Prep. Place your motor in gear prior to beginning this will help when you reassemble the lower unit and aid in aligning the drive shaft.

STEP 1.) Remove your Prop. A piece of wood wedged between your prop and the lower unit will keep the prop from spinning when taking off the prop nut. A screwdriver will help when bending the cotter key fins away from the prop nut.

 

Step 2.) remove all bolts that connect the lower unit to the motor each motor is different so be sure you get them all.

 

Step 3.) Make sure you remove this bolt under the steering trim tab

 

As you remove the bolts be sure to support the Lower Unit so it doesn't fall off.

 

Once removed the bottom of the power head is exposed. make sure when dropping the lower unit you remove the Speedometer tube. See Red Arrow.

 

Step 4.) Placing the Lower unit on a table will help. A Black and Decker table works great with the slit in it for the skeg to hang through.

 

Step 5.) Remove all Bolts from upper water pump housing.

 

Step 6.) Slide the Old Housing off the drive shaft.

 

Step 7.) Remove the gaskets from the lower Water Pump housing if present. Sometimes they stick to the upper housing.

 

Step 8.) The old Impeller will be inside the upper Water Pump Housing. You will be able to tell if it is worn because you will be able to turn it with your fingers.

 

Step 9.) The New Upper housing should come with a new set of gaskets to replace the old worn out ones.

 

Step 10.) Be sure to match up the old gaskets to the new ones so oyu put the correct ones on.

 

Step 11.) There are several different types and sometimes the old ones stick to the old water pump upper housing.

 

Step 12.) remove the slinger gasket from the water tube. This gasket makes it so that water that comes out of the upper housing does not shoot all the way up the drive shaft.

 

Step 13.) Place the new Impeller on the drive shaft. Notice the new key make sure you line up the new key prior to sliding the impeller all the way down.

 

Step 14.) Slide the new impeller all the way down the shaft. Make sure the key satys in place while doing this.

 

Step 15.) SLide the new upper housing over the new impeller. This is a very difficult thing to accomplish but it should slide over very tightly

 

Step 16.) Once all the way on the water pump housing needs to have the bolts tightened.

 

Step 17.) Tighten the bolts on the new water pump upper housing.

 

Step 18.) Place a line of high temp sealant between the exhaust and the water pump housing on the lower unit. There should be an older line of the sealant still there placing another line where this one is located is your best bet.

 

Step 19.) Grease the lower unit shifting shaft.

 

Step 20.) Grease the upper portion of the drive shaft. IT is a tight fit so do not put grease on the TOP of the shaft only the sides.

 

Step 21.) Line up your drive shaft and lower unit mounting bolts. Leaving your boat in gear when you removed this will help at this stage. You can now turn your prop to align the drive shaft.

 

Step 22.) Line up all sections of the motor and ensure the drive shaft and water tube are seated correctly. Be sure to check your speedometer tube if you have one.

 

Step 23.) Start your engine and let it run for about 20 minutes until it reaches optimal operating temperature. If you notice any elevated temperature stop your engine immediately and check your installation again.