waterpump replacement for auto-transmisson models
Contents
1. slide ball bearing L washer sealing cover with rubber ring installed impeller plate and impeller onto the driveshaft Lubricate impeller with liquid soap or light grease Install drive shaft into housing Rotate driveshaft clockwise at splined end while pulling to seat impeller and bearing in place Push out driveshaft Then install the ball bearing lock ring and tighten turn counterclockwise left hand thread 5 Checking End Play A Using Transmission Gauge Measure end play as described in the manual B Dial Indicator Install driveshaft and transmission without the neutral and forward reverse springs Bolt on lower unit Measure the end play at the driveshaft end with a dial indicator C End Play Stop Bar Make a stop bar as shown in Pic06 End Play Stop Bar This is a flat bar with two holes to bolt bar to driveshaft housing and a bolt centered above the driveshaft Install driveshaft and transmission without the neutral and forward reverse springs Bolt on lower unit Measure gap between bolt and driveshaft with dial caliper or feeler gauge Pull up on driveshaft and measure clearance The difference is the endplay PicO6 End Play Stop Bar AGF 04 03 10 Page 8 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 6 Install the neutral and forward reverse springs on transmission assembly Turn driveshaft counterclockwise and push into neutral spring 72. 32 screw can be used to pull out the transmission assembly and then the driveshaft as described in the manual Disassemble the transmission if necessary Note location of bronze thrust washers Lower thrust washer is 020 thick upper washer is 020 or 031 on some models Working on driveshaft housing use Ball Bearing Lock Ring Tool to remove ball bearing lock ring Turn tool clockwise to loosen left hand thread Ball Bearing Lock Ring Tool Options A See Pic01 amp Pic02 Ball Bearing Lock Ring Tool Weld two bars 3 8 x1 4 x1 to a pipe The bars extend 3 8 from the pipe pipe is 3 4 nominal size Critical dimensions are the 3 8 bar width and 1 1 4 distance across the bars The pipe bar assy can be squeezed in a vise to get the 1 1 4 distance Overall pipe length is 15 amp pipe is drilled for a 3 8 dia crossbar handle Basically we made it from scrap material Note the 1 1 4 distance across the bars gives a loose fit Dimension can be increased to 1 3 8 if the ends are radiused to fit lock ring 7 Pic0O1 Ball Bearing Lock Ring Tool AGF 04 03 10 Page 3 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 Lom mA ee M se i ee ee ee oO i ee MMiIMtlM Sas epee ae ee ee ee Mas eer MFM QTY PART NUMBER _OESSRICTION dg PRB ine e eeN G0 438 TERU Y ates Pic02 Ball Bearing Lock Ring Tool B Modify a
3. on a motor Early models i e Mark 10 10A 15 15A 28 and Mark 28A below s n 1236090 the water pump cartridge has to be pulled out to change the impeller Later models Mark 28A s n 1236090 amp up and Merc models have the water pump cartridge reversed for easier disassembly The impeller can be changed without removing the water pump cartridge or the powerhead The Service Manual describes the repair of both types together which is confusing Mercury really did not write this procedure very well Disassembly 1 Shift motor to forward 2 Remove transmission cover plate Be careful the pawl springs behind the cover plate may pop out Remove pawl springs shaft and spacer 3 Remove lower unit 4 Remove cotter pin from lower control shift rod and turn transmission shaft lever up or pull the pawls outward to clear the neutral and forward reverse springs AGF 04 03 10 5 6 1 8 9 Page 2 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 Remove powerhead On Mark 10 10A and 15A the shift linkage must be disconnected and removed with the powerhead Later style models Mark 28A s n 1236090 and up and Merc models can be serviced without removing the powerhead recommend removing it to make it easier to work on Push down on driveshaft to remove entire driveshaft transmission assembly On later models powerhead installed a long 10
4. top using a large wooden dowel 11 Clean and inspect all parts for wear If impeller vanes are broken off make sure all pieces are removed and water passages are clear AGF 04 03 10 Page 6 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 Reassembly 1 Replace all seals and gaskets 2 Manual shows a Water Pump Assembler Shaft Tool The motor can be assembled without this it was a later addition It s basically a dummy shaft made to fit the Ball Bearing Lock Ring Tool use the driveshaft as an assembly tool 3 Tilt driveshaft housing up for reassembly Another way is to install the housing upside down on a motor stand or to a 2x6 clamped in a vise The housing can be tilted into the best position Pic05 Housing Inverted Pic05 Housing Inverted AGF 04 03 10 Page 7 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 4 Early models install cover plate in housing below locating pin Slide ball bearing water pump cartridge with sealing ring and L washer installed and impeller onto the driveshaft Install driveshaft into housing being careful to align cartridge groove with the dowel pin in housing Pull on driveshaft to seat cartridge and bearing in place Push out driveshaft Then install the ball bearing lock ring and tighten turn counterclockwise left hand thread Later models
5. 3 8 universal joint Disassemble a 3 8 universal joint Cut a 3 8 square bar to a length of 1 1 4 see note above Center the bar in the prongs of the u joint drill amp re install the pin C Obtain a pipe or tubing having approx 1 1 4 to 1 375 O D Cut it to leave two tabs 3 8 wide x 3 8 deep D Modify a deep socket by cutting tabs to fit the lock ring E Use a piece of 1 4 flat bar about 7 long and 1 3 8 wide F Use a 3 8 square bar Cut notches in a piece of pipe and weld or glue a 3 8 square bar by 1 1 4 long in the end AGF 04 03 10 Page 4 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 G Early Models pull out impeller water pump cartridge assembly and driveshaft bearing using water pump puller tool Make sure the tool is pulling on the impeller not the driveshaft housing above it Manual says cover plate large washer cannot be removed without tilting it Not true it will pull out with the impeller just bent but easily flattened H Later Models pull out impeller impeller plate sealing cover L washer and ball bearing Pull on the impeller not the water pump cartridge above it 10 Water Pump Puller Tool Options A Mercury still sells this tool made one from heavy wire generally bent to the shape shown in the manual The wire was too thin but it did work made another from wire approx 3 1
6. 6 dia see Pic03 Puller Tool The bent ends have to be small enough to fit thru the water pump as shown in the manual The cartridge can be hard to pull out on the earlier models sometimes put a 2x4 thru the handle as a crossbar to pull on it Pic03 Puller Tool AGF 04 03 10 Page 5 of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 11 Water Pump Puller Tool Options cont d B now use a small slide hammer with 2 expandable hooks see Pic04 Slide Hammer Puller The hooks expand and do not slip off A couple of tugs and it is out Wish I d known that before it would have eliminated a lot of the contortions went thru trying to pull these things out Source http Awww harbortfreight com cpi ctaf displayitem taf ltemnumber 5469 Pic04 Slide Hammer Puller C Or Push out from the top Early models use a round bar or deep socket and extension with a dia of 0 675 max to fit thru the hole in the driveshaft housing and push on the impeller Hit the bar with a hammer to push out the impeller and water pump cartridge Later models Mark 28A s n 1236090 amp up and Merc models only the impeller cover and bearing are pulled out The service manual does not describe how to remove the water pump cartridge Oldmercs com states Unnecessary removal of this housing is not recommended If removing it use a puller or drive it out from the
7. Check impeller key is on driveshaft 8 Insert driveshaft into driveshaft housing Turn driveshaft clockwise from the splined end until impeller and key align Push assembly in all the way The driveshaft and transmission can also be installed separately as per the manual 9 Check impeller key is in properly by turning driveshaft clockwise The shaft should be difficult to turn by hand 10 Install gear housing 11 Install flinger ring and o ring on driveshaft 12 Install powerhead 13 With motor in neutral and transmission shift lever horizontal adjust the lower control rod till it fits into shift lever Install cotter pin 14 Install pawl springs as per the manual 15 Hold the pawl springs in place with a thin putty knife or shim stock Loosely bolt on the cover and gasket then pull out the putty knife or shim stock 16 Fill with Lubriplate 105 grease or equivalent 17 Check telltale or pee hole is not plugged 18 Start motor in water and check for water from telltale Note when running in a test tank water level should be above the lower dynafloat mounts to prime the water pump 19 That s it tune it up and run it hope this has been helpful any comments or questions are welcome Allan Fuller fullerag hotmail com Acknowledgements have shamelessly plagiarized the Merc Service Manual Some of the info was obtained from posts on John s Old Mercury Q amp A Board Rev01 04 03 10 Pics a
8. Page of 8 WATER PUMP REPAIR ON AUTOMATIC TRANSMISSION MODELS Mark 10 10A 15 15A 28 28A and Merc 100 150 200 250 Introduction The water pump is located in the driveshaft housing It is more time consuming to replace than others but it can be done take your time and be patient The Reader s Digest version of how to repair the water pump is Changing the impeller really is not that hard to do First remove the powerhead Remove the cover to the shift pawls Remove the lower unit Remove the cotter pin on the shift lever Now rotate the shift lever at the transmission so that the hole is at the top You can now push on the drive shaft to remove the wrap spring transmission Use a piece of 1 4 flat bar about 7 long and 1 3 8 wide to remove bearing locknut left hand thread Pull the bearing and then the impeller Posted by Sparky This paper provides info on making the tools and repairing the water pump It is to be used along with the Mercury Service Manual A copy of the Mercury Service Manual and a Parts List can be purchased at www oldmercs com e Bay etc Parts Lists are also online at http www wnyaomci wizardoutboardforum com manual html and http Awww mercruiserparts com Another option is to purchase a seal kit from htip www vintageoutboard com which includes the repair instructions Manuals Tools Parts also available at http Awww johnsmcintosh com Tools htm Follow the manual carefully when working
9. dded AGF 04 03 10
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