and Inspecting Drive Housing Lubricant
1. Position a clean drain pan under the gear housing. Remove the vent screw and the fill/drain screw with gaskets from the gear
housing.
2. Inspect the fill and vent sealing washers for cuts or abrasions. Replace the washers if necessary.
Bottom view
a - Fill/drain screw
b - Vent screws
3. Inspect the gear lubricant for metal particles. Presence of a small amount of fine metal particles resembling powder indicates
normal wear. Presence of larger particles or a large quantity of fine particles, indicates need for gear housing disassembly
and inspection.
4. Note the color of the gear lubricant. White or cream color indicates the presence of water in the lubricant. Check the drain
pan for water separation from the lubricant. Presence of water in the gear lubricant indicates the need for disassembly, and
inspection of oil seals, seal surfaces, O‑rings, and gear housing components.
NOTE: The drive housing should be pressure tested prior to disassembly. Using Leakage Tester FT8950, the gear housing
should hold 69–83 kPa (10–12 psi) of pressure for five minutes without leakage. Failure to hold specified pressure indicates
worn or damaged sealing surfaces or improperly assembled gear housing. The cause of leakage must be corrected before
returning the gear housing assembly into service.
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b
a
45672
a
b