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500 Series Technical Manual - i - October 2009 Konrad MODELS 500 Series STERN DRIVE TECHNICAL MANUAL Part #10-591 Konrad, Inc. 1421 Hanley Road Hudson, WI 54016 USA 715-386-4203 fax 715-386-4219

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  • 500 Series Technical Manual - i - October 2009

    Konrad

    MODELS

    500 Series

    STERN DRIVE TECHNICAL MANUAL

    Part #10-591

    Konrad, Inc. 1421 Hanley Road

    Hudson, WI 54016 USA 715-386-4203

    fax 715-386-4219

  • 500 Series Technical Manual - ii - October 2009

    500 Series Technical Manual

    EDITION 5

    All rights reserved. Reproduction or use, without the express consent of Konrad, Inc. of content in any manner is prohibited. All material in this manual at the time of publication is assumed to be free of omissions or errors. However while every precaution has been taken in the preparation of this mannual, it is possible that errors or incorrect material may have been included. In the effort of continuing product improvement, changes in product design and appearance may be made since the time of this publication. Publication of this manual is intended as a service guide for the 500 Series stern drives and is not in any form a binding contract to liability for damage or injuries caused by improper procedure, errors or omissions. All service done to the product using this manual is done solely at the risk of the consumer or service personnel. Publication of the service manual does not imply approvals from Konrad, Inc. for any warranty or liability work to be done by anyone not authorized by Konrad, Inc. All diagrams, procedures and instructions have been reviewed for accuracy and methods of application. Safe practices and success for service of the product described herein, is contributed to the individual’s skill, accuracy and caution. Konrad, Inc. assumes no responsibility for any damage to property or injury to persons engaging in procedures described within this manual. Persons engaging in any service to the product described herein do so entirely at their own risk Printed in the USA Copyright 2003 Konrad, Inc. Pictures and Technical Data: Randall Sofie Illustrations: David Scott

  • 500 Series Technical Manual - iii - October 2009

    TABLE OF CONTENTS

    Chapter 1 Page GENERAL STERN DRIVE INFORMATION . . . . . . . . . . . 1-1

    Hazard Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Consumer Questions and Concerns . . . . . . . . . . . . . . . 1-4 Weights, 500 Series Stern Drives . . . . . . . . . . . . . . . . . 1-5 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Overall Drive Specifications . . . . . . . . . . . . . . . . . . . . . 1-7 Torque Specifications for Fasteners 520 Gear Ratio Specifications 540 Gear Ratio Specifications 560 Gear Ratio Specifications Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Steering Recommendations . . . . . . . . . . . . . . . . . . . . . . 1-10 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

    Chapter 2 TOOLS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Tool/Gauge Order Form . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

    Chapter 3 520 LOWER GEAR HOUSING ASSEMBLY

    (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . 3-1 Drawing #30-061M Building 520 Lower Gear Housing . . . . . . . . . . . . . . . . 3-3

  • 500 Series Technical Manual - iv - October 2009

    Chapter 4 Page 520 LOWER GEAR HOUSING ASSEMBLY

    (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Drawing #30-007M Building 520 Lower Gear Housing . . . . . . . . . . . . . . . . 4-3

    Chapter 5 DISASSEMBLY OF 520 LOWER GEAR HOUSING . . . 5-1 Tearing Down 520 Lower Gear Housing . . . . . . . . . . . 5-2

    Chapter 6 500 Series UPPER GEAR HOUSING ASSEMBLY . . . . 6-1 Drawing #30-006M Drawing #30-445M Building 500 Series Upper Gear Housing . . . . . . . . . . . 6-3

    Chapter 7 500 Series UPPER GEAR HOUSING DISASSEMBLY. . 7-1 Tearing Down 500 Series Upper Gear Housing . . . . . . . 7-3

  • 500 Series Technical Manual - v - October 2009

    Chapter 8 Page TRANSOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Drawing #30-003M Drawing #30-004M Drawing #30-005M Building Transom Assembly . . . . . . . . . . . . . . . . . . . . . 8-3

    Chapter 9 GIMBAL HOUSING BEARING CARRIER ASSEMBLY . 9-1 Drawing #30-019 Drawing #30-044M Building Gimbal Housing Bearing Carrier . . . . . . . . . . . 9-3

    Chapter 10 TRIM PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Drawing #30-002

    Drawing #30-186 Building Trim Pump Assembly . . . . . . . . . . . . . . . . . . . . 10-3

    Chapter 11 540 LOWER GEAR HOUSING ASSEMBLY (Left Hand) 11-1 Drawing #30-052M Building 540 Lower Gear Housing . . . . . . . . . . . . . . . . . 11-3

  • 500 Series Technical Manual - vi - October 2009

    Chapter 12 Page 540 LOWER GEAR HOUSING ASSEMBLY (Right Hand) 12-1 Drawing #30-047M Building 540 Lower Gear Housing . . . . . . . . . . . . . . . . . 12-3

    Chapter 13 560 LOWER GEAR HOUSING ASSEMBLY . . . . . . . . . . . 13-1 Drawing #30-552M Building 560 Lower Gear Housing . . . . . . . . . . . . . . . . . 13-3

  • 500 Series Technical Manual 1- 1 October 2009

    General Information

    Chapter 1

    General Information

  • 500 Series Technical Manual 1- 2 October 2009

    General Information

    HAZARD SYMBOL!

    This manual has incorporated the use of international HAZARD symbols to alert service personnel when special instructions are required at a specific step or procedure.

    ! CAUTION

    Hazards and practices which have the potential to cause injury to personnel, product or to damage property, will be identified using this marker.

    Attention Manual Users

    This manual has been published by Konrad, Inc. as a guide to mechanics and service personnel for working on the 500 Series stern drives. Konrad assumes that these personnel are familiar with the service of this product, or that of similar products, before attempting any work. Service personnel should possess the recommended training and necessary hand tools before any service is performed. Konrad could not conceivably know of all possible procedures to which service can be performed on this product, or of all the hazards of any particular method. Any person using procedures not recommended by Konrad in this manual, should first completely satisfy oneself that neither they nor the product will be endangered.

  • 500 Series Technical Manual 1- 3 October 2009

    General Information

    ! CAUTION

    Diesel engines contain electrical components that are not external ignition protected. DO NOT USE OR STORE GASOLINE ON BOATS THAT ARE EQUIPPED WITH DIESEL ENGINES, UNLESS PREVENTATIVE MEASURES HAVE BEEN MADE TO EXLUDE GASOLINE VAPORS FROM THE ENGINE COMPARTMENTS. Konrad stern drives have been designed and manufactured to use electrical systems that comply with U.S Coast Guard standards to minimize the risks of fire and explosions. All replacement parts on electrical systems should comply with U.S. Coast Guard regulations to minimize the risk of possible fire or explosion hazards. For safest results, use only Konrad suggested replacement parts, or those approved by the U.S. Coast Guard. Extreme care in installation should be observed, so that all electrical components are properly installed and tightened to reduce the risk of spark and the ignition of vapors.

  • 500 Series Technical Manual 1- 4 October 2009

    General Information

    Consumer Questions and Concerns

    contact:

    Konrad, Inc. 1421 Hanley Road

    Hudson, Wisconsin 54016-9376 USA

    Factory 1-715-386-4203 FAX 1-715-386-4219 Sales 1-800-927-3545

    E-mail [email protected] Website http://www.konradmarine.com

    Made with pride in the USA

  • 500 Series Technical Manual 1- 5 October 2009

    General Information

    Weights

    520 Stern Drive Item Description 520 Weight

    Trim cylinders with anchor pins 26 lbs 11.8 kg Trim pump 13 lbs 5.9 kg Upper housing assembly 100 lbs 45.4 kg Lower housing assembly 88 lbs 39.9 kg Transom assembly (with inner transom plate) 88 lbs 39.9 kg Total Dry Weight 315 lbs 142.9 kg

    540 Stern Drive Item Description 540 Weight

    Trim cylinders with anchor pins 26 lbs 11.8 kg Trim pump 13 lbs 5.9 kg Upper housing assembly 100 lbs 45.4 kg Lower housing assembly 53 lbs 24.0 kg Transom assembly (with inner transom plate) 88 lbs 39.9 kg Total Dry Weight 280 lbs 127.0 kg

    560 Stern Drive Item Description 560 Weight

    Trim cylinders with anchor pins 26 lbs 11.8 kg Trim pump 13 lbs 5.9 kg Upper housing assembly 100 lbs 45.4 kg Lower housing assembly 67 lbs 30.4 kg Transom assembly (with inner transom plate) 88 lbs 39.9 kg Total Dry Weight 294 lbs 133.4 kg

  • 500 Series Technical Manual 1- 6 October 2009

    General Information

    Safety Precautions

    ! CAUTION

    Read and understand all safety precautions and warnings before performing any repairs. This list contains the general safety precautions that must be followed to provide personal safety. Additional safety precautions are included within the procedures where applicable.

    • Make sure that work area surrounding the product is safe. Be aware of hazards and dangerous conditions that may exist.

    • Always wear protective eye and footwear while working.

    • Avoid wearing loose-fitting and torn clothing that may become caught in

    machinery or moving parts. • Use hoist or other proper lift assistance whenever necessary. Always verify the

    condition and capacity of the equipment to perform the task. Never risk personal injury by attempting to lift alone.

    • Do not use lifting jacks or hoists as the only support when working on the

    product. Always use the appropriate stands and blocks when servicing the product and it’s components.

    • Only use the appropriate tools in good condition and be familiar with their correct

    usage before attempting any service to the product.

    • Always use the correct fasteners and replacement parts when performing repairs and service. Never use lesser quality or used replacement parts when new parts are required.

  • 500 Series Technical Manual 1- 7 October 2009

    General Information

    Overall Drive Specifications Listed below are the torque specifications for those fasteners that have a specified torque value. Securely tighten all other fasteners.

    Torque Specifications for Fasteners

    520 Gear Ratio Specifications

    Overall Gear Ratio

    Drive Shaft Housing Gear Teeth Number

    (Drive/Driven)

    Gear Housing Gear Teeth Number

    (Drive/Driven) 1.30 : 1 22 / 19 16 / 24 1.43 : 1 22 / 21 16 / 24 1.57 : 1 21 / 22 16 / 24 1.79 : 1 21 / 25 16 / 24 2.00 : 1 24 / 32 16 / 24

    540/560 Gear Ratio Specifications

    Overall Gear Ratio

    Drive Shaft Housing Gear Teeth Number

    (Drive/Driven)

    Gear Housing Gear Teeth Number

    (Drive/Driven) 1.09 : 1 22 / 19 15 / 19 1.21 : 1 22 / 21 15 / 19 1.33 : 1 21 / 22 15 / 19 1.51 : 1 21 / 25 15 / 19 1.69 : 1 24 / 32 15 / 19

    Description Torque Value Drive Shaft Flange to Transmission

    Output Flange Shaft Nuts/Bolts 35 lb-ft (48 Nm)

    Gimbal Housing Stud to Inner Transom Plate Nuts 25-30 lb-ft (34-41 Nm)

    Drive Shaft Housing to Gear Housing Nuts and Bolts 35 lb-ft (48 Nm)

    Power Trim Cylinder to Anchor Pin, Nut

    Tighten until approximately two (2) threads show - Do not over tighten

    Propeller Nut 80 lb-ft (109 Nm) Top Cover Bolts (and Emergency Tiller Arm Bracket if applicable) 20 lb-ft (27 Nm)

    Adapter Plate Bolts and Nuts 35 lb-ft (48 Nm) Stern Drive Unit to Bell Housing

    Attaching Nuts 55 lb-ft (74 Nm)

    Gimbal Carrier Bolts 70 lb-ft (94.9 Nm)

  • 500 Series Technical Manual 1- 8 October 2009

    General Information

    Propeller Installation WARNING: Remote Control must be in NEUTRAL, the engine must be turned off and ignition key removed from switch before removing and/or installing propeller.

    Model 520 Model 540

    Description Qty Part # a Prop shaft (L) OR 1 10-360 Prop shaft (R) 1 10-363 b Forward thrust hub 1 10-292 c Propeller 1 variabled Spline washer 1 10-293 e Tab washer 1 10-295 f Propeller nut 1 10-296

    Description Qty Part # a Prop shaft (L) OR 1 10-677 Prop shaft (R) 1 10-596 b Propeller 1 variablec Prop Hardware Kit 1 10-680 d Propeller Nut 1/0 10-667

  • 500 Series Technical Manual 1- 9 October 2009

    General Information

    Model 560 When using a stainless steel propeller, care must be taken to ensure continuity between the propeller and the propeller shaft, or corrosion of the drive components will occur. Periodic removal of the propeller, a thorough cleaning of all components, and correct lubrication will help maintain good continuity and extend propeller and drive unit life.

    Description Qty Part # a Forward prop shaft 1 12-502 b Forward thrust hub 1 12-509 c Forward propeller 1 variable d Forward prop nut 1 30-554 e Rear prop shaft 1 12-503 f Rear thrust hub 1 12-508 g Rear propeller 1 Variable h Rear prop nut 1 12-529

  • 500 Series Technical Manual 1- 10 October 2009

    General Information

    Steering Recommendations

    Konrad stern drive assemblies do not include steering systems. The boat builder may choose a steering system suitable to the boat application. Internal hydraulic steering is usually used for most sport boat and light commercial applications. The use of an external power steering system works better for heavy commercial, continuous duty or high-speed single or twin-engine applications, and/or boats with unusual handling characteristics. Due to the many variables involved, the final decision on a steering system should be based upon the boat manufacturer’s recommendations, and after thorough testing of the specific boat model. If there is any question whether or not external power steering should be used, Konrad suggests that it be installed. External power steering and hydraulic helm systems can be obtained from many sources. For your convenience, several suppliers are listed here:

    Latham Marine, Inc. Teleflex Canada 280 SW 32nd Court 3831 N 6 Rd Fort Lauderdale, FL 33315 Richmond, BC Canada V6V1P6 954-462-3055 604-270-6899

    Marine Machine, Inc. Warlock Performance Marine 12890 NW 30th Avenue 392 Elizabeth Lane Opa Locka, FL 33054 Corona, CA 92880 305-681-1815 909-371-8247

  • 500 Series Technical Manual 1- 11 October 2009

    General Information

    Maintenance Schedule

    USE SERVICE HOURS OR TIME INTERVAL, WHICHEVER OCCURS FIRST!!

    Location and Service Weekly

    Every 50 Hours or 60 Days

    Every 100 Hours or 120

    Days Every 400

    Hours At Least Once a

    Year Stern Drive Unit Oil

    (Check Level) EVERY DAY

    Stern Drive Unit Oil (Change Break-in Oil) Change the break-in oil after the first 10 hours

    Stern Drive Unit Oil (Change)

    Standard Oil - EVERY 200 HOURS Synthetic Oil - EVERY 400 HOURS

    Transom Assembly and Stern Drive Unit – (Inspect

    for corrosion or impact damage, including propeller)

    X

    X

    X Hoses – (Inspect for cracks, swelling, or other signs of

    deterioration. Check connections for adequate

    tightness)

    X

    X

    Continuity Circuit – (Check components for continuity,

    loose connections, and broken or fraying wires)

    X

    X

    X

    Universal Joints (Grease) Replace Every 200 Hours for Heavy Use Replace Every 1000 Hours for Light Use Universal Joints (Replace) X

    Propeller Shaft and Nut (Lubricate and Tighten) X X X

    Transom Gimbal Housing Assembly Swivel Shaft and

    Gimbal Bushing, (Inspect for Wear)

    X

    X

    X

  • Tools and Gauges

    500 Series Technical Manual 2-1 September 2009

    Chapter 2

    Tools andGauges

  • Tools and Gauges

    500 Series Technical Manual 2-2 September 2009

    TO = Tools Bearing Driver

    Konrad #TO-017

    Tool Description: Installs bearing races into lower drive housings.

    Tool Used In:520 / 540 Lowers

    Bearing Driver

    Konrad #TO-019

    Tool Description: Installs needle bearing into lower bearing carrier.

    Tool Used In:520 Lower

    Bearing DriverKonrad #TO-021

    Tool Description: Used with #T0-022 to install vertical bearing race.

    Tool Used In:520 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-3 September 2009

    Bearing Driver AssemblyKonrad #TO-022

    Tool Description: Used to seat lower bearing race for the vertical shaft in the lower gear housing.

    Tool Used In:520 Lower

    Bearing Driver

    Konrad #TO-023

    Tool Description: Removes bearing races from lower drive housing.

    Tool Used In:520 Lower

    Bearing Driver

    Konrad #TO-025

    Tool Description: Installs bearing races into upper drive shaft housing, 520 LH lower and RH carrier.

    Tool Used In:500 Series Uppers520 LowerGimbal Carrier

  • Tools and Gauges

    500 Series Technical Manual 2-4 September 2009

    Slide Hammer

    Konrad #TO-028

    Tool Description: Used to remove bearing races.

    Tool Used In:500 Series Uppers500 Series Lowers

    Cover Nut Wrench Konrad #TO-029

    Tool Description: Used to install and remove cover nut (10-242) in lower drive housing.

    Tool Used In:520 Lower

    Seal Driver

    Konrad #TO-030

    Tool Description: Used to install grease and water seals.

    Tool Used In:520 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-5 September 2009

    Bearing Driver

    Konrad #TO-031

    Tool Description: Used for installing smaller diameter bearing races and front seal in upper housings.

    Tool Used In:500 Series Uppers

    Universal Puller Plate

    Konrad #TO-032

    Tool Description: Removes bearings in lower and upper drive units.

    Tool Used In:500 Series Uppers500 Series Lowers

    Socket WrenchKonrad #TO-033

    Tool Description: Used for fastening Konrad Lock Nut (10-573) in lower housing and Lock Nut (10-576) in upper housing.

    Tool Used In:500 Series Uppers500 Series Lowers

  • Tools and Gauges

    500 Series Technical Manual 2-6 September 2009

    Spline SocketKonrad #TO-034

    Tool Description: Used on gear shafts for assembly and disassembly.

    Tool Used In:500 Series Uppers500 Series Lowers

    Bearing Puller

    Konrad #TO-035

    Tool Description: General puller used with several Konrad tools.

    Tool Used In:500 Series Uppers500 Series Lowers

    Alignment PlateKonrad #TO-036

    Tool Description: Guides driving rod when installing race into nose of the lower housing.

    Tool Used In:520 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-7 September 2009

    Impact Rod

    Konrad #TO-037

    Tool Description: Installs bearing races.

    Tool Used In:500 Series Uppers500 Series Lowers

    Bearing Driver

    Konrad #TO-040

    Tool Description: Installs top vertical bearing race into lower.

    Tool Used In:540 / 560 Lowers

    Bearing Driver

    Konrad #TO-041

    Tool Description: Used with tool #T0-035 to install bottom vertical bearing race.

    Tool Used In:540 / 560 Lowers

  • Tools and Gauges

    500 Series Technical Manual 2-8 September 2009

    Bearing Driver

    Konrad #TO-042

    Tool Description: Installs bearing races into the bearing carrier of the lower.

    Tool Used In:540 Lower

    Seal DriverKonrad #TO-043

    Tool Description: Installs seals into seal carrier.

    Tool Used In:540 Lower

    Bearing Driver

    Konrad #TO-047 and #TO-047A

    Tool Description: Removes bearing race from the nose of lower.

    Tool Used In:520 Lower

    TO-047

    TO-047-A

  • Tools and Gauges

    500 Series Technical Manual 2-9 September 2009

    Bearing Driver

    Konrad #TO-049

    Tool Description: Removes needle bearing from lower housing.

    Tool Used In:540 / 560 Lowers

    Bearing Driver

    Konrad #TO-050 and #TO-047A

    Tool Description: Used to remove bearing race from nose of lower housing.

    Tool Used In:540 Lower

    Spanner Socket

    Konrad #TO-051

    Tool Description: Installs seal carrier(10-678) into lower housing.

    Tool Used In:540 Lower

    TO-050

    TO-047-A

  • Tools and Gauges

    500 Series Technical Manual 2-10 September 2009

    Cover Nut Wrench

    Konrad #TO-052

    Tool Description: Used to Install and remove cover nut (10-607) in lower housing.

    Tool Used In:540 Lower

    Alignment PlateKonrad #TO-053

    Tool Description: Guides driving rod when installing race into the nose of the lower housing.

    Tool Used In:540 / 560 Lowers

    Spanner Socket

    Konrad #TO-054

    Tool Description: Installs retainer nut (10-613).

    Tool Used In:540 / 560 Lowers

  • Tools and Gauges

    500 Series Technical Manual 2-11 September 2009

    Bearing Driver

    Konrad #TO-057

    Tool Description: Installs bearing over shaft in bearing carrier.

    Tool Used In:Gimbal carrier

    Bushing Driver

    Konrad #TO-059

    Tool Description: Installs upper bushing for steering shaft into transom.

    Tool Used In:Transom assembly

    Bushing DriverKonrad #TO-060

    Tool Description: Installs lower steering shaft bushing into transom.

    Tool Used In:Transom assembly

  • Tools and Gauges

    500 Series Technical Manual 2-12 September 2009

    Bushing Driver Konrad #TO-062

    Tool Description: Installs bushing into gimbal Ring and seal into transom.

    Tool Used In:Gimbal ringTransom assembly

    Seal Aligner

    Konrad #TO-064

    Tool Description: Installs seal to correct height in Gimbal Carrier Driver (10-473).

    Tool Used In:Gimbal carrier

    Torque Wrench Adapter

    Konrad #TO-066

    Tool Description: Used to tighten SHCS (11-190) in the 30-226 Rubber Coupling Driveshaft.

    Tool Used In:Rubber Coupling Driveshaft (30-226)

  • Tools and Gauges

    500 Series Technical Manual 2-13 September 2009

    Torque Wrench Adapter, 7/8”

    Konrad #TO-067

    Tool Description: Used to tighten HHCS (10-486) on the Rubber Coupling Driveshaft(30-226).

    Tool Used In:Rubber Coupling Driveshaft (30-226)

    Torque Wrench Adapter, 22 mm

    Konrad #TO-068

    Tool Description: Used to tighten M16 bolts on the Rubber Coupling Driveshaft(30-226).

    Tool Used In:Rubber Coupling Driveshaft (30-226)

    Bearing Race Driver

    Konrad #TO-070

    Tool Description: Installs bearing race into gimbal carrier.

    Tool Used In:Gimbal carrier

  • Tools and Gauges

    500 Series Technical Manual 2-14 September 2009

    Drive Stand Base Unit

    Konrad #TO-075

    Tool Description: Used to hold the Lower Stand Unit (TO-076) and the Upper Stand Unit (TO-077).

    Tool Used In:500 Series Uppers500 Series Lowers

    Lower Stand

    Konrad #TO-076

    Tool Description: Attaches to the Drive Stand Base Unit (TO-075) and holds the Lower Housing for assembly.

    Tool Used In:500 Series Lowers

    Upper Stand

    Konrad #TO-077

    Tool Description: Attaches to the Drive Stand Base Unit (TO-075) and holds the upper housing for assembly.

    Tool Used In: 500 Series Uppers

  • Tools and Gauges

    500 Series Technical Manual 2-15 September 2009

    Spanner Wrench

    Konrad #TO-079

    Tool Description: Used to install Locking Nut (11-585).

    Tool Used In:Gimbal carrier

    Race Remover

    Konrad #TO-080

    Tool Description: Removes Bearing Race (10-267) from standard upper

    Tool Used In:500 Series Uppers

    Tailpiece Aligner Konrad #TO-094

    Tool Description: Aligns tailpiece unit (30-273).

    Tool Used In:500 Series Sterndrives

    TO-094-A

    TO-047-B

  • Tools and Gauges

    500 Series Technical Manual 2-16 September 2009

    Drive Shaft Aligner

    Konrad #TO-096

    Tool Description: Used for correct alignment of driveshaft.

    Tool Used In:Rubber Coupling Driveshaft (30-226).

    Spanner Wrench

    Konrad #TO-098

    Tool Description: Used to install and remove locknuts (12-033 and 12-034) upper housings.

    Tool Used In:500 Series HD Uppers

    Seal Driver

    Konrad #TO-100

    Tool Description: Used with impact rod (TO-037) to install front seal in HD upper housings.

    Tool Used In:500 Series HD Uppers

  • Tools and Gauges

    500 Series Technical Manual 2-17 September 2009

    Bearing Remover

    Konrad #TO-101

    Tool Description: Removes front bearing race from HD upper housing.

    Tool Used In:500 Series HD Uppers

    Bearing Driver

    Konrad #TO-102

    Tool Description: Used with impact rod (TO-037) to install front bearing race in HD upper housing.

    Tool Used In:500 Series HD Uppers

    Pressure Tester

    Konrad #TO-103

    Tool Description: Used to test pressure in the 500 Series Sterndrives

    Tool Used In:500 Series Sterndrives

  • Tools and Gauges

    500 Series Technical Manual 2-18 September 2009

    Backlash Checker

    Konrad #TO-105

    Tool Description: Used to check the backlash in the X-Factor lower.

    Tool Used In:X-Factor Lower

    Bearing Driver/Remover

    Konrad #TO-107

    Tool Description: Installs and removesneedle bearing #12-522 from carrier #12-510.

    Tool Used In:560 Lower

    Race Driver

    Konrad #TO-109

    Tool Description: Installs bearing race#12-519 into nose of lower housing #12-500.

    Tool Used In:560 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-19 September 2009

    Race Driver/Remover

    Konrad #TO-110Tool Description: Installs and removes bearing race #12-522 from forward propeller shaft #12-502

    Tool Used In:560 Lower

    Bearing Driver

    Konrad #TO-111 and #TO-47A

    Tool Description: Removes bearing race #12-519 from the nose of lower housing #12-500. Use #TO-035 (without hooks) to pull #TO-047A.

    Tool Used In:560 Lower

    Gear Support

    Konrad #TO-112

    Tool Description: Supports gear #12-501 in order to press bearing #12-521 onto hub and not damage gear teeth.

    Tool Used In:560 Lower

    TO-111

    TO-047-A

  • Tools and Gauges

    500 Series Technical Manual 2-20 September 2009

    Bearing Driver

    Konrad #TO-113

    Tool Description: Installs bearing #12-519 onto hub of gear #30-553 and installs bearing #12-521 onto hub of gear #12-501.

    Tool Used In:560 Lower

    Bearing Driver

    Konrad #TO-114

    Tool Description: Installs needle bearing #12-520 into forward propeller shaft #12-502.

    Tool Used In:560 Lower

    Race Driver

    Konrad #TO-115

    Tool Description: Used to press needle bearing race #12-520 onto rear propeller shaft #12-503. Also can be used to press roller bearing race #10-653 onto vertical shaft #12-511.

    Tool Used In:560 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-21 September 2009

    Seal Driver

    Konrad #TO-116

    Tool Description: Used to press seals #12-525 and #12-517 to their correct depths into forward propeller shaft #12-502.

    Tool Used In:560 Lower

    Seal Driver

    Konrad #TO-117

    Tool Description: Used to press seals #12-526 and #12-518 to their correct depths into bearing carrier #12-510.

    Tool Used In:560 Lower

    Spanner Wrench

    Konrad #TO-118

    Tool Description: Installs and removes carrier #12-510 from lower housing #12-500.

    Tool Used In:560 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-22 September 2009

    Spanner Wrench

    Konrad #TO-119

    Tool Description: Installs and removes retaining nut #12-513 from lower housing #12-500.

    Tool Used In:560 Lower

    Prop Nut Wrench

    Konrad #TO-121

    Tool Description: Installs propeller nut #30-554. This will cinch the forward propeller to the thrust hub #12-509 on the forward prop shaft #12-502.

    Tool Used In:560 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-23 September 2009

    GO = Gauges

    Gauge

    Konrad #GO-013

    Tool Description: Used with GO-024 to check gap spacing and gear height in the upper gear housing.

    Tool Used In:500 Series Uppers

    Gauge

    Konrad #GO-014

    Tool Description: Used in upper gear housing to measure gap spacing of gear on horizontal shaft.

    Tool Used In:500 Series Uppers

    Gauge

    Konrad #GO-015

    Tool Description: Used with GO-024 to check gear height and component spacing in lower housing.

    Tool Used In:520 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-24 September 2009

    Indicator Rod

    Konrad #GO-016

    Tool Description: Used to check backlash in lower housing.

    Tool Used In:520 / 540 Lowers

    Dial Indicator

    Konrad #GO-017

    Tool Description: Used to indicate backlash measurement (0.000-1.000 inches at .001 increments).

    Tool Used In:500 Series Upper500 Series Lower

    Gimbal Ring Alignment Gauge

    Konrad #GO-018

    Tool Description: Inserted into upper bearing carrier when adjusting gimbal ring height.

    Tool Used In:Gimbal assemblyTransom assembly

    Gauge

  • Tools and Gauges

    500 Series Technical Manual 2-25 September 2009

    Konrad #GO-020

    Tool Description: Used to check gear height and component spacing in lower housing.

    Tool Used In:540 Lower

    Gauge

    Konrad #GO-024

    Tool Description: Used as a handle on the GO-013 and GO-015.

    Tool Used In:500 Series Uppers520 Lower

    Pinion Height Gauge

    Konrad #GO-025

    Tool Description: Used to check pinion (#11-639) height and component spacing in lower housing (#12-500).

    Tool Used In:560 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-26 September 2009

    Backlash Gauge

    Konrad #GO-026

    Tool Description: Used to check backlash on rear propeller shaft #12-503 between gear #30-553 and pinion #11-639.

    Tool Used In:560 Lower

    Backlash Gauge

    Konrad #GO-027

    Tool Description: Used to check backlash on forward propeller shaft #12-502 between gear #12-501 and pinion #11-639.

    Tool Used In:560 Lower

  • Tools and Gauges

    500 Series Technical Manual 2-27 September 2009

    To the Service Technician:This page has been inserted to provide a list of tools that may be required if the licensed service center has not already purchased a Tool Package. Use the tooling section preceding this page to identify the tool name and part numbers required, then record it on this page. Contact Konrad Marine for tool prices and ordering information. Insert a copy of this page when ordering by mail or fax (715-386-4219).

    Tool/Gauge Order FormTool/Gauge Name Part Number Quantity Price

    Bearing Driver TO-017

    Bearing Driver TO-019Bearing Driver TO-021

    Bearing Driver Assembly TO-022Bearing Driver TO-023Bearing Driver TO-025Slide Hammer TO-028

    Cover Nut Wrench TO-029Seal Driver TO-030

    Bearing Driver TO-031Universal Puller Plate TO-032

    Socket Wrench TO-033Spline Socket TO-034Bearing Puller TO-035

    Alignment Plate TO-036Impact Rod TO-037

    Bearing Driver TO-040

    Bearing Driver TO-041

    Bearing Driver TO-042

    Seal Driver TO-043Bearing Driver TO-047Bearing Driver TO-047ABearing Driver TO-049Bearing Driver TO-050Spanner Socket TO-051

  • Tools and Gauges

    500 Series Technical Manual 2-28 September 2009

    Tool/Gauge Name Part Number Quantity PriceCover Nut Wrench TO-052

    Spanner Socket TO-054

    Spanner Socket TO-054

    Spanner Socket TO-054

    Bearing Driver TO-057

    Bushing Driver TO-059

    Bushing Driver TO-060

    Bushing Driver TO-062Seal Aligner TO-064

    Torque Wrench Adapter TO-066

    Torque Wrench Adapter, 7/8” TO-067

    Torque Wrench Adapter, 22 mm TO-068

    Bearing Race Driver TO-070

    Drive Stand Base Unit TO- 075

    Lower Stand TO-076

    Upper Stand TO-077

    Spanner Wrench TO-079

    Race Remover TO-080

    Rod Alignment Tool TO-094A

    Boss Alignment Tool TO-094B

    Drive Shaft Aligner TO-096

    Spanner Wrench TO-098

    Seal Driver TO-100

    Bearing Remover TO-101

    Bearing Driver TO-102

    Pressure Tester TO-103

    Backlash Checker TO-105

    Bearing Driver/Remover TO-107

  • Tools and Gauges

    500 Series Technical Manual 2-29 September 2009

    Tool/Gauge Name Part Number Quantity PriceRace Driver TO-109

    Race Driver/Remover TO-110

    Bearing Driver TO-111

    Gear Support TO-112

    Bearing Driver TO-113

    Bearing Driver TO-114

    Race Driver TO-115

    Seal Driver TO-116

    Seal Driver TO-117

    Spanner Wrench TO-118

    Spanner Wrench TO-119

    Prop Nut Wrench TO-121

    Gauge GO-013

    Gauge GO-014

    Gauge GO-015

    Indicator Rod GO-016

    Dial Indicator GO-017

    Gimbal Ring Alignment Gauge GO-018Gauge GO-020

    Handle GO-024

    Pinion Height Gauge GO-025

    Backlash Gauge GO-026

    Backlash Gauge GO-027

  • 500 Series Technical Manual 3- 1 October 2003

    520 Lower Gear Housing Assembly (Right Hand)

    Chapter 3

    520 LOWER GEAR

    HOUSING ASSEMBLY

    (Right Hand)

  • 500 Series Technical Manual 3- 2 October 2003

    520 Lower Gear Housing Assembly (Right Hand)

    ! Notice

    To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a 500 Series stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.

  • DATE

    Konrad

    DRAWING NUMBER

    NEXT ASS'Y

    30-061M

    .020

    SYM REVISIONDRAWING NO. 30-061M DR

    DO NOT SCALE DRAWING

    1:2.5

    6/22/0672.89LBSWEIGHT: DATE:

    TITLE:

    TOLERANCE

    MAT'L:

    520 LOWER GEAR HOUSING ASS'Y, R.H.

    DRAWN BY: LH

    .XXX

    SCALE:

    .005

    .XXAPP.BY:

    .010

    .X

    THIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUSTNOT BE USED, REPRODUCED, OR ITSCONTENT DISCLOSED, IN WHOLE OR INPART, WITHOUT PRIOR WRITTEN CONSENTOF KONRAD MARINE.

    25

    5

    12

    11

    44

    4

    3

    5

    238

    40

    7

    5

    6

    10

    9

    8

    32

    42

    31

    30

    1

    43

    31

    34

    33

    35

    41

    39

    36

    37

    45

    15

    14

    13

    16

    17

    18

    19

    20

    21

    22

    23

    24

    26

    29

    27

    28

    3

    45 10-508 SLINGER, OIL 144 30-205 SET, LOCKNUT 143 10-457 WASHER, FLAT 642 10-313 STUD 641 10-334 NUT 140 10-496 STUD 139 10-433 PLATE, INHIBITOR 238 10-432 PLATE, INHIBITOR 137 10-333 NUT 436 10-253 STUD 435 10-461 F.H.C.S. 234 10-155 PLUG, DRAIN, MAGNETIC 133 10-285 WASHER, SEAL 132 10-399 O-RING 131 10-314 NUT 730 10-279 STUD 129 10-293 WASHER, SPLINED 128 10-296 LOCKNUT, NYLON 127 10-295 WASHER, TAB 126 10-292 THRUST HUB 125 10-017 KEY 124 10-242 COVER, NUT 123 10-203 WASHER, TAB 122 10-639 SEAL 121 10-291 SEAL 120 10-394 BEARING, ROLLER 119 10-364 CARRIER, BEARING 118 10-290 O-RING 117 10-499 WASHER, THRUST 116 10-289 LOAD RING 115 10-269 BEARING 114 10-258 GEAR, HORIZONTAL 113 10-363 SHAFT, PROP, RH 112 10-400 O-RING 111 10-397 SLEEVE, ALIGNMENT 110 10-261 PINION, VERTICAL 19 10-358 WASHER, BELLEVILLE 18 10-260 LOCKNUT, STAKE 17 10-557 SPACER, LOWER HSG 16 10-377 PINION BEARING 15 10-288 SET, SHIM 34 10-526 WASHER, TONGUED 13 10-259 BEARING 22 10-200 SHAFT, VERTICAL, BOTTOM 11 10-245 520 LOWER HOUSING 1

    ITEM NO. PART NO. DESCRIPTION QTY.

    *

    *

    402-03 TES RAEG SA DLOS *

    RAEG REWOL DRADNATS A SI SIHT ** ,YSSA MOTSUC A SI SRUOY FI ,YSSA

    OT YROTCAF EHT TCATNOC ESAELP STNENOPMOC TCERROC YFIREV

    LOWERGEARHOUSINGRH ASS’Y

  • 500 Series Technical Manual 3- 3 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-1

    Start to rebuild the lower gear housing (10-245) by first inspecting the casting for any damage or defects. Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities. Best results can be achieved by using compressed air and a dry rag, as demonstrated in figure 3-1.

  • 500 Series Technical Manual 3- 4 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-2

    Onto vertical gear shaft (10-200), slide over bearing (10-259) so that it is orientated as seen in figure 3-2. Once bearing has been installed, place tongued washer (10-526) over top of gear shaft as shown in drawing 3-1 below. Drawing 3-1

    Figure 3-3

    At top of shaft, fasten on first half of lock nut (10-573)*. See figure 3-3.

    * First nut of assembly is placed with chamfered corners face down as shown in drawing 3-2. Drawing 3-2

  • 500 Series Technical Manual 3- 5 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-4 Figure 3-5 Figure 3-6

    To begin assembly, place .020 in (.51 mm) shims (10-288) and bearing race (10-377) into seat at bottom of housing as shown in figures 3-4 through 3-6. Lubricate race with 90w oil for ease of installation. Refer to diagram 3-1 for correct tools and orientation required to install bearing race. Tools required for this procedure are bearing driver (TO-021) and bearing driver assembly (TO-022). Diagram 3-1

    A: Nut (TO-022) B: Locating Disk (TO-022) C: Casting (10-245) D: Drive Screw

    (TO-022) E: Shims (10-288) F: Bearing Race

    (10-377) G: Bearing Driver

    (TO-021) Place tools as seen in diagram and turn nut clockwise to pull bearing race into housing to properly seat bearing race.

    AB

    CD

    EFG

  • 500 Series Technical Manual 3- 6 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-7

    As shown in figure 3-7, lubricate the upper bearing race (10-259) with 90w oil and drive into seat as shown. Use bearing driver (TO-017) and impact rod (TO-037) to ensure that race is installed correctly. Refer to figure 3-8 for correct installation of race.

    Figure 3-8

  • 500 Series Technical Manual 3- 7 October 2003

    520 Lower Gear Housing Assembly (Right Hand)

    Figure 3-9 Through top of gear housing, insert upper bearing and vertical gear shaft assembly so splines and threads are visible as shown in figure 3-9 and 3-10 below. Figure 3-10

    Figure 3-11 While holding shaft in place, rotate gear housing to install lower bearing (10-377) to vertical gear shaft. Splines and threads will show when bearing is pushed on correctly. Refer to figure 3-11 and drawing 3-3 for assistance. Drawing 3-3

  • 500 Series Technical Manual 3- 8 October 2003

    520 Lower Gear Housing Assembly (Right Hand)

    Figure 3-12

    ! CAUTION This procedure may not be the final time that the lock nut is fastened to the vertical shaft. Post procedures may require that shim adjustments be performed to this vertical shaft’s bearing sets. If adjustments are required, then the nut will need to be removed. This lock nut has been designed to be applied safely only ONE TIME, and should never be reused for operation of the drive. It is required that the assembler obtain two lock nuts to rebuild this part of the stern drive. Use one lock nut for all adjustments and the other for final installation once all adjustments have been performed.

    Figure 3-13 As shown in figure 3-12, slide pinion gear (10-261) onto splines at bottom of vertical shaft. Secure gear to shaft with washer (10-358) and lock nut (10-260) as shown in figure 3-13. After all adjustments have been made, at the final installation, apply *Loctite 271 or equivalent to threads of lock nut.

    New Used

    New lock nut will still retain its oval thread hole, while used nut will have been rounded

    . after being applied once.

  • 500 Series Technical Manual 3- 9 October 2003

    520 Lower Gear Housing Assembly (Right Hand)

    Figure 3-14 Double checking that the first part of upper lock nut system has been fastened down hand tight, proceed by placing spline socket (TO-034) over splines as shown in figure 3-14. Over end of spline socket, use an appropriate torque wrench to turn shaft and fasten lock nut (10-260) at bottom to 150 lb-ft (203 Nm) as shown in figure 3-15.

    Figure 3-15

  • 500 Series Technical Manual 3- 10 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-16

    Once the lock nut has been secured to shaft, proceed by measuring rolling torque with gauge as demonstrated in figure 3-16. Rolling torque measurements should range from 10-12 lb-in (1.13-1.36 Nm) when properly set.

    Figure 3-17

    To adjust rolling torque, set tools up as shown in figure 3-17. Use socket wrench (TO-033) over nut and spline socket (TO-034) to tighten or loosen the nut to adjust rolling torque.

  • 500 Series Technical Manual 3- 11 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-18

    Through bottom opening of gear housing, insert gauge (GO-015) to check gap of pinion gear. Refer to figure 3-18 for assistance in set up of measurement. Using a feeler gauge, as shown in figure 3-19, check gap of pinion gear.

    Figure 3-19

    Ideal gap should range from .024-.026 in (.61-.66 mm). If gap needs to be increased, then decrease the amount of shims that are at the bearing race. If gap needs to be decreased, then shims are added. When making these adjustments, the pinion gear and nut will have to be removed in order to access the bearing race. Be sure to reassemble all parts as described in figures 3-12 through 3-18. When rebuilding a drive unit, try to use the exact amount and size of shims that were taken out. This will minimize the amount of adjustments that may need to be made and reduce the number of

    times that the bearing race is removed and replaced.

  • 500 Series Technical Manual 3- 12 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-20 Drawing 3-4

    bearingrace

    shim

    Into the nose cone, place .015 in (.38 mm) shim (10-288) in front of bearing race (10-259) as shown in figures 3-20, 3-21 and drawing 3-4 . Use bearing driver (TO-017), alignment plate (TO-053) and impact rod (TO-037) to correctly install bearing race,

    lubricated with 90w oil, into nose cone.

    Figure 3-21 The diagram 3-2 below illustrates an order of parts that are assembled over the next few steps.

    A: Bearing race (10-394) B: Bearing (10-269) C: Gear (10-258) D: Propeller shaft (10-363) E: Oil slinger (10-508) F: Bearing (10-259)

    Diagram 3-2

    A B C D E F

  • 500 Series Technical Manual 3- 13 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-22

    Press bearing (10-269) onto gear (10-258). Lubricate mating surfaces with 90w gear oil before pressing the two (2) components together. Refer to figure 3-22.

    ! CAUTION

    inner surface

    Figure 3-23

    Figure 3-23 shows bearing pressed correctly on the gear. When assembling gear and bearing cluster, always press components together using the inside ring of the bearing. Never apply force to any other surfaces as damage may result to rollers or retainer on bearing. Use an electric or hydraulic press to properly combine components if available.

  • 500 Series Technical Manual 3- 14 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-24

    Press gear and bearing assembled in previous assembly step onto propeller shaft (10-363). Refer to figure 3-24 for visual description of component orientation on shaft.

    Figure 3-25

    Press gear and bearing onto propeller shaft using hydraulic press as shown in figure 3-25.

    Figure 3-26

    Proper assembly will have gear and bearing seated firmly against ridge on shaft. Refer to figure 3-26 for complete installation of gear and bearing to shaft.

  • 500 Series Technical Manual 3- 15 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-27

    As shown in figure 3-27, press oil slinger (10-508) on propeller shaft until firmly seated against shoulder.

    Figure 3-28

    With oil slinger in place, proceed by pressing on bearing (10-259) as demonstrated in figure 3-28. Lubricate shaft surface before installing bearing.

  • 500 Series Technical Manual 3- 16 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-29

    Press needle bearing race (10-394) over end of propeller shaft so that the two (2) holes shown in figure 3-29 are aligned.

    Drawing 3-5

    ! CAUTION

    To prevent damage and minimize wear, keep holes aligned when installing bearing race. This alignment will ensure that proper oil flow through shaft and bearings is created when shaft is in motion, as shown in drawing 3-5. Do not press race beyond ridge of shaft. Severe risk of metal fatigue and flying debris may result from part shattering.

    Needle Bearing

    Oil Passage WayPropeller Shaft

    Oil Passage Hole

    Bearing Race

  • 500 Series Technical Manual 3- 17 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-30

    Install propeller shaft assembly into lower gear housing as shown in figure 3-30.

    Figure 3-31

    Notice: The next few procedures will demonstrate a complete overhaul of the lower bearing carrier, shown in figure 3-31. If bearings and races in carrier are suitable for reuse, then only follow procedure for replacement of seals. Never reuse carrier seals if grease and water seals have been exposed to more than two hundred (200) hours of operation.

  • 500 Series Technical Manual 3- 18 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-32

    Obtain lower bearing carrier (10-364) and inspect for damage before continuing assembly.

    Figure 3-33

    Using bearing driver (TO-019), install needle bearing (10-394) into carrier as shown in figures 3-33 through 3-35 and drawing 3-6. Apply 90w gear oil to bearing on all surfaces before installing into the carrier.

  • 500 Series Technical Manual 3- 19 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Drawing 3-6 Figure 3-34

    Figure 3-35

  • 500 Series Technical Manual 3- 20 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-36

    Install right hand rotation prop shaft’s bearing race (10-269) into carrier using bearing driver (TO-025) as shown in figure 3-36.

    Figure 3-37

    Proper installation will have the taper of the bearing race facing outward, as shown in figure 3-37.

  • 500 Series Technical Manual 3- 21 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-38

    Using seal driver (TO-030), press seal #1 (10-291) and seal #2 (10-639) into bearing carrier as shown in figure 3-38. To install correctly, slide on two (2) seals at opposite ends of the seal driver. Verify that seals oppose one another while resting on seal driver, and that rubber gaskets rest against circular ridge before installing into carrier. Around outside surface of each seal, apply thin layer of *Loctite 271 or equivalent to lock seal in place. Refer to diagram 3-3 for assistance regarding installation of seals into the bearing carrier.

    Diagram 3-3

    Step #1 Step #2

    Seal Driver

    Carrier

    Press in seal #1 and flip tool over to install seal #2

    TO-030

    10-63910-291

  • 500 Series Technical Manual 3- 22 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-39 Figure 3-40

    Once seals are in place, apply grease to them and slide carrier over propeller shaft as seen in figure 3-39. Place tab washer (10-295) on top of carrier as shown in figure 3-40. Next, apply oil to cover nut (10-242) threads, then fasten into lower gear housing as shown in figure 3-41. Tighten cover nut into lower gear housing using cover nut wrench (TO-029). Tighten nut until all movement (back and forth) of the propeller shaft is eliminated. Figure 3-41 Figure 3-42

  • 500 Series Technical Manual 3- 23 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-43

    Place indicator rod (GO-016) onto top of vertical drive shaft to verify backlash of gears. Set dial indicator (GO-017) perpendicular to indicator rod. Set probe tip of dial indicator on mark (II) of the indicator rod, as shown in figure 3-43. Verify that propeller shaft (10-363) is secure from movement by tightening cover nut until no shaft rotation occurs. Place hand at top of vertical shaft and turn back and forth lightly to feel gear mesh. Find where gears touch and set indicator. Next, turn shaft slowly until gears come in contact with each other again. The amount of movement that occurs between gear contact is the gap spacing or backlash.

    Spacing should be .017-.021 in (.43-.53 mm) when properly set. If adjustments are

    required, shimming will need to be performed at the nose cone bearing race. Refer to figure 3-20 and drawing 3-4.

    Figure 3-44

    To make adjustments, disassemble lower drive unit, using Chapter 5 for assistance. Remove bearing race and adjust with appropriate shims, (more shimming will increase backlash, less shimming will decrease backlash) then replace all removed components and recheck backlash. Note: Several adjustments to the shims may need to be made in order to properly set the backlash of the gears. A trial and error approach may need to be performed before the proper backlash can be achieved.

  • 500 Series Technical Manual 3- 24 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-45

    When backlash of gears has been properly set, remove cover nut and bearing carrier from lower housing. When removed, proceed by inserting load ring (10-289) into opening at bottom of lower housing as demonstrated in figure 3-45. Note: Only install load ring for final assembly. Only install load ring after all other adjustments are made, and never reuse ring once it has been installed.

    Figure 3-46

    With load ring in place, proceed by placing thrust ring (10-499) into gear housing as shown figure 3-46. Note: Install thrust ring so that tapered end is facing down in the lower housing.

  • 500 Series Technical Manual 3- 25 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-47

    Apply grease between seals (10-291 and 10-639) and grease o-ring (10-290), then place in housing as shown in figure 3-47.

    ! CAUTION Drive unit may suffer serious damage if o-ring is omitted from installation. Always be sure that o-ring is properly placed before operating stern drive.

    Figure 3-48

    When load ring, thrust ring, and o-ring are in place, proceed by installing bearing carrier assembly into housing as shown in figure 3-48. Note: Make sure that key way is aligned before continuing to next step.

  • 500 Series Technical Manual 3- 26 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-49

    Using pliers or appropriate tool, insert key (10-017) into key way as shown in figure 3-49.

    Figure 3-50

    With key in key way, place tab washer (10-295) onto bearing carrier so that tabs are aligned in their respective slots as shown in figure 3-50. For easier assembly in the following steps, bend all square tabs up thirty degrees (30o) before installing cover nut.

  • 500 Series Technical Manual 3- 27 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-51 Figure 3-52 Figure 3-53

    If cover nut (10-242) is aluminum, apply anti-seize compound to threads before fastening into lower gear housing. If cover nut (10-242) is brass, lubricate with 90w oil before fastening into lower gear housing. Tighten cover nut into lower gear housing as shown in figure 3-51, using cover nut wrench (TO-029) as demonstrated in figure 3-52. Tighten nut until shaft has rolling torque ranging between 25-30 lb-in (2.82-3.39 Nm) as shown in figure 3-53. While tightening cover nut, periodically check rolling torque measurement, using spline socket (TO-034) and a rolling torque wrench, being sure not to exceed the maximum setting of 30 lb-in (3.39 Nm). When rolling torque has been adjusted to the correct setting, proceed by bending a tab into an aligning slot on the cover nut as demonstrated in figure 3-54. Never loosen nut to align tabs, as load ring will not expand to fill the gap created when nut is backed off. After one (1) tab is bent into slot, bend the other three (3) tabs down. Figure 3-54 Drawing 3-7

    Turn retainer nut until tab is aligned,thenpry up to lockposition.

  • 500 Series Technical Manual 3- 28 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-55

    Proceed by removing first half of lock nut (10-573) by using socket wrench (#TO-033), and then bearing from shaft (10-200). When these parts have been removed, insert spacer tube (10-557) onto vertical gear shaft, as demonstrated in figure 3-55, and drawing 3-8. With spacer installed, replace bearing over shaft and fasten down with first half of lock nut. Tighten nut down to 150 lb-ft (203 Nm). After nut has been tightened, measure rolling torque on shaft as shown in figure 3-53 on the previous page. When properly set, torque should range between 25-30 lb-in (2.82-3.39 Nm). If adjustments to torque are required, then remove the upper

    bearing race and add shims to increase the rolling torque resistance. Drawing 3-8

    Note: This spacer does not exist in all 520 stern drive models made prior to 1999. It has been introduced as a product improvement and is suggested that it be included in older models when being rebuilt.

  • 500 Series Technical Manual 3- 29 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-56

    Next, fasten second half of lock nut (10-574) down so that the two (2) surfaces come in contact. Once surfaces come in contact as shown in figure 3-56, back nut off until holes are aligned. When holes are aligned, turn nut off 2/6 or two (2) holes counter clockwise. Next, fasten two (2) halves together using the six (6) set screws (10-578) that are part of the assembly. Tighten each screw to 75 lb-in (8.47 Nm) using a star pattern to fasten nuts together as demonstrated in diagram 3-4. Use *Loctite 271 or equivalent on set screws and nut when fastening final assembly together. Figure 3-57 shows these procedures completed.

    Diagram 3-4 Figure 3-57

    1

    234

    5

    6

  • 500 Series Technical Manual 3- 30 October 2003

    520 Lower Gear Housing Assembly (Right Hand) Figure 3-58

    Install alignment sleeve (10-397) then o-ring (10-399) and o-ring (10-400) as shown in figure 3-58.

    Figure 3-59

    At nose of bullet on lower gear housing, install washer/gasket (10-285) and magnetic drain plug (10-155) until snug in housing.

  • 520 Lower Gear Housing Assembly (Left Hand)

    Chapter 4

    520 LOWER GEAR

    HOUSING ASSEMBLY

    (Left Hand)

    500 Series Technical Manual 4 - 1 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand)

    ! Notice

    To the Service Technician: This section of the manual describes specific instructions for rebuilding one aspect of a stern drive unit. As in all stern drives, critical torque and component interactions are completed using metal shims under bearing races. When servicing a 500 Series stern drive, it is suggested that all reassembly be done using the same shim set-up as installed by the manufacturer. While reading this section, you will notice that shim thicknesses are called out at various assembly steps. These shim call-outs are intended as a guide to eliminate excess adjustments when starting from scratch. To minimize excess adjustments, use original factory settings when available as they will be more accurate for the particular stern drive being assembled. * Note: Loctite 271 or equivalent requires 24 hours to cure.

    500 Series Technical Manual 4 - 2 October 2003

  • .020

    Konrad

    DRAWING NUMBER

    NEXT ASS'Y

    30-007M

    DATE SYM REVISION DR30-007MDRAWING NO.

    DO NOT SCALE DRAWING

    1:2.5

    6/22/0672.42LBSWEIGHT: DATE:

    TITLE:

    TOLERANCE

    .XXX .005

    SCALE:APP.BY:

    .XX

    MAT'L:

    520 LOWER GEAR HOUSING ASS'Y, L.H.

    DRAWN BY: LH

    .010

    .XTHIS DOCUMENT AND THE INFORMATIONCONTAINED HEREIN IS CONFIDENTIALAND PROPRIETARY PROPERTY AND MUSTNOT BE USED, REPRODUCED, OR ITSCONTENT DISCLOSED, IN WHOLE OR INPART, WITHOUT PRIOR WRITTEN CONSENTOF KONRAD MARINE.

    *

    *

    * SOLD AS GEAR SET 30-204

    ** THIS IS A STANDARD LOWER GEAR ASSY, IF YOURS IS A CUSTOM ASSY, PLEASE CONTACT THE FACTORY TO VERIFY CORRECT COMPONENTS

    LOWERGEAR HOUSINGLH ASS'Y

    30

    12

    11

    46

    4

    3

    5

    240

    42

    7

    5

    6

    10

    9

    8

    34

    44

    33

    32

    1

    45

    33

    36

    35

    3743

    41

    38

    39

    16

    15

    14

    13

    18

    19

    20

    17

    21

    22

    23

    24

    25

    26

    28

    31

    2927

    46 30-205 SET, LOCKNUT, K-70 145 10-457 WASHER, FLAT 644 10-313 STUD 643 10-334 NUT 142 10-496 STUD 141 10-433 PLATE, INHIBITOR 240 10-432 PLATE, INHIBITOR 139 10-333 NUT 438 10-253 STUD 437 10-461 F.H.C.S. 236 10-155 PLUG, DRAIN, MAGNETIC 135 10-285 WASHER, SEAL 134 10-399 O-RING 133 10-314 NUT 732 10-279 STUD 131 10-293 WASHER, SPLINED 130 10-296 LOCKNUT, NYLON 129 10-295 WASHER, TAB 128 10-292 THRUST HUB 127 10-017 KEY 126 10-242 COVER, NUT 125 10-203 WASHER, TAB 124 10-639 SEAL 123 10-291 SEAL 122 10-394 BEARING, ROLLER 121 10-364 CARRIER, BEARING 120 10-290 O-RING 119 10-499 WASHER, THRUST 118 10-289 LOAD RING 117 10-509 BEARING 116 10-299 SHIM SET 115 10-269 BEARING 114 10-258 GEAR 113 10-360 SHAFT, PROP, LH 112 10-400 O-RING 111 10-397 SLEEVE, ALIGNMENT 110 10-261 PINION 19 10-358 WASHER, BELLEVILLE 18 10-260 LOCKNUT, STAKE 17 10-557 SPACER, LOWER HSG 16 10-377 PINION BEARING 15 10-288 SET, SHIM 24 10-526 WASHER, TONGUED 13 10-259 BEARING 12 10-200 SHAFT, VERTICAL, BOTTOM 11 10-245 520 LOWER HOUSING 1

    ITEM NO. PART NO. DESCRIPTION QTY.

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-1

    Start to rebuild the lower gear housing (10-245) by first inspecting the casting for any damage or defects. Next, thoroughly clear any sediment, metal shavings or debris that may be adhered to internal surfaces or hidden in pockets or cavities, as demonstrated in figure 4-1. Best results can be achieved by using compressed air and a dry rag.

    500 Series Technical Manual 4 - 3 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-2

    Onto vertical gear shaft (10-200), slide over bearing (10-259) so that it is orientated as shown in figure 4-2. Once bearing has been installed, place tongued washer (10-526) over top of gear shaft as demonstrated in drawing 4-1 below. Drawing 4-1

    Figure 4-3

    At top of shaft, fasten on first half of lock nut (10-573)*. See figure 4-3.

    * First nut of assembly is placed with chamfered corners face down as shown in drawing 4-2. Drawing 4-2

    500 Series Technical Manual 4 - 4 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-4 Figure 4-5 Figure 4-6

    To begin assembly, place .020 in (.51 mm) shims (10-288) and bearing race (10-377) into seat at bottom of housing as shown in figure 4-4 through 4-6. Lubricate race with 90w oil for ease of installation. Refer to diagram 4-1 for correct tools and orientation required to install bearing race. Tools required for this procedure are bearing driver (TO-021) and bearing driver assembly (TO-022). Diagram 4-1

    AB

    CD

    EFG

    A: Nut (TO-022) B: Locating Disk

    (TO-022) C: Casting (10-245) D: Drive Screw

    (TO-022) E: Shims (10-288) F: Bearing Race

    (10-377) G: Bearing Driver

    (TO-021) Place tools as seen in diagram and turn nut clockwise to pull bearing driver into housing to properly seat bearing race.

    500 Series Technical Manual 4 - 5 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-7

    As shown in figure 4-7, lubricate the upper bearing race (10-259) with 90w oil and then drive into seat as shown. Use bearing driver (TO-017) and impact rod (TO-037) to ensure that race is installed correctly. Refer to figure 4-8 for correct installation of race.

    Figure 4-8

    500 Series Technical Manual 4 - 6 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-9

    Through top of gear housing, insert upper bearing and vertical gear shaft assembly so splines and threads are visible as shown in figures 4-9 and 4-10 below. Figure 4-10

    Figure 4-11

    While holding shaft in place, rotate gear housing to install lower bearing (10-377) to vertical gear shaft. Splines and threads will show when bearing is pushed on correctly. Refer to figure 4-11 and drawing 4-3 for assistance. Drawing 4-3

    500 Series Technical Manual 4 - 7 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand)

    Figure 4-12

    ! CAUTION This procedure may not be the final time that the lock nut is fastened to the vertical shaft. Pprocedures may require that shim adjustments be performed to thisvertical shaft’s bearing sets. If adjustments are required, then the nut will need to be removThis lock nut has been designed to be applied safely only ONE TIME, and should never be reused for operation of the drive.

    ost

    ed.

    It is required that the assembler obtain two lock nuts to rebuild this part of the stern drive. Use one lock nut for all adjustments and the other for final installation once all adjustments have been performed.

    Figure 4-13 As shown in figure 4-12, slide pinion gear (10-261) on to splines at bottom of vertical shaft. Secure gear to shaft with washer (10-358) and lock nut (10-260). After all adjustments have been made, at the final installation, apply *Loctite 271 or equivalent to threads of lock nut.

    New Used

    New lock nut will still retain its oval thread hole, while used nut will have been rounded

    after being applied once.

    500 Series Technical Manual 4 - 8 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-14

    Double checking that the first part of upper lock nut system has been fastened down hand tight, proceed by placing spline socket (TO-034) over splines as shown in figure 4-14. Over end of spline suse an appropriwrench to turn shaftfasten lock nut (10-260) atbottom to 150 lb-ft (203 Nm) as shown i

    ocket, ate torque

    and

    n

    igure 4-15

    figure 4-15.

    F

    500 Series Technical Manual 4 - 9 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-16

    Once lock nut has been secured to shaft, proceed by measuring rolling torque with gauge as demonstrated in figure 4-16. Rolling torque measurements should range from 10-12 lb-in (1.13-1.36 Nm) when properly set. To adjust rolling torque, set tools up as shown in figure 4-17. Use socket wrench (TO-033) over nut and spline socket (TO-034) to tighten or loosen the nut to adjust rolling torque.

    Figure 4-17

    500 Series Technical Manual 4 - 10 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-18

    Through bottom opening of gear housing, insert gauge (GO-015) to check gap of pinion gear. Refer to figure 4-18 for assistance in set up of measurement. Using a feeler gauge as shown in figure 4-19, check gap of pinion gear.

    Figure 4-19

    Ideal gap should range from .024-.026 in (.61-.66 mm). If gap needs to be increased, then decrease the amount of shims that are at the bearing race. If gap nto be decreased, then shims are added. When making these adjustments, the pinion gear and nut will have to be removed in order to access the bearing race. Be sure to reassemble all parts as described in directions that accompany figures 4-12 through figures 4-18. When rebuilding a drive unit, try to use the exact amount and size of shims that were taken out. This will minimize the amount of adjustments that may need to be made and reduce the

    eeds

    number of times that the ring race is removed and replaced.

    500 Series Technical Manual 4 - 11 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Diagram 5-2 The diagram below illustrates the order of parts that are assembled over the next few steps. The drawing is intended to serve as a general idea for the order in which the parts are to be assembled and should not be substituted for assembly procedures described in this section.

    A: Bearing Race (10-394) B: Bearing (10-509) C: Propeller Shaft (10-360) D: Gear (10-258) E: Bearing (10-269)

    A B C D E

    500 Series Technical Manual 4 - 12 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-20

    Press bearing (10-269) onto gear (10-258). Lubricate mating surfaces w90w oil before pressing the two (2) components together. Refer to figur4-20 for

    ith

    e visual description of assembly.

    ! CAUTION

    inner surface

    When assembling gear and beari g

    e

    ncluster, always press components together using the inside ring of thbearing. Never apply force to any other surfaces as damage may result to rollers or retainer on bearing. Use an electric or hydraulic press to combine components if available.

    Figure 4-21 Into the nose cone, place .020 in (.51 mm) shim

    and

    (10-299) in front of bearing race (10-269). Use impact rod (TO-037), alignment plate (TO-036)bearing driver (TO-025) to correctly install bearing race into nose cone.

    Bearing Race

    Shim

    500 Series Technical Manual 4 - 13 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-22

    Place gear and bearing previously assembled into bearing race at the front of the nose bore. This setup is required for the installation of a counter rotating propeller shaft (10-360). Refer to figure 4-22 for visual description of component. Gear and lock nut on vertical shaft will need to be removed in order to properly assemble all components of lower gear housing.

    Figure 4-23

    Over the splines at the end of the shaft, replace lower pinion gear (10-261). Secure shaft with washer (10-358) and lock nut (10-260). Note: There are several shim adjustments that may be required to properly reassemble this drive variation. Use old lock nut when making these adjustments. When all settings are correct, remove old lock nut and replace with new one using *Loctite 271 or equivalent for added safety. Tighten nut down to 150 lb-ft (204 Nm).

    500 Series Technical Manual 4 - 14 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-24 Figure 4-25

    Obtain counter rotating propeller shaft (10-360) and install components as instructed. As shown in figure 4-24, take propeller shaft and press on bearing (10-509) until seated firmly against ridge at center. Next, press needle bearing race (10-394) over end of propeller shaft so that the two (2) holes are aligned as demonstrated in figure 4-25. Drawing 4-4

    Needle Bearing

    Oil Passage WayPropeller Shaft

    Oil Passage Hole

    Bearing Race

    ! CAUTIONTo prevent damage and minimize wear, keep holes aligned when installing bearing race. This alignment will ensure that proper oil flow through shaft and bearings is created when shaft is in motion, as shown in drawing 4-4. Do not press race beyond ridge of shaft. Severe risk of metal fatigue and flying debris may result from part shattering.

    500 Series Technical Manual 4 - 15 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-26

    Install propeller shaft assembly into lower gear housing as shown in figure 4-26.

    Figure 4-27

    Notice: The next few procedures will demonstrate acomplete overhaul of the lower bearing carrier. If bearings and races in carrier are suitable for reuthen only follow procedure for replacement of seals

    se, .

    ever reuse carrier seals if grease and water Nseals have been exposed to more than two hundred (200) hours of operation.

    500 Series Technical Manual 4 - 16 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand)

    Figure 4-28

    Obtain lower bearing carrier

    igure 4-29

    Using bearing driver (TO-019), to

    it

    (10-364) and inspect for damage before continuing assembly.

    F

    install needle bearing (10-394) incarrier as shown in figures 4-29 through 4-31 and drawing 4-4. Lubricate bearing on all surfaceswith 90w gear oil before installinginto the carrier.

    500 Series Technical Manual 4 - 17 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Drawing 4-4 Figure 4-30

    Figure 4-31

    500 Series Technical Manual 4 - 18 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-32

    Install left hand rotation prop shaft’s bearing race (10-509) into carrier

    using bearing driver (TO-017) as shown in figure 4-32.

    Figure 4-33

    Proper installation will have the taper of the bearing race facing outward as shown in figure 4-33.

    500 Series Technical Manual 4 - 19 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-34

    Using seal driver (TO-030), press seal #1 (10-291) and seal #2 (10-639) into bearing carrier as shown in figure 4-34. To install correctly, slide on two (2) seals at opposite ends of the seal driver. Verify that seals oppose one another while resting on seal driver and that rubber gaskets rest against circular ridge before installing into carrier. Around outside surface of each seal, apply thin layer of * Loctite 271 or equivalent to lock seal in place. Refer to diagram 4-4 for assistance in installation of seals into the bearing carrier.

    Diagram 4-4

    Step #1 Step #2

    Seal Driver

    Carrier

    Press in seal #1 and flip tool over to install seal #2

    TO-030

    10-63910-291

    500 Series Technical Manual 4 - 20 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-35 Figure 4-36

    Once seals are in place, apply grease to them and slide carrier over propeller shaft as seen in figure 4-35. Place tab washer (10-295) on top of carrier as shown in figure 4-36. Next, apply oil to cover nut (10-242) threads, then fasten into lower gear housing as shown in figure 4-37. Tighten cover nut into lower gear housing using cover nut wrench (TO-029). Tighten nut until all movement (back and forth) of the propeller shaft is eliminated. Figure 4-37 Figure 4-38

    500 Series Technical Manual 4 - 21 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-39

    Place indicator rod (GO-016) onto top of vertical drive shaft to verify backlash of gears. Set dial indicator (GO-017) perpendicular to indicator rod. Set probe tip of dial indicator on mark (II) of the indicator rod as shown in figure 4-43. Verify that propeller shaft (10-360) is secure from movement by tightening cover nut until no shaft rotation occurs. Place hand at top of vertical shaft and turn back and forth lightly to feel gear mesh. Find where gears touch and set indicator. Next, turn shaft slowly until gears come in contact with each other again. The amount of movement that occurs between gear contact is the gap spacing or backlash.

    Spacing should be .011-.013 in (.28-.33 mm) . when properly set. If adjustments are required, shimming will need to be performed at the nose cone bearing race. Refer to figure 4-21.

    Figure 4-40

    To make adjustments, disassemble lower drive unit, using Chapter 5 for assistance. Remove bearing race and adjust with appropriate shims, (more shimming will decrease backlash, less shimming will increase backlash) then replace all removed components and recheck backlash. Note: Several adjustments to the shims may need to be made in order to properly set the backlash of the gears. A trial and error approach may need to be performed before the proper backlash can be achieved.

    500 Series Technical Manual 4 - 22 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-41

    When backlash of gears has been properly set, remove cover nut and bearing carrier from lower housing. When removed, proceed by inserting load ring (10-289) into opening at bottom of lower housing as demonstrated in figure 4-41. Note: Only install load ring for final assembly. Only install load ring after all other adjustments are made, and never reuse ring once it been installed.

    has

    Figure 4-42

    With load ring in place, proceed by placing thrust ring (10-499) into gear housing as shown figure 4-42. Note: Install thrust ring so that tapered end is facing down in the lower housing.

    500 Series Technical Manual 4 - 23 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-43

    Apply grease between seals (10-291 and 10-639) and grease o-ring (10-290), then place in housing as shown in figure 4-43.

    ! CAUTION Drive unit may suffer serious damage if o-ring is omitted from installation. Always be sure that o-ring is properly placed before operating stern drive.

    Figure 4-44

    hen load ring, thrust ring, and

    own

    ote: Make sure that key way is

    Wo-ring are in place, proceed by installing bearing carrier assembly into housing as shin figure 4-44. Naligned before continuing to next step.

    500 Series Technical Manual 4 - 24 October 2003

  • 520 Lower Gear Housing Assembly (Left Hand) Figure 4-45

    Using pliers or appropriate tool, insert key (10-017) into key way as shown in figure 4-45.

    Figure 4-46

    With key in key way, place tab washer (10-295) onto bearing carrier so that tabs are aligned in their respective sl