5007698 EVINRUDE Cylinder/Crankcase Gasket & Seal Kit

1. Loosen spanner nut on forward clutch end of shaft using tool (A). 2. Remove spanner nut (1) and collector sleeve (2). 3. Loosen spanner bolt holding spider on clutch shaft using tool (A). 4. Remove spanner bolt (3) and O-ring seal (4). 5. Pull spider (5) from the clutch shaft using tool (B). 6. Remove bearing carrier (6). 7. Remove bearing (7). 8. Install two 5/8"-11NC forged eyebolts (8) in forward clutch. Fasten hoist and put clutch shaft on transmission stand. 9. Install sleeve (9), part of tool (C), and spanner nut. Leave minimum clearance of .12 in. (3.0 mm) as shown between the spanner nut and the end of the shaft. 10. Loosen the forward clutch from the shaft using tools (C). Remove tools (C) and the spanner nut. Remove the clutch from the shaft. 11. Remove dump valve cover bolts and locks (10). 12. Remove dump valve cover (11), spacer (12), piston (13), and spring (14). 13. Remove clutch bolts and locks (15). 14. Install two 5/8"-11NC forged eyebolts (16), fasten hoist, and remove clutch cylinder (17). 15. Remove clutch release springs (18). 16. Remove brass clutch discs (19) and steel discs (20). 17. Remove clutch back plate (21). 18. Remove four retaining rings (22) from shaft assembly. 19. Remove clutch hub, bearing, and reverse drive gear as a unit. 20. Remove clutch hub retaining bolts and lock (23). 21. Remove clutch hub retainer (24). 22. Remove bearing inner race retaining ring (25) 23. Remove bearing inner race using tool (D). 24. Pull clutch hub and roller bearing from reverse driving gear using tool (E). 25. Remove bearing from clutch hub using tool (F). 26. Remove reverse driving gear bearing (26). 27. Remove forward pinion, bearings, and clutch hub (27) as a unit. 28. Remove bolts and lock (28) from the clutch hub. 29. Remove clutch hub retainer (29). 30. Separate clutch hub from forward pinion using tool (G). 31. Remove bearing retainer ring (30). 32. Remove clutch hub roller bearing using tool (H). 33. Remove bearing from the forward pinion using tool (I). 34. Loosen reverse clutch bolts (31). 35. Remove clutch back plate (32). 36. Remove reverse clutch release springs (33). 37. Remove clutch discs (34). 38. Remove reverse clutch piston (35). 39. Remove piston seal (36). 40. Remove piston seal expander (37). 41. Remove cylinder piston seal (38). 42. Remove cylinder piston seal expander (39).Assemble Clutch Shaft
1. Install cylinder piston seal expander (1). 2. Install cylinder piston seal (2). 3. Install piston seal expander (3). 4. Install piston seal (4). 5. Install piston (5) in cylinder. 6. Install reverse clutch discs in cylinder, starting with a brass disc (6) and follow with a steel disc (7). 7. Install reverse clutch release springs (8). 8. Install reverse clutch back plate (9). 9. Install clutch bolts (10) and bend locks. 10. Put bearings in 275°F (135°C) oil, and then install them on hub and pinion. Assemble clutch hub and forward pinion using tool (A). 11. Install clutch hub, bearings, and forward pinion as a unit (11). 12. Install reverse gear bearing (12). 13. Put bearings in 275°F (135°C) oil, and install them on hub and reverse drive gear. Press clutch hub and reverse driving gear together using tool (A). 14. Install clutch hub, bearings, and reverse drive gear (13). 15. Install retaining rings (14). 16. Install forward clutch back plate (15). 17. Install forward clutch discs. Start with a brass disc (16) and follow with a steel disc (17). 18. Install forward clutch release springs (18). 19. Install two 5/8"-11NC forged eyebolts (19) in clutch cylinder (20). Fasten hoist and put cylinder on shaft. Use weight of clutch for preload on shaft taper. Shaft taper must be clean and dry. Use a cleaning solvent. DO NOT USE KEROSENE. 20. Install new locks and clutch bolts (21). 21. Using a depth micrometer (22), measure distance from top of shaft to clutch cylinder. 22. Install adapter (23) (part of tool B) on shaft. 23. Push the clutch on shaft using tool (B) until clutch moves .052 to .072 in. (1.32 to 1.83 mm) on the shaft. Use the depth micrometer or dial indicator to measure movement. 24. Install dump valve spring (24), piston (25), spacer (26), and cover (27). 25. Install collector sleeve (28) on shaft. 26. Install spanner nut (29).