sc service manual
Contents
1. 27 27A 28 28A 29 29A 30 sti 32 33 34 35 36 a7 38 39 40 40A 41 41A 42 42A 7 27A Bearing Cone Pinion Bearing Bearing Cup Pinion Bearing Pinion Bearing Spacer Bearing Cup Pinion Bearing Bearing Cone Pinion Bearing Yoke Gear End Shims Pinion Shoulder Washer Pinion Shoulder Washer HD Yoke Gear End Seal Yoke Gear End Seal HD Pinion Seal Carrier Pinion Seal Carrier HD Page 5 Note PINION YORE REASSEMBLY m Place the pinion shim s 2 33 onto the pinion gear 2 32 2 Press the small pinion bearing cone 2 34 onto the pinion gear 3 Place the small pinion bearing cup 2 35 pinion bearing spacer 2 40 flat side against small bearing cup amp large pinion bearing cup 2 37 onto the pinion gear 4 Press the large pinion bearing cone 2 38 onto the pinion gear making sure that the pinion bearing spacer can move freely between the bearing cups 5 Place the pinion seal carrier 2 42 with seal pinion shoulder washer 2 40 amp yoke gear end shim s 2 39 onto the yoke gear end 2 26 6 Assemble the pinion with bearings washer yoke gear end 2 31 amp nut yoke gear end 2 30 onto the input yoke 7 Torque the nut yoke gear end to 75 Ib ft 8 Check for proper pinion bearing pre load by measuring the rolling torque of the pinion assembly correct torque is 6 to 10 Ib in Re shi2. IMCO 510 East Arrow Highway San Dimas CA 91773 800 899 8058 909 592 6162 Fax 909 592 6052 TABLE OF CONTENTS Upper Gearhead Disassembly Pinion Yoke Disassembly Upper Drive Shaft Disassembly Upper Case Accessories Drawing Upper Case Accessories Paten Upper Case Gears amp Components Drawing LL LL Upper Case Gears amp Components Parts List LL LL Le Pinion Yoke Upper Clutch Shaft Upper Gearhead Reassembly Upper Gearhead Reassembly Continued SC Setup Diagrams SC Work Sheet re EINE V SION ORO IT AE TOT Backlash Assembly Drawing ____ LL Lower Gear Case Disassembly Lower Gear Case Drawing 21 sa LL au EE Lower Gear Case Parts List Lower Gear Case Assembly LL ll ll ili ill Lower Gear Case Assembly Continued Lower Pinion Height Measurment Drawing Dissassembly Assembly Tools Check Oil Before Running First break in oil change 5 8 hours Oil is filled to upper drain screw Fig 1 24 pump oil from bottom drain screw Fig 3 32 Recommended oil change intervals 20 30 hours Heavy use or high HP change more often Serial Number Date of Purchase Purchased From 1 27 10 Rev 8 UPPER GEARHEAD DISASSEMBLY NOTE The follovving instructions assume that the drive has been removed from the transom assembly and is shifted to the neutral position The lower unit has also been removed along with the drive shaft center socket and U joints The f
3. 5 8 18 locknut 2 30 amp washer 2 31 Remove the pinion gear with bearings pinion shim s 2 33 pinion shoulder washer 2 40 amp pinion seal carrier 2 42 from the yoke gear end 2 26 Note If the yoke gear end seal 2 41 needs replacement it must be removed and installed from the side of the pinion seal carrier which faces the large pinion bearing cup 3 1 Remove the large bearing 2 37 38 pinion bearing spacer 2 40 small bearing 2 34 35 amp pinion shim s 2 33 from the pinion gear UPPER DRIVE SHAFT DISASSEMBLY Press down on the upper clutch gear 2 13 to release the upper drive shaft retainer keepers 2 9 and remove all components from the clutch shaft 2 17 Page 1 Upper Case Accessories Fig 1 Std and 1 Lovvers Only Page 2 Upper Case Accessories Fig 1 Item Description Qty Part Number 1 Upper Case Black 1 Logg 1A Upper Case Silver LL 011184 2 TopCap LL Rear Cap Black 1 01 1528 Rear Cap Silver 01 1528 Mid Section Black LL 01 1050 Mid Section Silver 014052 e Screw 5 16 18 x 1 2 Button Head 1 08 040705041 Top Cap Lid LL 01 2071 _____ Screw 3 8 16 x 1 1 4 S S 12 Point 8 08 070806091 Upper Cooling Hose LL 09 2006 Screw 3 8 16 x 1 S S Allen Head 2 08 060806081 10 Shift Shaft Seal Disc Upper 1 111016 ST 11 Screw 3 8 16
4. Nut 7 16 20 Nylock S S Thin 2 08 090904001 5 Washer 7 16 AN S S Thin 2 08160900001 6 O Ring Oil Passage LI 11 4011 7 O Ring Water Passage LL 11 2143 8 O Ring Cooling Water Passage 1 1204 9 Pipe Plug 1 8 NPT SS 1 00207 10 Stud 7 16 x 2 S S 2 08 130904121 11 Retainer Ring Vertical Shaft Coupler 1 08 121500001 Vertical Shaft Coupler 1 02148 O Ring Alignment Space LL Alignment Spacer 1 01205 15 Shim Vertical Shaft Upper Kit 012012 16 Tab Washer Vertical Shaft 1 01 2043 17 Bearing Cup Vertical Shaft Upper 1 10202 18 Bearing Cone Vertical Shaft Upper 1 101011 19 Bearing Cone Vertical Shaft Lower 1 101000 20 Bearing Cup Vertical Shaft Lower 1 102009 21 Shim Vertical Shaft Lower Kit 012013 22 Shim Prop Gear Kit 012014 23 Bearing Cup Prop Gear LI 102007 24 Bearing Cone Prop Gear LL 10 1008 _____ 25 Prop 8 Pinion Gear 1 50 Set 01840 25A Prop amp Pinion Gear 1 34 Set 018444 258 Prop 8 Pinion Gear1 25 Set 01828 26 Bushing Prop Shaft X LL et 27 PropShaf i 1 018009 27A Prop Shaft 114 1 03000 278 Prop Shaft 1716 1 013570 28 Bearing
5. Roller LL 103006 29 Nut Pinion Gear LL O1 2251 E f 80 Cover Nuit LL 0208 31 TabWasher BearingCarrier LL 01202 DrainScrew 1 012504 33 Drain Screw Sealing Washer 1 111017 Bearing Carrier 1 Prop Shaft 1 01 2130 Bearing Carrier 1 1 4 Prop Shaft 1 00 2181 Bearing Carrier 1 7 16 Prop Shaft 1 01 2575 35 Seal Prop Shaft 1 1 11 3085 35A Seal Prop Shaft 1 Line Cut 1 113032 35B Seal Prop Shaft 1 1 4 2 11 3033 35C Seal Prop Shaft1 7 16 2 113044 36 Bearing Cup I Prop Shaft 1 10204 36A Bearing Cup 1 1 4 Prop Shaft 1 10 2016 368 Bearing Cup 1 7 16 Prop Shaft 14 10 2018 37 BearingCone 1 PropShaft 1 1000738 37A Bearing Cone 1 1 4 Prop Shaft 1 10105 OI 378 BearingCone 17 16 PropShaft 1 101017 38 O Ring Bearing Carrier LL 112344 39 Shim Bearing Carrier Kit 0201 40 Thrust Washer 109 Thick Page 13 1 012590 LOVVER GEAR CASE ASSEMBLY Note Optimum performance of lovver gears requires pinion height setup use Lovver Pinion Gear Height Measurement Fig 7 sheet to set pinion gear d 2 3 ae tO 17 18 18 20 21 22 23 24 25 26 27 Install the vertical shaft roller bearing 6 28
6. into the gear case Install the vertical shaft lower bearing cup 6 20 amp shims 6 21 Install the lower 6 19 upper 6 18 bearing cones and roller bearing race 6 3 onto the vertical shaft 6 2 Install the vertical shaft into the gear case Install the upper bearing cup 6 17 Tab washer 6 16 shims 6 15 amp alignment spacer 6 14 onto the vertical shaft Install the vertical shaft clamp plate onto the gear case Mercury Part 43559T Check the rolling torque of the vertical shaft optimum 3 to 5 Ib in Adjust the thickness of the upper shim to obtain the correct rolling torque Temporarily install the pinion gear 6 25 amp flange nut 6 29 Check the pinion gear height optimum 025 see Lower Pinion Height Measurement Fig 7 If pinion gear height requires correction remove all associated components and adjust the lower bearing shims Any adjustment here requires that the upper bearing shims be compensated by the same amount Remove the vertical shaft amp pinion Install the prop gear bearing shims 6 22 amp bearing cup 6 23 into the gear case Install the prop gear bearing cone 6 24 onto the prop gear 6 25 Install the prop gear with bearing into the gear case The prop shaft bushing 6 26 used only with the 01 8244 and 01 8248 gear sets must be installed into the prop gear at this time Re install the vertical shaft components described above and install the
7. vertical shaft clamp plate Install the bearing carrier bearing cone 6 37 onto the prop shaft Install the prop shaft with bearing into the gear case Install the prop shaft seals 6 35 amp bearing carrier bearing cup 6 36 into the bearing carrier 6 34 Temporarily install the bearing carrier into the gear housing Install the bearing carrier tab washer 6 31 amp retainer nut 6 30 and torque the retainer nut to 150 Ib ft Rotate the vertical shaft at least 3 turns and check the prop gear backlash optimum 012 to 015 Adjust the thickness of the prop gear bearing cup shims 6 22 to obtain the correct backlash readings During final assembly be sure to clean amp loctite the vertical shaft flange nut 6 29 Torque the nut to 100 Ib ft Temporarily install the bearing carrier thrust washer 6 40 amp shims 6 39 prior to prop shaft amp bearing carrier installation Torque the bearing carrier retainer nut to 150 Ib ft Check overall rolling torque at the vertical shaft optimum 11 to 17 Ib in Page 14 LOVVER GEAR CASE ASSEMBLY CONT 28 Adjust the thickness of the bearing carrier shims 6 39 to obtain the correct rolling torque readings 29 Upon final assembly be sure to install the bearing carrier O ring 6 38 prior to installation of the bearing carrier 30 After applying final torque of the bearing carrier retainer nut 6 30 bend one tab of the tab washer 6 31 to engage with one of
8. x 2 S S Allen Head 1 08 060806121 O Ring Rear Cap 1 11 4015 13 DetentKit BallCylinder LL 01 2044 14 Fitting 3 8 NPT to 8JIC S S 1 09 2005 15 Fitting 1 4 Hose to 1 8 NPT Brass 1 09 2004 16 Lower Cooling Hose LL 09 2003 17 Screw 7 16 14x21 4 S S12Poin 2 08 070907141 18 Screw 3 8 16 x 3 1 4 S S Allen Head Std amp 1 1 08 060806171 19 Stud z16x2 LI 8 08 130904121 20 Dowel Pin 1 8 x 7 8 Long 2 01 2113 21 O Ring Upper Cap 1 11 2157 22 O Ring Cooling Jet 2 11204 23 Cooling Jet 2 012184 TT 24 OillevelScrew LL 01 2504 28 Oil Level Screw Washer 1 11 1017 lt 26 SpringKit LL 01 2045 O Ring Gimbal Shift 1 1121389 28 O Ring Gimbal Water 1 11 4021 29 O Ring Retainer Nut Pinion Gear 1 11 2154 30 Screw 5 16 18 x 1 2 Allen Set Tower Retainer 1 08 050705041 31 O Ring Lower Shaft Seal 1 11213 32 O Ring Lower Oil Pressure Seal 1 114012 33 O Ring Lower Water Seal 10 34 Fitting 1 4 Hose to 4 JIC Brass 1 09 2002 35 Fitting 1 8 NPT to 4 JIC 45 Brass 1 09 2001 36 Lock Nut 7 16 20 S S Thin Nylock Nut 8 08 090904001 Washer 7 16 AN S S Flat Washer Thin 8 08 160900001 38 Screw 7 16 14x11 2 S S12Poin 1 08 070907101 39 Guide Pads Port amp Starb
9. Case ie TTT An W i Bearing Cup d 10 2022 Pinion Clutch Gear 1 Parallel TR K We AL S A TU Mounting ATA Distance AY ER 1 i Bearing Seat Clutch Shaft perns Retainer Spacing Page 8 SC VVO RR SHEET Fig 4 Serial UPPER C AP Parallels 2 250 Measurement A Nom 1 994 Cap Deck to Thrust Sat Total B Nom 0 256 DEC K TO PINION C ENTERLINE Deck to Tool Measurement C Nom 1 719 Less Parallel 1 000 Total Nom 0 719 Plus 1 2 tool 1 9065 Deck to Pinion CL Total D Nom 2 6255 UPPER THRUST SEAT Deck to Pinion CL D Nom 2 6255 B Nom 0 256 Pinion CLto Upper Thrust Seat Total E ____ Nom 2 3695 Bearing Thickness 0 125 Mounting Distance 2 183 Race Thickness F Nom 0 061 LOWER THRUST SEAT Measurement G Nom 5 994 Parallel 1 000 Deck to Lower Thrust Seat Total Nom 4 994 Deck to Pinion CL D Nom 2 6255 Pinion CLto Lower Thrust Seat Total H Nom 2 3685 Bearing Thickness 0 125 Mounting Distance 2 183 Race Thickness J Nom 0 061 GEAR MEASURMENTS Gear One Measurement K1 Nom 1 874 Less Parallel 1 000 Gear Depth One Total L Nom 0 874 Gear Two Measurement K2 Nom 1 874 Less Parallel 1 000 Gear Depth Two Total M Nom 0 874 GEAR ASSEMBLY Gear Depth One L Nom 0 874 Gear Depth Two Nom 0 874 Race Thickness F Nom 0 061 Race Thickness J Nom 0 061 2 x Bearing Thickness 0 250 Retainer Spacing Measurement N Norm 2 650 Gear Ass
10. embly Total O 4 768 CAP C RUSH Pinion CLto Upper Thrust Seat E Nom 2 3695 Pinion CL to Lower Thrust Seat H Nom 2 3695 Upper Thrust Seat to Lower Thrust Seat Total P Nom 4 739 Gear Assembly Total O Nom 4 768 Cap Crush Page 9 Nom 020 030 Backlash Assembly Fig 5 01 5407 Backlash Wand 01 5408 Dial Indicator 01 5404 Backlash Tower 01 5406 Pinion Gear Lock Page 10 LOVVER GEAR CASE DISASSEMBLY Note The following instructions assume that the lower unit has already been separated from the upper gearhead Steps followed by asterisks are required only if inspection indicates component replacement Brackets following the part name represent the drawing figure and item 1 2 3 4 Bend the tabs of the bearing carrier tab washer 6 31 away from the bearing carrier retainer nut 6 30 Remove the bearing carrier retainer nut 6 30 Remove the bearing carrier 6 34 Remove the prop shaft 6 27 The prop shaft bushing 6 26 used only with the 01 8244 amp 01 8248 gear sets may come out with the prop shaft NO a Remove the bearing carrier O ring 6 38 shims 6 39 amp thrust washer 6 40 Remove the vertical shaft flange nut 6 29 Remove O ring 6 13 amp alignment spacer 6 14 shims 6 15 amp tab washer 6 16 Remove the vertical shaft 6 2 with bearings amp pinion gear 6 25 Remove the prop gear 6 25 with bearing The prop shaft bushi
11. hat the O ring is fully contained in the outer groove of the pinion seal carrier 8 Install the pinion retainer nut 2 25 until contact is made 9 Rotate the yoke and recheck alignment of clutch gear timing marks 10 Torque the pinion retainer nut to 200 lb ft When using an extension tool remember to recalculate torque value 11 Place the yoke amp cam 2 23 into the clutch cone groove with the nuts facing down RUDA NOD Page 6 14 15 17 18 19 UPPER GEARHEAD REASSEMBLY CONTINUED Insert the shift linkage 2 19 with shift cable retainer into the shift link cavity from the front side of the gearhead From the rear of the gearhead place the small hole of the shift arm onto the pin of the shift linkage and secure with washer amp cotter key Be sure that the shift arm is positioned correctly Install the shift shaft 2 21 align holes in shift shaft with the yoke and cam and the shift arm Install the two 4 28 socket cap screws 2 22 and torque to 100 Ib in Place the cooling jets 1 23 into the gear head Rotate to position correctly Replace the upper shift shaft seal disc 1 10 cooling jet O rings 1 22 and O ring upper cap 1 21 Attach the top cap 1 2 with bearings torquing the screws alternately to 20 Ib ft Attach the rear cap 1 3 including the detent kit 1 13 Page 7 SC Setup Diagrams Fig 3 1 Parallel 1 25 Parallel C Upper
12. m the yoke if required UPPER CLUTCH SHAFT REASSEMBLY Optimum performance of the upper gearhead requires setting up the pinion amp clutch gears with IMCO SC Setup Diagrams Fig 3 and SC Work Sheet Fig 4 1 Place the lower clutch gear 2 13 onto the upper clutch shaft 2 17 allowing it to rest on the thrust collar 2 Place the lower thrust bearing clutch spring 2 14 silver side up lower clutch spring 2 15 clutch cone 2 16 upper clutch spring 2 15 upper thrust bearing clutch spring 2 14 silver side down upper clutch gear 2 13 and clutch shaft retainer thrust collar 2 10 onto the upper clutch shaft 3 Compress the upper clutch gear and install the keepers 2 9 Release the upper gear and check that the retainer keepers are seated correctly UPPER GEARHEAD REASSEMBLY Position the lower clutch gear thrust race 2 7 into the upper gearhead Place the lower clutch gear thrust bearing 2 8 onto the lower race and center Install the upper drive shaft gear assembly 2 9 thru 17 into the gearhead Place the upper clutch gear thrust bearing 2 8 amp thrust race 2 7 onto the upper clutch gear 5 Align the clutch gear timing marks over or over with the center of the rear face of the gearhead Install the yoke pinion assembly 2 26 42 into the gear head Place the O ring retainer nut 1 29 over the yoke making sure t
13. ng 6 26 may be removed from the gear at this time if it was not removed in step 4 Remove the lower vertical shaft bearing cup 6 20 amp shims 6 21 Remove the vertical shaft roller bearing 6 28 Remove the upper 6 18 amp lower 6 19 bearing cones from the vertical shaft Remove the roller bearing race 6 3 from the vertical shaft Remove the bearing cup 6 36 from the bearing carrier Remove the prop shaft seals 6 35 from the bearing carrier Remove the prop gear bearing cone 6 24 from the prop gear Remove the prop gear bearing cup 6 23 amp shims 6 22 Remove the bearing cone 6 37 from the prop shaft Remove the O ring 6 6 O ring 6 7 amp O ring 6 8 Page 11 Lovver Gear Case Fig 6 Indicates Drive Length 0 Standard Length 1 1 l Shorter IA 2 2 Shorter 18 J 3 3 Shorter IC men 8 2 O Lower Gear Case Fig 6 Description Gy Part Number 1 LowerCase 0 StandardLength 1 01110____ __1A LowerCase 1 Shorter 1 Im 1B Lower Case 2 Shorter 1 011122 Lower Case 3 Shorter 1 01 1128 2 Vertical Shaft Standard Length 1 018255 2A Vertical Shaft 1 Shorter 14 01 3256 2B VerticalShaft 2 Shorter 1 013257 Vertical Shaft 3 Shorter 14 01 8258 3 Bearing Race LL 106005 4
14. oard 1 01 206 40 Screw 3 8 16 x 3 4 S S Hex Head 2 08 010806061 A1 Washer 3 8 S S Star Washer 2 08 110800001 42 Anode 1 01 2067 Page 3 Upper Case Gears amp Components Fig 2 Pi KAS Di GB SS a Te S On I a K an CO I B Cu Page 4 Upper Case Gears amp Components Fig 2 Upper Case Black Upper Case Silver Top Cap Roller Bearing Clutch Shaft Cap Mid Section Black Mid Section Silver Tower Race Roller Bearing Clutch Shaft Tower Thrust Race Thrust Bearin N Clutch Shaft Retainer Thrust Collar Snap Ring Clutch Gear Bearing Retainer Roller Bearing Internal Gear SC Clutch Gear 16 19 Thrust Bearing Clutch Spring Clutch Spring SC Clutch Cone 17 SC Clutch Shaft SC Tower SC Shift Linkage Ass Shift Shaft Bushing SC Shift Shaft Screw 1 4 28 x 3 4 Socket Cap oke amp Cam Seal Shift Shaft Retainer Nut Yoke Gear End Yoke Gear End HD Cross amp Bearing Cup dia 1 078 Cross amp Bearing HD Cup dia 1 219 Center Socket Center Socket HD Yoke Coupler End Yoke Coupler End HD Nut Yoke Gear End 5 8 18 Thin Nylock Steel Washer Yoke Gear End SC Pinion Gear 2 Item 1 TA EC El 28 E 6 EE EE 8 9 10 11 12 13 14 EC 16 17 18 19 20 ler 22 23 V 24 25 26 26A
15. ollowing drawings show the upper drive complete It is not necessary to remove the gearhead from the mid section Steps followed by asterisk are required only if inspection indicates component replacement Brackets following the part name represent the drawing figure and item NEG NF D Remove the rear cover 1 3 shift detent ball amp spring 1 13 Remove 12 point 3 8 16 screws 1 7 top cap 1 2 and O ring 1 21 Remove 1 4 28 socket cap screws 2 22 from shift shaft Remove the cooling jet O rings 1 22 amp cooling jets 1 23 Remove the upper shift shaft seal disc 1 10 Shift shaft 2 21 amp yoke and cam 2 23 Remove the shift linkage cotter key washer shift linkage assembly 2 19 amp shift cable retainer Shift linkage is removed from the front of the gearhead Remove the pinion retainer nut 2 25 retainer nut O ring 1 29 amp pinion yoke assembly 30 42 Note In steps 8 and 10 be sure to maintain correct assembly position of the upper amp lower thrust bearings amp races 8 9 10 11 Remove the upper thrust race 2 7 8 upper thrust bearing 2 8 Remove the clutch shaft 2 17 and gear assembly 2 9 17 Remove the lower thrust bearing 2 8 and lower thrust race 2 7 Remove the shift shaft bushings 2 20 amp shift shaft seals 2 24 note position of components if replacement is required PINION YOKE DISASSEMBLY Remove
16. the slots in the retainer nut Lower Pinion Height Measurement Fig 7 a Pinion Gear 025 Feeler Gage UE VAVaAVavaVAVA NA RRI RR DOR MA LA AI Pinion Height Gage Mercury Part Number 9 1 42840 Page 15 Disassembly Assembly Tools SC Upper IMCO Mercury 1 Tower amp Cap Race Puller Kit 91 90774 2 Pinion Retainer Nut Wrench 91 17256 3 Bearing amp Race Installer Tower 91 90773 4 Tower Internal Bearing Puller 01 5401 5 Tower Removal Tool 01 5402 6 Bearing amp Race Installer Cap 01 5403 7 Backlash Tool Kit 01 8018 A Backlash Tower 01 5404 B Indicator Bracket 01 5405 C Pinion Gear Lock 01 5406 D Backlash wand 01 5407 E Dial Indicator 01 5408 SC Lower 1 Cover Nut Wrench 1 Prop Shaft 91 61069T 2 Cover Nut Wrench 1 Lo Prop Shaft 91 840393 3 Lower Pinion Height Gauge 91 42840 4 Prop Gear Cup Installer 91 31106 5 Vertical Shaft Roller Bearing Driver A Pilot 91 813653 B Driver Rod 91 37323 C Bearing Remover 91 63638T 6 Vertical Shaft Roller Bearing Installer A Pilot 91 813653 B Threaded Rod 91 31229 C Bearing Installer 91 89867 7 Clamp Plate 91 43559T 8 Dial Indicator 91 58222A1 9 Vertical Shaft Bearing Cup Puller 01 5409 10 Prop Gear Cup Puller 01 5410 11 Bearing Carrier Cup 8 Seal Installer 1 V4 01 5411 Page 16
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