Mercury Lower Unit Repair – Ultimate Step-by-Step Guide

Mercury 40-60 HP Lower Unit Repair – THE ONLY GUIDE YOU NEED (Step-by-Step With All Tools) Can you handle the rebuilding of the lower unit on your own? You only need four things: a documentation, tools, brains, and inspiration. This is what this video is about. You will see the repair of a Mercury 40-60 HP gear case (8M0086325/893680T05) in great detail - no one else will show you this. You will also see all the necessary and unnecessary tools with details on how they work and how much they cost. 0:00 Do-it-yourself specialist. 2:47 Important aspects from the service manual. 4:48 Lubricants. ** Lower Driveshaft Bearing Installation PROCEDURE ** 7:48 Bearing 812768 and Lower Driveshaft Bearing Driver Assembly tool 91-817058A1. It's strange, but we see 817059 on the tool. 9:28 We drive the bearing of the driveshaft with the flat side (with numbers) towards the flange of the tool, having previously lubricated it with 2-4-C. ** Forward Gear Bearing Race Installation PROCEDURE ** 11:28 The most important step. 12:37 About shims. The documentation recommends starting with 0.25 mm. The old one had 0.9 mm. About the part numbers for the shims watch here:    • All Parts of Mercury 50 EFI Lower Unit (8M...   14:14 Forward Gear Bearing Race Driver Cup 91-817009 tool for the procedure of driving the race. 14:53 What tool should I use to drive 91-817009? 16:34 You need to lubricate the race with Assembly Grease 8M0071836, but I lubricated with 2-4-C. 17:37 Driving the cup/race - procedure with all aspects you need to consider. 21:42 Installing the front gear. ** Vertical shaft installation PROCEDURE ** 23:12 About the drive shaft installation procedure. 24:48 Driveshaft Holding Tool 91-877840A1, wrench for the pinion nut is 11/16. The nut is tightened with a torque of 67 Nm. 25:43 Installing the shim, upper driveshaft race and retainer nut on the driveshaft. Tightening torque is 102 Nm. It is recommended to start with 0.36 mm shim, my shim is 0.5 mm. Bearing Retaining Tool 91-43506. 27:17 Humpty Dumpty. What actually lifts it? Somehow I doubt that anything lifts it. ** Pinion Gear Depth PROCEDURE ** 27:54 We need to check the position of the pinion gear - the gap between this gear and the reverse gear. Bearing Preload Tool 91-14311A2 (91-14311A04 on the box). 29:10 What exactly do we check and how? Pinion Gear Location Tool (Pinion Gauge Tool) 91-817008A2. 30:58 The first doubts about the 0.25mm shim behind the big race. But we will check this only at the very end. 32:49 For Bearing Preload Tool 91-14311A2 watch:    • Gear Shifting On Mercury 40-60 HP   33:29 We need to get a clearance of 0.64 mm (0.025") between the Pinion Gauge Tool and the pinion gear. 34:35 There is something to tell about Pinion Gear Depth procedure. 37:17 For the second time, doubts about the shim 0.25 mm behind the forward gear race. ** INTERMEDIATE RESULTS ** 38:51 Finally, we go on the Forward Gear Backlash procedure - checking the clearance between the pinion and the forward gear. 39:48 For the puller watch:    • Lower Unit Bearing Carrier Puller - Try DI...   40:38 For the assembly of the bearing carrier, prop shaft and clutch watch:    • Clutch and Bearing Carrier Assembly for Me...   41:09 Corrections regarding all procedures and documentation. ** FINAL STEPS ** 45:35 As a result, we have a 0.9 mm shim under the forward gear race, 0.5 mm under the race of the drive shaft bearing and we have the clearance of 0.32 mm within the spec! Watch all the headache here:    • The Ultimate Guide to Lower Unit Backlashes   47:30 Regarding Loctite 7649 Prime N (92-809824) for degreasing. 48:17 Cleaning is very important. 49:28 Regarding the shift shaft you can look at, for example, this:    • Don't Pull the Shift Shaft Until You See T...   50:18 Installing the prop shaft and the bearing carrier with O-ring 25-815460, about bolts and washers. Tightening torque is 30 Nm. 51:32 Shift shaft sealing. 52:09 Again about the sealing lip, or which side do you install the seal 26-8M0204708. 52:40 Installing the seals 26-8M0204708 (set on Loctite 271), 45258 (O-ring, lubricate with 2-4-C). 54:21 Installing the water pump:    • Lower Unit Water Pump Assembly - HOW TO DO...   54:46 Let's check forward gear backlash again when everything is assembled. Clean up as per the doc. Watch here:    • The Ultimate Guide to Lower Unit Backlashes   ** TESTS ** 55:53 Gear Housing Pressure Test. 10-12 psi for 15 minutes. 57:51 It holds! Conclusion. 1:00:51 About filling the oil:    • The Proper Way to Fill Oil into a Mercury ...   1:01:34 About installing the lower unit on the mid unit. 1:02:30 First start-up. 1:03:42 Gear shifting. 1:04:00 Tests at high revs. 1:04:40 Smartcraft readings. 1:04:51 Tests on water. 1:07:49 That's it. Full playlist for this lower unit:    • Mercury 40-60 HP EFI (2009) Lower Unit 1.8...