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0008G7

Step 18 Step 20

DT9.9 t DT35 and DT40

The gearcase used on these models varies primaril y in shape size and component location his is a basic procedure that covers all mo dels l isted Yourmodel may vary slightly from the on e shown but has the same basic components and all models listed are serviced in essentially the same way

1 Remove the engi ne cover and disconnect the spark plug leads to prevent

accidenta starting of the eng ine du ring lower unit removal2 Shft the outboard into FORWAR3. Remove the propeller4 Loosen the clutch rod ocknut 5 Loosen the cl utch rod turn buck le and separate the clutc h rod from the

shift rod6 Remove the bolts and lockwashers securing the gearcase to the drive

shaft housing 7 Carefu ly separate the gearcase fro m the driveshaft hou sin g8 Insta ll the gearcase in an appropriate hod ing fixture9 Place a suitable container under he gearcase Remove the vent and

drain the lubricant from the unit

If the lubicat is ceamy i clo o metall c partcles ae foud thegeacase must be completely dsassembled to deteme ad coectthe cause of the poblem.

0 Wipe a smal amount of the drained l ubricant on a finger and rub thefinger and thumb together C heck for the presence of metal ic particles in thelubr icant Note the col or of the l ubricant A white or creamy col or indicateswater in the lubri cant Check the drain cont ainer for signs of water separationfrom the lubr icant

** CAUTON

D nt ease the t the vesat. Ths may exessvey eladte dvesa and ansat when t e mn tn astenes ae tigtened an d case a pemate ae te we ead eaase.

T nstal:1 1 Pull t he lower shift rod upward as far as possible to make sure it is in

the FORWAR position and lightly lubri cae the driveshaft spl ines with waterproo marine grease

12 Apply a thin but uniform coat of a sil icone sealer to the gearcase anddriveshaft housing mating surfaces 3 Make sure the locating dowels are in pace14 Position the gearcase under the driveshaft housi ng15 Alig n the driveshaft splines with the crankshaft insert the water tube into

the water pump case and the water pump seal tub e

1 989-o mode ls, make se to conect the clutch od to the shiftshaft with chamfeed side of the lowe ut facg upwad

1 6 Attach the shift rod into the clutch rod

** CAUTON

D t tate the lyweel tekwse. Ts a n damae tewate pm m pele.

LOWER UNIT 8-5

0008G4

05008G6

Step 21

17 Seat the gearcase in place, rotating the flywheel cockwise as requireduntil the driveshat and crankshaft engage

8 Install the gearcase bolts and lockwashers and tighten to specification1 9 Make sure the engine shift lever is in FORWAR and tighten the shift

rod connector or upper shift rod turnbuckle Place the shif lever in NEUTRALand make sure the prope ler rotates freely, then s hift back into FORWAR andmake sure the propell er will only rotate clockwise If the propell er does notrotate as i ndicated loosen the shift rod con nector or upper shit rod turn buck eand readjust the positio n of the connector/turnbuck le or rods as requir ed Whenshift pattern is correct tighten the shift rod co nnector locknut securely

20 Install the prope ler21 Reconnect the spark pl ug leads and refil l the gearcase with proper type

and quantity o lu bricant22 nstall the engi ne cover

DT55 ad DT65

1 Remove the engine cover and disconnect the spark plug leads to preventaccidental starting of the engin e durin g lower unit removal

2 Place a container und er the gearcase Remove the vent and drain pl ugs Drain the lubricant from the unit

f the lbcat s ceamy col o o metall ic paricles ae foud thegeacase must be completely dsassembled to detemie ad coectthe case of the poblem

3. Wipe a smal amount of lubricant on a finger and rub the finger andthumb together C heck for the presence of metalli c paticles in the lubri cant Notethe col or of the lu bri cant A whte or creamy col or in dicates water in th e l ubricantCheck the drain container for signs of water separation from the lub ricant

4 Remove the propell er as described in this chapter5 Place the outboard in NEUTRAL6 Remove the nut from the clutch shaft7 Disconnect the clutch shaft from the clutch rod8 Remove the bolts and lockwashers securing the gearcase to the drive

shaft housing 9 Remove the gearcase from the driveshaft housing and mo unt it in a suit

able hol ding fixture

** CAUTION

D t gease the tp the dvesat Ts may exessvely ead te dvesat and as wen te mn t ts ae ttened and ase a emate ae the we ead eaase.

T nstall:1 0 Lightly lu bricate the driveshaft spli nes and the 0-ring seal around the

driveshaft be aring wi th waterproof mar ine grease . Apply a thin but unifo rm coat of a sil icone sealer to the gearcase and

driveshat housing mating surfaces2 Make sure the locating dowels are in place13 Position the gearcase under the driveshaft housi ng14 Aig n the driveshaft splines with the crankshaft inset the water tube into

the water pump case and the water pump sea l tube15 Guide the clutch rod into the clutch shaft