0398095 EVINRUDE GEAR & PINION ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components of the rear power take-off (RPTO) are clean and free from wear and damage.
Illustration 1 g02070454
Illustration 2 g02069024
If necessary, follow Steps 2a through Steps 2c to install the sleeve bearings from the flywheel housing.
Accurately align oil Holes (X) in sleeve bearing (20) with the oil holes in flywheel housing (9).
Use Tooling (A) to install sleeve bearing (20) into flywheel housing (9).Note: Ensure that the oil holes are correctly aligned. If the oil holes are not correctly aligned, the sleeve bearing should be removed.
Repeat Step 2a through Steps 2b to install sleeve bearing (21) to flywheel housing (9).
Illustration 3 g02070455
If necessary, follow Steps 3a through Steps 4 to install the sleeve bearing to the gears.
Place gear (17) onto suitable support.
Accurately align Grooves (Z) in sleeve bearing (19) with Grooves (Y) in gear (17).
Use Tooling (A) and a suitable press to install sleeve bearing (19) into gear (17).
Illustration 4 g03453500
Repeat Steps 3a through Step 3c to install the sleeve bearing to gear (18).
Place gear (18) onto suitable support.
Accurately align Grooves (Z) in sleeve bearing (19a) with Grooves (Y) in gear (18).
Use Tooling (A) and a suitable press to install sleeve bearing (19a) into gear (18).
Illustration 5 g02069021
Lubricate idler hub (15) and gear (17) with clean oil. Install idler hub (15) to gear (17).Note: Ensure that the gear and the idler hub are correctly oriented.
Install gear (17) and idler hub (15) assembly to flywheel housing (9).Note: Ensure that the oil hole in the idler hub is correctly positioned.
Install bolts (13) to idler hub (15) and hand tighten bolts.Note: Ensure that the idler hub is correctly aligned to the flywheel housing.
Repeat Steps 5 through Step 7 to install gear (18), idler hub (16) and bolts (14) to flywheel housing (9).
Tighten bolts (13) and bolts (14) to a torque of 100 N m (74 lb ft).
Ensure that there is tactile backlash between gear (17) and gear (18). Ensure that there is end play between the idler hubs and the gears.
Illustration 6 g02069020
install gear assembly (11) and gear assembly (12) to flywheel housing (9).
Illustration 7 g02069019
Illustration 8 g02070473
If necessary, follow Steps 12a through Steps 12c to install the sleeve bearings to the adapters.
Place adapter (2) onto suitable support.
Use Tooling (A) and a suitable press to install sleeve bearing (10) into adapter (2).
Repeat Steps 12a through Step 12b to install the sleeve bearing into adapter (5).
Install a new O-ring seal (3) (not shown) to adapter (2).
Install adapter (2) to flywheel housing (9).Note: Ensure correct orientation of the adapter.
Install bolts (1) and tighten the bolts to a torque of 55 N m (41 lb ft).
Install a new O-ring seal (6) (not shown) to adapter (5).
Install adapter (5) to flywheel housing (9).Note: Ensure correct orientation of the adapter.
Install bolts (4) and tighten the bolts to a torque of 55 N m (41 lb ft).
Ensure that there is tactile backlash between the gears. Ensure that there is end play between the gears and the flywheel housing and the adapters.
Install gear (7) to crankshaft (8).
If necessary, install the Original Equipment Manufacture (OEM) equipment to the rear power take-off (RPTO).End By:
Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install" for the correct procedure.