LPH ONE GENERTION II STERNDRIVE 2 74243
Tle of Contents Pge Instlltion Speifitions.................. 2-1 Torque Speifitions.................. 2-1 Lurints, Selers, n hesives...... 2-1 Speil Tools.......................... 2-1 Trnsom Speifitions................. 2-1 Instlltion Proeures.................... 2-2 Trnsom ssemly Instlltion.......... 2-2 Power Steering Control Vlve n Cle Instlltion..................... 2-3 Power Steering Hose Connetions....... 2-4 Stern Drive Unit Instlltion............. 2-4 Trim Cyliner Connetion............... 2-4 Propeller Instlltion................... 2-5 Drive Shft Housing Speifitions......... 2-6 Torque Speifitions.................. 2-6 Upper Drive Shft Bering Prelo....... 2-6 U-joint Bering Prelo................. 2-6 Ger Shimming Speifitions........... 2-6 Lurints, Selers, n hesives...... 2-6 Speil Tools.......................... 2-6 Drive Shft Housing Exploe Prts View... 2-8 U-Joint n Driven Ger Components.... 2-8 Drive Shft Components............... 2-10 Drive Shft Housing Shimming............ 2-11 Ger Distne, Driven Ger............ 2-11 Ger Distne, Drive Ger............. 2-11 Drive Shft Housing Speil Informtion...................... 2-12 Top Cover Bering Cup................ 2-12 Top Cover Bering Cup Drivers......... 2-12 Stnr Rottion Ger Housing Speifitions.................. 2-13 Torque Speifitions................. 2-13 Shimming Speifitions............... 2-13 Lurints, Selers, n hesives..... 2-13 Speil Tools......................... 2-14 Stnr Rottion Ger Housing Exploe Prts View................... 2-16 Drive Shft Components............... 2-16 Propeller Shft Components........... 2-18 Speil Informtion For Stnr Rottion Ger Housing............... 2-20 Pge Stnr Rottion Ger Housing ssemly Speifitions................ 2-21 Pre-Disssemly Inspetion............ 2-21 Pinion Ger Height................... 2-21 Shift Spool En Ply.................. 2-21 Forwr Ger Bklsh............... 2-22 Reverse Ger Bklsh............... 2-22 Counter-Rottion Ger Housing Speifitions.......................... 2-23 Torque Speifitions................. 2-23 Shimming Speifitions............... 2-23 Lurints, Selers, n hesives..... 2-23 Speil Tools......................... 2-24 Counter-Rottion Ger Housing Exploe Prts View................... 2-26 Drive Shft Components............... 2-26 Propeller Shft Components........... 2-28 Speil Informtion For Counter-Rottion Ger Housing....... 2-30 Counter-Rottion Ger Housing ssemly Speifitions................ 2-32 Pre-Disssemly Inspetion............ 2-32 Forwr n Reverse Ger Ientifition........................ 2-32 Pinion Ger Height................... 2-32 Shift Spool En Ply.................. 2-32 Forwr Ger Bklsh............... 2-33 Reverse Ger Bklsh............... 2-33 Trnsom ssemly Speifitions......... 2-35 Torque Speifitions................. 2-35 Speil Tools......................... 2-35 Lurints, Selers, n hesives..... 2-35 lph One Trnsom ssemly Exploe View......................... 2-36 Bell Housing Components............. 2-36 Giml Housing Components.......... 2-38 Inner Trnsom Plte Components...... 2-40 Giml Ring n Steering Lever Components........................ 2-41 2-0 lph One Genertion II Sternrive 90-806534970 1096
Instlltion Speifitions Torque Speifitions NOTE: Seurely tighten ll fsteners not liste elow. ITEM TORQUE l. in. l. ft. N m Exhust Pipe to Giml Housing Srews 23 31 Propeller Nut 1 55 75 Steering Cle Coupler Nut Tighten Nut Until It Bottoms Out ginst Flt Wsher, then Loosen 1/2 Turn Steering Cle Coupler Nut 35 48 Steering system Pivot Bolts 50 68 Trnsom ssemly tthing Srews n Nuts 23 31 Power Steering Hyruli Hose Fittingsi Stern Drive Unit to Bell Housing tthing Nuts 1 : mount speifie is MINIMUM. 23 31 50 68 Trnsom Speifitions e f 22170 - Trnsom Thikness-2-2 1/4 in. (51-57mm) - Trnsom Surfes-Prllel to within 1/8 in. (3.2 mm) - re Covere y Inner Trnsom Plte - Flt to within 1/8 in. (3.2 mm) - re Covere y Giml Housing ssemly - Flt to within 1/16 in. (1.6 mm) e - Trnsom ngle-10 to 16 f - Keel (if Equippe) - Remove 4 ft. (1.2 m) forwr of trnsom Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint 92 8254073 with Teflon Quiksilver Speil Lurint 101 92-138721 Perfet Sel 92-34227-1 Liqui Neoprene 92-25711--2 Quiksilver Engine Coupler Spline Grese 92-8163914 Speil Tools DESCRIPTION lignment Tool ssemly PRT NUMBER 91-8054751 90-806534970 1096 lph One Genertion II Sternrive 2-1
Instlltion Proeures Trnsom ssemly Instlltion! CUTION Steering lever groun wire MUST e positione s shown or wire my ftigue. 2 4 1 5 70015 70011 2 3 8 70006 50632 7 2 2 6 70012 50632 70005 1 - Speeometer Tue Pik-up Connetion 2 - Loknuts n Flt Wshers 3 - Srew 4 - Steering Lever Continuity Wire 5 - Trim System Wires 6 - Shift Cle 7 - Trim Hoses (n MerCthoe Wires, if so equippe) 8 - Ger Lue Hose Fitting 7 Torque Speifition 23 l. ft. (31 N m) 70-90 l.in. (8-10 N m) 2-2 lph One Genertion II Sternrive 90-806534970 1096
Power Steering Control Vlve n Cle Instlltion 7 5 6 8 9 5 73901 71906 10 3 1 2 4 71903 71901 1 - Steering Cle 2 - Grese Fitting 3 - Cle Coupler Nut 4 - Cle Guie Tue 5 - Cle En 6 - Clevis 7 - Clevis Pin 8 - Cotter Pin 9 - Flts on Guie Tue MUST Be Vertil 10- Pivot Bolt Lurints, Selers, n hesives - Quiksilver Speil Lurint 101............ 92-138721 Torque Speifition 35 l. ft. (47 N m) 50 l. ft. (68 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-3
Power Steering Hose Connetions STERN DRIVE TO BELL HOUSING CONNECTION Typil Hose Routing 73786 - Hose Fittings - Torque Both Fittings to 23 l. ft. (31 N m). Stern Drive Unit Instlltion USING THE LIGNMENT TOOL! CUTION Foring the lignment tool into position my mge the Giml Bering or Engine Coupler. Do not ttempt to fore the lignment tool! Rise or lower the engine s neessry until lignment tool moves freely. 22062 - Loknut n Flt Wshers - Torque to 50 l. ft. (68 N m) - Loknut n Continuity Ciruit Wsher - Torque to 50 l. ft. (68 N m) Trim Cyliner Connetion e 71463 70027 - lignment Tool - Giml Bering - Engine Coupler - ft nhor Pin - Bushings - Flt Wshers (2) - E-ring Clips (2) e - Plsti Cps (2) 2-4 lph One Genertion II Sternrive 90-806534970 1096
Propeller Instlltion e f Typil Propeller - Propeller Shft - Forwr Thrust Hu - Propeller - Continuity Wsher e - Spline Wsher f - T Wsher g - Propeller Nut-Torque to 55 l. ft. (75 N m) g e f g 70134 Propeller With Flo-Torque Hu - Propeller Shft - Forwr Thrust Hu - Drive Sleeve - Propeller e - Drive Sleeve pter f - T Wsher g - Propeller Nut-Torque to 55 l. ft. (75 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-5
Drive Shft Housing Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Top Cover Srews 17-23 23-31 U-joint Retiner Nut 200 271 Oil Vent Srew 30-50 Upper Drive Shft Bering Prelo DESCRIPTION New Berings 6-15 Use Berings* 3-7.5 NOTE: Seurely tighten ll fsteners not liste elow. 3.4-5.6 TORQUE l. in. N m *Berings re onsiere use if spun uner lo one. U-joint Bering Prelo DESCRIPTION New Berings 6-10 Use Berings* 3-7.5 0.7-1.7 0.3-0.8 TORQUE l. in. N m *Berings re onsiere use if spun uner lo one. Ger Shimming Speifitions 0.7-1.1 0.3-0.8 DESCRIPTION GER LOCTION inhes millimeters Drive Ger.025 0.64 Driven Ger.025 0.64 Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint 92-8254073 with Teflon Quiksilver U-Joint n Giml Bering 92-8280522 Grese 3M Brn hesive 92-25234-1 Quiksilver Bellows 92-86166 hesive Quiksilver Neele Bering ssemly 92-8252651 Lurint Quiksilver Perfet Sel 92-34227-1 Permtex Ultr Blue Otin Lolly Silione Selnt Quiksilver Speil 92-138721 Lurint 101 Quiksilver High Performne Ger 92-8160264 Lue Speil Tools DESCRIPTION PRT NUMBER ptor 91-38756 Bering Cup Driver 91-38918 Bering Driver Cup 91-33493 Driver Cup 91-36577 Driver Ro 91-37323 Driver Tool 91-90774 Oil Sel Driver 91-817570 Shimming Tool (Driven Ger) 91-60526 Shimming Tool (Drive Ger) 91-60523 Slie Hmmer Puller 91-345691 Torque Wrenh (l. in.) 91-66274 U-joint Bering Retiner Wrenh 91-17256 Universl Puller Plte 91-37241 2-6 lph One Genertion II Sternrive 90-806534970 1096
TORQUE CONVERSION CHRT Use the following tle to torque the u-joint retiner to 200 l. ft. (271 N m). Torque Wrenh Length in Inhes (m) 15 (38) 16 (41) 17 (43) 18 (46) 19 (48) 20 (51) 21 (53) 22 (56) 23 (58) 24 (61) 25 (64) 26 (66) 27 (69) 28 (71) 29 (74) 30 (76) 31 (79) 32 (81) 33 (84) 34 (86) 35 (89) 36 (91) Torque Wrenh Reing in l. ft. (N m) to hieve 200 l. ft. (271 N m) of Torque 111 (151) 114 (155) 117 (159) 120 (163) 123 (167) 125 (170) 127 (172) 129 (175) 131 (178) 133 (180) 135 (183) 136 (184) 138 (187) 140 (190) 141 (191) 143 (194) 144 (195) 145 (197) 147 (200) 148 (201) 149 (202) 150 (203) - Torque Wrenh Length 26363 90-806534970 1096 lph One Genertion II Sternrive 2-7
Drive Shft Housing Exploe Prts View U-Joint n Driven Ger Components D 13 8 12 11 D 10 11 9 C B 23 24 18 17 16 15 14 20 19 27 19 2 3 5 B 25 26 23 22 21 4 1 7 6 29 28 70690 2-8 lph One Genertion II Sternrive 90-806534970 1096
1 - Drive Shft Housing 2 - Srew 3 - O-ring 4 - Spring ssemly 5 - Oil Sel 6 - Wer P 7 - Plug 8 - Universl Joint 9 - Yoke, Universl Joint - Ger En 10- Soket, Center - Universl Joint 11- Cross n Bering 12- Yoke ssemly, Universl Joint - Coupling En 13- O-ring 14- Retiner 15- Ring 16- O-ring 17- Crrier ssemly 18- Oil Sel 19- Roller Bering n Cups 20- Cup Sper 21- Shim 22- Shim 23- Drive Ger ssemly 24- Roller Bering n Cup 25- Wsher 26- Nut 27- Shims 28- Groun Plte 29- Srew Lurints, Selers, n hesives - 2-4-C Mrine Lurint with Teflon............ 92-82540712 B - Quiksilver High Performne Ger Lue............. 92-8160254 C - Quiksilver Speil Lurint 101............ 92-138721 D - Quiksilver Engine Coupler Spline Grese... 92-8163914 Torque Speifition 200 l. ft. (271 N m) - See Chrt on Pge 7 Rolling Prelo Tighten in Smll Inrements Until 6-10 l. in. (.07-1.1 N m) of Rolling Prelo 90-806534970 1096 lph One Genertion II Sternrive 2-9
Drive Shft Components 5 1 4 3 2 8 18 B 11 12 15 10 14 16 13 9 17 74243 1 - Cover, top 2 - Bering n Cup 3 - Shim 4 - O-ring 5 - Srew 8 - Drive Shft, upper 9 - Filler Wll 10- Wsher 11 - Nut 12- noi Plte 13- Srew 14- Lokwsher 15- Srew 16- Sel 17- Wter Tue 18- Stuffer Plug Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon... 92-82540712 B - Quiksilver High Performne Ger Lue. 92-8160264 Torque Speifitions 20 l. ft. (27 N m) 35 l. ft. (47.5 N m) 2-10 lph One Genertion II Sternrive 90-806534970 1096
Drive Shft Housing Shimming Ger Distne, Drive Ger SHIMMING TOOL 91-60523 Ger Distne, Driven Ger SHIMMING TOOL 91-60526 Overll Drive Unit Ger Rtio 1.47:1 1.62:1 1.81:1 1.94:1 2.40:1 Tool Position Z X Y Y Y Overll Drive Unit Ger Rtio 1.47:1 1.62:1 1.81:1 1.94:1 2.40:1.025 (0.64mm) Tool Position Z Y Y Y Y.025 (0.64mm ) 23012 23012 23012 - Feeler Guge -.025 in. (0.635mm) - Feeler Guge -.025 in. (0.635mm) 90-806534970 1096 lph One Genertion II Sternrive 2-11
Drive Shft Housing Speil Informtion Top Cover Bering Cup Drivers Use the pproprite river for instlltion of the ering up. Top Cover Bering Cup The lter style ering up is thinner thn the erlier style up. e 70701 - Erlier Style Bering Cup 1.938 in. Dimeter (Prior to S/N OF680000) - Lter Style Bering Cup 1.781 in. Dimeter (S/N OF680000 n ove) 75240 - Shims - Bering Cup - Bering Cup Driver (91-38918) use with 31-61100 1 Bering OR Bering Cup Driver (91-808053) use with 31-32575 1 Bering - Driver Ro (91-37323) e - Top Cover 2-12 lph One Genertion II Sternrive 90-806534970 1096
Stnr Rottion Ger Housing Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Wter Pump Boy Srews 60 6.8 Pinion Ger Nut 70 95 Ger Housing to Drive Shft Housing Srews 28 38 Ger Housing to Drive Shft Housing Nuts 35 47 Trim T Srew 23 31 Shift Shft Bushing Srews 60 6.8 Drive Shft Retiner 100 136 Ber Crrier Retiner 210 285 Oil Fill/Drin Srew NOTE: Seurely tighten ll fsteners not liste elow. 30-50 3.4-5.6 Propeller Nut 1 55 75 Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint with Teflon 92-8254073 3M Brn hesive 92-25234-1 Quiksilver Bellows hesive 92-86166 Quiksilver Neele Bering ssemly Lurint 92-8252651 Quiksilver Perfet Sel 92-34227-1 Permtex Ultr Blue Silione Selnt Otin Lolly Quiksilver Speil Lurint 101 92-138721 Lotite 8831 92-823089-1 Quiksilver High Performne Ger Lue 92-8160264 1 : mount speifie is MINIMUM. Shimming Speifitions DESCRIPTION GER LOCTION inhes millimeters Pinion Ger Height.025 0.64 Forwr Ger Bklsh.017-.028 0.43-0.71 Reverse Ger Bklsh.034-.054 0.86-1.37 90-806534970 1096 lph One Genertion II Sternrive 2-13
Speil Tools DESCRIPTION PRT NUMBER Bklsh Initor Ro 91-53459 Bering Crrier Retiner Wrenh 91-61069 Bering Prelo Tool 91-143112 Belleville Wsher 12-54048 Dil Initor 91-582221 Dil Initor Holing Tool 91-89897 Drive Shft Nut Wrenh 91-56775 Cup Driver 91-36577 Drive Shft Bering Wrenh 91-43506 Neele Bering Driver 91-15755 Neele Bering Driver 91-33491 Oil Sel Driver 91-31108 Oil Sel Driver 91-817569 Pinion Ger Shimming Tool 91-56048 Pinion Nut pter 91-610673 Drive Shft pter 91-61077 Puller Bolt 91-85716 Puller Jws 91-460861 Slie Hmmer Puller 91-345691 Torque Wrenh (Inh Poun) 91-66274 Wter Pump lignment Pins 91-8215711 Universl Bering Removl n Instlltion (Inlues the 91-312295 Following Items) Bering pter 91-37263 Bering Instlltion Tool 91-38628 DESCRIPTION PRT NUMBER Collr 91-30366 Driver He 91-32366 Driver He 91-36569 Driver He 91-37311 Driver He 91-37312 Driver He 91-52393 Driver He Ro 91-37323 Nut 11-24156 Pilot Wsher 91-36571 Pilot Wsher 91-37324 Pilot Wsher 91-37350 Puller Plte 91-29310 Puller He 91-36379 Puller He 91-32325 Puller He 91-38628 Puller Ro 91-52394 Puller Shft 91-31229 Roller Bering Removl n Instlltion Tool 91-37292 Wsher 12-34961 *The 91-143112 Bering Prelo Tool is lso use on Merury n Mriner V-6 ger ses. Chek your inventory efore uying. NOTE: Wter Pump Fe Sel Tool is not ville seprtely, 26-8165752 is kit prt numer whih inlues the tool n the fe sel. 2-14 lph One Genertion II Sternrive 90-806534970 1096
THIS PGE IS INTENTIONLLY BLNK 90-806534970 1096 lph One Genertion II Sternrive 2-15
Stnr Rottion Ger Housing Exploe Prts View Drive Shft Components 31 29 18 30 25 26 21 19 20 22 13 f 27 12 24 11 D 17 23 28 10 32 (ID) 9 38 3 34 36 38 37 7 33 C 7 6 5 E 4 h B 8 14 1 15 16 D 2 74242 2-16 lph One Genertion II Sternrive 90-806534970 1096
1 - Ger Housing 2 - Pin 3 - Stu 4 - Oil Fill/Drin Srew 5 - O-ring 6 - Sel 7 - Dowel Pin 8 - Roller Bering 9 - Speeometer Fitting 10- Drive Shft 11- Shim 12- Bering n Cup 13- Nut 14- Ger Drive 15- Wsher 16- Nut 17- Fe Plte 18- Crrier 19- Oil Sel 20- Oil Sel 21- O-ring 22- Wter Pump 23- Gsket 24- Gsket 25- Fe Sel 26- Srew 27- Impeller 28- Key 29- Coupling 30- O-rings 31- Sleeve 32- Shift Shft 33- Retining Ring 34- Sleeve 35- Bushing ssemly 36- Oil Sel 37- O-rings 38- Srew Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon... 92-82540712 B - 3M Brn hesive....... 92-25234-1 C - Lotite 8831............. 92-823089-1 D - Quiksilver High Performne Ger Lue. 92-8160264 E - Quiksilver Neele Bering ssemly Lurint..... 92-8252651 Torque Speifitions 60 l. in. (6.8 N m) e f g h 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) 30-50 l. in. (3.4-5.6 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-17
Propeller Shft Components E C 32 e 1 35 31 33 34 B 3 2 9 7 5 4 13 6 C 12 8 10 D 15 14 11 23 22 18 17 16 C (OD) F 20 21 19 25 g 24 (ID) 30 29 28 27 26 73601 2-18 lph One Genertion II Sternrive 90-806534970 1096
1 - Ger Housing 2 - Shift Crnk 3 - Shift Spool ssemly 4 - Shim, Bering Outer Re 5 - Bering n Cup 6 - Forwr Ger 7 - Roller Bering 8 - Sliing Cluth 9 - Cross Pin 10- Spring 11- Propeller Shft 12- Reverse Ger 13- Thrust Wsher 14- Thrust Hu 15- Bll Bering 16- O-ring 17- Roller Bering 18- Bering Crrier ssemly 19- noe 20- Srew 21- Str Wsher 22- Oil Sel (Insie) 23- Oil Sel (Outsie) 24- T Wsher 25- Retiner 26- Thrust Hu 27- Continuity Wsher 28- Spline Wsher 29- T Wsher 30- Loknut - Propeller 31- noi Trim T (noi Plte - Some Moels) 32- Srew 33- Str Wsher 34- Srew 35- Nut Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon.... 92-82540712 B - Lotite 8831............. 92-823089-1 C - Quiksilver High Performne Ger Lue.. 92-160264 D - Quiksilver Perfet Sel.... 92-34277-1 E - Permtex Ultr Blue Silione Selnt....... Otin Lolly F - Quiksilver Speil Lurint 101............ 92-138721 Torque Speifitions 60 l. in. (6.8 N m) e f g 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-19
Speil Informtion For Stnr Rottion Ger Housing! CUTION voi mge to stern rive unit. Drive unit mge will our if Lter Style prts re intermixe with Erlier Style prts. SHIFT SPOOL SSEMBLY The lter style shift spool ssemly hs lrger gp thn the erlier style. This lter style shift spool eginning with seril numer 0K041000 is sol s whole ssemly n n e use when repling the erlier style (Prior to S/N 0K041000). The en ply for the spool will remin the sme s the erlier moels (.002-.010 in..051-.254 mm). FORWRD GER BERING BORE The lter style forwr ger ering ore is smller (3.2635 to 3.2650 in.) thn the erlier style (3.4985 to 3.5000 in.) This slightly smller ering ore for the forwr ger ering pter is pproximtely 1/4 in. (6.3 mm) smller. 3.4985 to 3.5000 75241 Erlier Style Forwr Ger Bore (Prior to S/N OF680000) 3.2635 to 3.2650 74877 75248 75219 Lter Style Forwr Ger Bore (S/N OF680000 n ove) - Erlier Style Shift Spool ssemly (Prior to S/N 0K041000) - Lter Style Shift Spool ssemly (S/N 0K041000 n ove) - Mesure En Ply Here t Gp The lter style ering up is thinner n hs smller imeter thn the erlier style. 75256 - Erlier Style Ger Bering Cup 3.500 in. imeter (Prior to S/N OF680000) - Lter Style Ger Bering Cup 3.265 in. imeter (S/N OF680000 n ove) 2-20 lph One Genertion II Sternrive 90-806534970 1096
Stnr Rottion Ger Housing ssemly Speifitions Pre-Disssemly Inspetion tion Move propeller shft from one sie to nother Rotte propeller shft Reing Less thn.003 in. (0.08 mm).005 in. (.127 mm) or less Shift Spool En Ply NOTE: The lter style shift spool ssemly hs lrger gp thn the erlier style. This lter style shift spool eginning with seril numer OK041000 is sol s whole ssemly n n e use when repling the erlier style (Prior to S/N OK041000). The en ply for the spool will remin the sme s the erlier moels (.002-.010 in..051-.254 mm). 74877 75219 22086 - Erlier Style Shift Spool ssemly (Prior to S/N 0K041000) - Lter Style Shift Spool ssemly (S/N 0K041000 n ove) - Mesure En Ply Here t Gp Pinion Ger Height Chek pinion height t four lotions. verge pinion ger height:.025 in. (0.64 mm). 26410 90-806534970 1096 lph One Genertion II Sternrive 2-21
Forwr Ger Bklsh pply forwr pressure to the propeller shft with puller jws. Torque the puller olt to 45 l. in. (5 N m ). Reverse Ger Bklsh Use the pinion nut ptor to pply kwr pressure on the propeller shft. Torque Propeller nut to 45 l. in. (5 N m). 70719 - Puller Jws - Puller Bolt Tke reings t four ifferent lotions, 90 prt, n verge them for the klsh reing. Bklsh reing:.017-.028 in. (0.43-0.71 mm) e f 23355 - Pinion Nut ptor - Wsher - Propeller Nut Bklsh reing:.034-.054 in. (0.86-1.37 mm). e f 70717 - Nuts (4) - Three Ro - Dil Initor Holing Tool - Dil initor e - Initor Pointer-Set t I on Bklsh Initor Ro f - Bklsh Initor Ro 70717 - Nuts (4) - Three Ro - Dil Initor Holing Tool - Dil initor e - Initor Pointer-Set t I on Bklsh Initor Ro f - Bklsh Initor Ro 2-22 lph One Genertion II Sternrive 90-806534970 1096
Counter-Rottion Ger Housing Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Wter Pump Boy Srews 60 6.8 Pinion Ger Nut 70 95 Ger Housing to Drive Shft Housing Srews 28 38 Ger Housing to Drive Shft Housing Nuts 35 47 Trim T Srew 23 31 Shift Shft Bushing Srews 60 6.8 Drive Shft Retiner 100 136 Ber Crrier Retiner 210 285 Oil Fill/Drin Srew NOTE: Seurely tighten ll fsteners not liste elow. 30-50 3.4-5.6 Propeller Nut 1 55 75 Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint with Teflon 92-8254073 3m Brn hesive 92-25234-1 Quiksilver Bellows hesive 92-86166 Quiksilver Neele Bering ssemly Lurint 92-8252651 Quiksilver Perfet Sel 92-34227-1 Permtex Ultr Blue Silione Selnt Otin Lolly Quiksilver Speil Lurint 101 92-138721 Lotite 8831 92-823089-1 Quiksilver High Performne Ger Lue 92-8160261 1 : mount speifie is MINIMUM. Shimming Speifitions DESCRIPTION GER LOCTION inhes millimeters Pinion Ger Height.025 0.64 Forwr Ger Bklsh.017-.028 0.43-0.71 Reverse Ger Bklsh.040-.050 1.02-1.27 90-806534970 1096 lph One Genertion II Sternrive 2-23
Speil Tools Desription Tool Prt Numer Bklsh Initor Ro 91-53459 Bering ptor Instlltion Tool 91-18605 1 Bering Crrier Retiner Wrenh 91-61069 Bering Driver 91-816244 Bering Prelo Tool 91-14311 2 Bering Removl Tool 91-816245 Belleville Wsher 12-54048 Dil Initor 91-58222 1 Dil Initor Holing Tool 91-89897 Drive Shft Nut Wrenh 91-56775 Drive Shft Bering Retiner Wrenh 91-43506 Guie Plte 91-816243 Neele Bering Driver 91-15755 Oil Sel Driver 91-31108 Oil Sel Driver 91-817569 Pinion Ger Shimming Tool 91-56048 Pinion Nut ptor 91-61067 3 Speil Tools (ontinue) Desription Tool Prt Numer Drive Shft ptor 91-61077 Puller Bolt 91-85716 Puller Shft 91-31229 Puller Jws 91-46086 1 Puller Jws 91-816242 Slie Hmmer Puller 91-34569 1 Forwr Ger Instlltion Tool 91-815850 Torque Wrenh (Inh Poun) 91-66274 Universl Puller Plte 91-37241 Wter Pump 91-821571 1 lignment Pins Universl Bering Removl n 91-31229 5 Instlltion Tool Driver He 91-36569 Driver He Ro 91-37323 Nut 11-24156 Pilot Wsher 91-36571 Puller Plte 91-29310 Puller/Driver He 91-38628 *The 91-143112 Bering Prelo Tool is lso use on Merury n Mriner V-6 ger ses. Chek your inventory efore uying. NOTE: Wter Pump Fe Sel Tool is not ville seprtely, 26-8165752 is kit prt numer whih inlues the tool n the fe sel. 2-24 lph One Genertion II Sternrive 90-806534970 1096
THIS PGE IS INTENTIONLLY BLNK 90-806534970 1096 lph One Genertion II Sternrive 2-25
Counter-Rottion Ger Housing Exploe Prts View Drive Shft Components 31 29 30 25 26 18 21 19 22 20 24 27 13 f 12 11 D 39 17 23 28 32 10 34 3 36 (ID) 37 9 38 7 33 C 7 6 5 E 4 h B 8 14 1 15 16 D 2 74242 2-26 lph One Genertion II Sternrive 90-806534970 1096
1 -Ger Housing 2 -Pin 3 -Stu 4 -Srew 5 -Oil Fill/Drin Srew O-ring 6 -Sel 7 -Dowel Pin 8 -Roller Bering 9 -Speeometer Fitting 10-Drive Shft 11 -Shim 12-Bering n Cup 13-Nut 14-Ger Drive 15-Wsher 16-Nut 17-Fe Plte 18-Crrier 19-Oil Sel 20-Oil Sel 21-O-ring 22-Wter Pump 23-Gsket 24-Gsket 25-Fe Sel 26-Srew 27-Impeller 28-Key 29-Coupling 30-O-rings 31-Sleeve 32-Shift Shft 33-Retining Ring 34-Sleeve 35-Bushing ssemly 36-Oil Sel 37-O-rings 38-Srew 39-Stuffer Plug Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon... 92-82540712 B - 3M Brn hesive...... 92 25234-1 C - Lotite 8831............. 92-823089-1 D - Quiksilver High Performne Ger Lue. 92-8160264 E - Quiksilver Neele Bering ssemly Lurint..... 92-8252651 Torque Speifitions 60 l. in. (6.8 N m) e f g h 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) 30-50 l. in. (3.4-5.6 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-27
Propeller Shft Components e 2 F 1 3 6 5 4 H 7 6 8 9 11 10 19 18 12 17 16 14 15 26 27 13 E 24 23 22 21 20 29 25 (ID) 33 30 25 26 27 28 G (OD) 32 31 E 33 40 39 38 37 36 35 g 34 74723 2-28 lph One Genertion II Sternrive 90-806534970 1096
1 - Ger Housing 2 - Srew - Trim Plte or T 3 - Nut 4 - Srew 5 - Lokwsher 6 - noi Plte or T 7 - Shift Crnk 8 - Shift Spool ssemly 9 - Shims 10- Bering pter - Reverse Ger 11- Roller Bering 12- Thrust Wsher 13- Thrust Bering 14- Roller Bering 15- Reverse Ger 16- Retiner Spring - Cross Pin 17- Cluth 18- Cross Pin 19- Propeller Shft 20- Forwr Ger 21- Shim Sper 22- Thrust Bering 23- Roller Bering 24- Bering pter - Forwr Ger 25- Thrust Wsher 26- Thrust Bering 27- Thrust Re 28- Keepers 29- O-ring 30- Neele Bering 31- Bering Crrier 32- Propeller noe n Srews 33- Sels 34- T Wsher 35- Retining Nut 36- Thrust Hu 37- Continuity Wsher 38- Spline Wsher 39- T Wsher 40- Loknut Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon............. 92-8254073 B - 3M Brn hesive...... 92 25234-1 C - Quiksilver Bellows hesive.................. 92-86166 D - Quiksilver Neele Bering ssemly Lurint..... 92-8252651 E - Quiksilver Perfet Sel.... 92-34227-1 F - Permtex Ultr Blue Silione Selnt....... Otin Lolly G - Quiksilver Speil Lurint 101............ 92-138721 H - Lotite 8831............. 92-823089-1 I - Quiksilver High Performne Ger Lue. 92-8160264 Torque Speifitions 60 l. in. (6.8 N m) e f g 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-29
Speil Informtion For Counter-Rottion Ger Housing! CUTION PROPELLER SHFT The lter style propeller shft hs groove on the shft where the luth slies onto the shft. The keeper slot is lso move towr the forwr en of the shft. voi mge to stern rive unit. Drive unit mge will our if Lter Style prts re intermixe with Erlier Style prts. SHIFT SPOOL SSEMBLY The lter style shift spool ssemly for the ounter rottion hs lrger gp thn the erlier style. This lter style shift spool eginning with seril numer OF726586 is sol s whole ssemly n must e use when repling the erlier style (Prior to S/N OF726586). 75223 - Erlier Style Propeller Shft (Prior to S/N OF680000) - Lter Style Propeller Shft (S/N OF680000 n ove) 74877 FORWRD GER BERING BORE The lter style forwr ger ering ore is smller (3.2635 to 3.2650 in.) thn the erlier style (3.4985 to 3.5000 in.)this slightly smller ering ore for the forwr ger ering ptor is pproximtely 1/4 in. (6.3 mm) smller. 3.4985 to 3.5000 75219 - Erlier Style Shift Spool ssemly (Prior to S/N OF726586) e - Lter Style Shift Spool ssemly (S/N OF726586 n ove) f - Mesure En Ply Here t Gp. Erlier Style Forwr Ger Bore (Prior to S/N OF680000) 3.2635 to 3.2650 75241 75248 Lter Style Forwr Ger Bore (S/N OF680000 n ove) 2-30 lph One Genertion II Sternrive 90-806534970 1096
BERING CRRIER The lter style ering rrier is somewht slimmer n out n 1/8 of n inh tller thn the erlier style ering rrier. FORWRD GER BERING DPTOR The forwr ger ering ptor hs the neele ering presse into the ptor. For future referene, the neele ering insie the ering pter oes not require speil river. The neele ering is presse into the ptor until the ering is flush with the ege of the ptor ore. 75231 - Erlier Style Bering Crrier (Prior to S/N OF680000) - Lter Style Bering Crrier (S/N OF680000 n ove) THRUST COLLR The lter style thrust ollr is thinner thn the erlier style, ut still mintins the sme imeter. 74720 74721 75220 - Erlier Style Thrust Collr (Prior to S/N OF680000) - Lter Style Thrust Collr (S/N OF680000 n fter) REVERSE GER BERING DPTOR 74888 74886 The lter style reverse ger ering ptor hs smller imeter thn the erlier style ptor n is esigne to fit into the smller ore ger housing. - Erlier Style Forwr Ger Bering ptor (Prior to S/N OF680000) - Lter Style Forwr Ger Bering ptor (S/N OF680000 n ove) - Lter Style Forwr Ger Bering ptor Neele Bering - Erlier Style Thrust Wsher 74719 74718 - Erlier Style Reverse Ger Bering ptor (Prior to S/N OF680000) - Lter Style Reverse Ger Bering ptor (S/N OF680000 n ove) 90-806534970 1096 lph One Genertion II Sternrive 2-31
Counter-Rottion Ger Housing ssemly Speifitions Pinion Ger Height Tke reings in three lotions, 120 prt. Reings:.025 in. (0.64 mm). Pre-Disssemly Inspetion CTION Move propeller shft from one sie to nother Rotte propeller shft REDING Less thn.003 in. (0.08 mm).005 in. (.127 mm) or less 26410. Shift Spool En Ply 22086 Forwr n Reverse Ger Ientifition e f g IMPORTNT: The forwr n reverse gers look lmost ientil. There re two wys to istinguish etween the reverse n forwr gers. The reverse ger hs shorter hu n it hs groove ut into the k of the ger just insie the thrust ering re. h 74877 REVERSE - Shorter Hu - Groove FORWRD 50885 - Wshers (2) - Spring - Retiner - Spool e - Shift Shft f - Cstle Nut g - Cotter Pin h - En Ply Mesurement:.002 in. (.05mm) to.010 in. (.25mm) 2-32 lph One Genertion II Sternrive 90-806534970 1096
Forwr Ger Bklsh pply slight prelo on forwr ger using tools s shown. Reverse Ger Bklsh pply slight prelo on reverse ger using tools s shown. 50880 - Torque Wrenh (91-66274) - Propeller Nut [Torque to 45 l. in. (5 N m)] - Wsher (91-54048) - Pinion Nut ptor (91-610673) Chek Bklsh in four ples. Rotte the rive shft 90 fter eh hek. Bklsh Reing:.017-.028 in (0.43-0.71mm). e f - Torque Wrenh (91-66274) - Driver Bolt [Torque to 45 l. in. (5N m)] - Bering ptor Instlltion Tool (91-186051) - Reverse Ger 70973 Chek Bklsh in four ples. Rotte the rive shft 90 fter eh hek. Bklsh Reing:.050-.060 in. (1.27-1.52 mm). e f 70717 - Nuts (4) (otin lolly) - Three Ro [3/8 in. (9.5 mm) otin lolly] - Dil Initor Holing Tool (91-89897) - Dil Initor (91-582221) e - Initor Pointer-set initor pointer t I on klsh initor ro f - Bklsh Initor Ro (91-53459) - Nuts (4) (otin lolly) - Three Ro [3/8 in. (9.5 mm) otin lolly] - Dil Initor Holing Tool (91-89897) - Dil Initor (91-582221) e - Initor Pointer-set initor pointer t I on klsh initor ro f - Bklsh Initor Ro (91-53459) 70717 90-806534970 1096 lph One Genertion II Sternrive 2-33
THIS PGE IS INTENTIONLLY BLNK 2-34 lph One Genertion II Sternrive 90-806534970 1096
Trnsom ssemly Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Shift Cle Core Wire nhor Srews 20 2.3 Bellows Hose Clmps 35 4 Giml Ring to Bell Housing Hinge Pins 102 143 Giml Ring Srews 55 74 Steering Srew n Nut 60 81 Trnsom ssemly tthing Srews, Nut 90 Fitting Nut NOTE: Seurely tighten ll fsteners not liste elow. 20-25 10-14 27-34 14-19 90 Fitting 70-90 8-10 Oil Fill/Drin Srew 23 30 Speil Tools DESCRIPTION PRT NUMBER Bering Removl n 91-312295 Instlltion Tool Bellows Expner Tool 91-454971 Slie Hmmer Puller 91-345691 Shift Cle Removl 91-12037 n Instlltion Tool Driver 91-33492 Driver 91-33491 Driver 91-33489 Driver He 91-32325 Driver Ro 91-37323 Drive Shft Nut Wrenh 91-56775 lignment Tool 91-8054751 ssemly Expner Tool 91-454971 Hinge Pin Tool 91-78310 Mnrel 91-30366 Nut 11-24156 Speil Tools (ontinue) DESCRIPTION PRT NUMBER Plte (2) 91-29310 Puller 91-63616 Puller He 91-38919 Puller Shft 91-31229 Wsher 12-34961 Bushing Instlltion 91-806928T Tool Sleeve Instlltion Tool 91-818169 Sleeve Removl Tool 91-818162 Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver Bellows 92-86166 hesive Quiksilver 2-4-C 92-82540712 Mrine Lurint with Teflon Quiksilver U-Joint n 92-8280522 Giml Bering Grese Perfet Sel 92-34227-1 nti-corrosion Grese 92-78376-12 Loqui Primer T 92-59327-1 Lotite 8831 92-823089-1 Quiksilver Speil 92-138721 Lurint 101 90-806534970 1096 lph One Genertion II Sternrive 2-35
lph One Trnsom ssemly Exploe View Bell Housing Components 18 18 17 13 15 B 22 C 3 24 1 14 23 6 B (O.D.) 20 12 11 10 4 16 14 21 7 9 14 33 B 38 37 36 5 C 35 34 30 31 2 E F 25 32 27 28 29 26 73316 2-36 lph One Genertion II Sternrive 90-806534970 1096
1 - Bell Housing ssemly 2 - Gsket 3 - Connetor 4 - Pipe Plug 5 - Bushing 6 - Bushing 7 - Gsket (Ruer) 8 - O-ring 9 - Wsher (Synthne) 10-Stu 11- Wsher 12- Nut 13- Universl Joint Bellows 14- Groun Clip 15- Clmp 16- Sleeve 17- Hose 18- Clmp 19- Exhust Bellows 20- Sels 21- Clmp 22- Lever ssemly 23- Wsher 24- Srew 25- Shift Shft (Upper) 26- Coupling ssemly 27- Tuing 28- Clip 29- Clmp 30- Fitting ssemly 31- Connetor 32- Clmp 33- Hose 34- Clmp 35- Connetor 36- O-ring 37- Vlve ssemly 38- O-ring Lurints, Selers, n hesives - Quiksilver Bellows......... hesive.................. 92-86166 B - Lotite 8831............. 92-823089-1 C - Perfet Sel.............. 92-34227-1 D - Speil Lurint 101..... 92-138721 E - Quiksilver High Performne......... Ger Lue............. 92-8160264 F - 3M Brn hesive....... 92-25234-1 Torque Speifitions Tighten Seurely pproximtely 35 l. in. (4 N m) 50 l. ft. (68 N m) 8 l. ft. (11 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-37
Giml Housing Components 43 B 45 44 42 46 41 40 13 40 41 5 3 4 C 29 30 18 1 2 14 16 17 D 14 15 8 9 49 6 11 10 27 26 21 19 20 48 31 12 7 36 47 33 32 34 37 35 39 38 74861 2-38 lph One Genertion II Sternrive 90-806534970 1096
1 - Giml Housing 2 - Stu 3 - Lower Bushing 4 - Oil Sel 5 - Upper Bushing 6 - Grese Fitting 7 - Lurip 8 - Grese Sel 9 - Bering ssemly 10- Tolerne Ring 11- O-Ring 12- Stu 13- Sel 14- Pipe Plug 15- Wter Tue 16- Bushing 17- Cover 18- Srew 19- Lower Swivel Pin 20- Cotter Pin 21- Wsher 22- Bolt 23- Wsher 24- Wsher 25- Nut 26- Bolt 27- Clmp 28- Clmp 29- Wsher 30- Nut 31- Gsket 32- Connetor 33- Lokwsher 34- Nut 35- noi Plte 36- Sel 37- Gsket 38- Srew 39- Lokwsher 40- Hose 41- Clmp 42-90 Fitting 43- Nut 44- Wsher 45- O-ring 46- Connetor 47- Continuity Wire 48- Continuity Wire Connetion 49- Hose Clmp Lurints, Selers, n hesives - Quiksilver Bellows hesive.................. 92-86166 B - Quiksilver Perfet Sel.... 92-34227-1 C - Lotite 8831............. 92-823089-1 D - Quiksilver U-Joint n Giml Bering Grese.. 92-8280522 Torque Speifitions 70-90 l. in. (8-10 N m) 10-14 l. ft. (14-19 N m) 35-42 l. in. (3.96-4.75 N m) 25 l. ft. (34 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-39
Inner Trnsom Plte Components 1 4 5 6 7 8 9 15 3 10 11 14 13 2 74850 12 19 16 20 17 18 74865 1 - Trnsom Plte ssemly 2 - Pivot Bolts 3 - T Wshers 4 - Srew Engine Mounting 5 - Wsher 6 - Sper 7 - Wsher - Fier 8 - Lokwsher - Doule Woun 9 - Loknut 10- Wsher 11- Loknut 12- Shift Cle Outer Csing 13- En Guie 14- Core Wire nhor 15- nhor Srews 16- Core Wire 17- Shift Slie 18- Srew - Core Wire Cvity 19- Giml Housing Eyelet 20- Cle Wrpping Torque Speifitions 25 l. ft. (34 N m) 23 l. ft. (30 N m) 37 l. ft. (50 N m) 2-40 lph One Genertion II Sternrive 90-806534970 1096
Giml Ring n Steering Lever Components 24 11 17 15 25 8 10 9 12 6 18 21 7 16 13 19 23 22 20 1 5 26 4 3 14 10 9 8 2 73318 1 - Giml Ring 2 - Bushing 3 - Grese Fitting 4 - Lurip 5 - Hinge Pin 6 - Trim Limit Swith 7 - Wsher 8 - Srew 9 - Lokwsher 10- Retiner 11- Trim Wire Clmp 12- Srew 13- Steering Lever 14- Swivel Shft 15- Wsher 16- Wsher 17- Nut 18- Srew 19- Nut 20- Srew 21- Wsher 22- Wsher 23- Loknut 24- Clevis Pin 25- Cotter Pin 26- Trim Position Sener Lurints, Selers, n hesives - Resiwel Seler.......... 92-65150-1 Torque Speifitions 60 l. ft. (81 N m) 55 l. ft. (74 N m) 110 l. ft. (148 N m) 90-100 l. in. (10-11 N m) 90-806534970 1096 lph One Genertion II Sternrive 2-41