How do I remove the lower unit in a 1995 (Merc) 40HP Force?

[DenisD]

I've had this boat/motor combo since it was new in 1995 but never did any of my own work on the motor. I've alway had it done my a marine mechanic. Now I want to rep ace the water pump and would really like to do it myself. When I try to remove the lower unit I can only get it to frop about 6 inches and then it won't come out any further. I have the 5 bolts removed (4 flange bolts plus the one under the trim tab). It seems as though there is a connection in the right-angle gear in the LU housing. I can see far enough into the shaft housing to know that there's no fitting up there.

Can someone please help me?

Thanks in advance.

 

[roscoe]

Re: How do I remove the lower unit in a 1995 (Merc) 40HP Force?

Welcome to iboats DenisD.

THere is a coupler and jam nut on the shift shaft.

Get a Sharpie marker, and draw a continuous line on one side of the shaft, over the jam nut, down the side of the coupler, and onto the lower shaft.
This will help you get it aligned and shifting properly when you re-assemble it.


Now loosen the small jam nut, and unscrew the coupler so the 2 shift shafts disconnect.

That should do it.

 

[DenisD]

Re: How do I remove the lower unit in a 1995 (Merc) 40HP Force?

Thanks for the quick reply Roscoe. Is this nut under the rubber boot, or is it higher up the shaft?
Also, does it matter what position the shifter is in (reverse, neutral, forward)?

 

[roscoe]

Re: How do I remove the lower unit in a 1995 (Merc) 40HP Force?

The book says put it in neutral.
But I have done it in forward several times.


The big black arrow is pointing to where the coupler is located.



View attachment 109431

 

[DenisD]

Re: How do I remove the lower unit in a 1995 (Merc) 40HP Force?

thanks again. i couldn't open the attachment. I got aan error message saying "Invalid Attachment". is there a chance that you could try another message. perhaps I could PM me email address to you?

 

[roscoe]

Re: How do I remove the lower unit in a 1995 (Merc) 40HP Force?

thanks again. i couldn't open the attachment. I got aan error message saying "Invalid Attachment". is there a chance that you could try another message. perhaps I could PM me email address to you?

Hmmm, attachments haven't been working this month, since they upgraded the forum software.


Thats alright, as I posted the info for a 1994 model.

The coupler on the 1995 model is just above the lower unit, PORT side. It looks like a long hex nut, with a small hex nut tightened up to it. It is full exposed, not hidden.