5040519 EVINRUDE SPRING RETAINER CLUTCH

1. Bend the tabs on two locks and remove bolts, locks (1) and retainer (2) from manifold. 2. Remove bearing (3) from retainer. 3. Remove bolts (4), pipe (6) and cover assembly (5) from pump assembly. 4. Put cover assembly in vise and install tooling (A) on gear (7) and remove gear from shaft assembly. Remove shaft assembly from cover. 5. Remove bearing (8) from cover. 6. Remove bolt (10) and washer (9) from shaft assembly. 7. Install tool (B) on gear and remove gear (11) from shaft. Remove key. 8. Remove nine bolts (12) and housing assembly (13) from pump. 9. Remove bearings (14) and (15) from housing. 10. Remove two bolts (19) from manifold assembly. Remove manifold assembly (18). Remove three seals (17) from manifold assembly (18).11. Remove two gears (16) from shaft. 12. Remove two bearings (20) from gears (16). 13. Remove shaft assembly (21) from manifold assembly (22). 14. Use a press to remove shaft (23) from gear (24). Remove key from shaft. 15. Remove plug (25), spring (26) and plunger (27) from manifold. 16. Remove two shafts (29) from the manifold with tooling (C). Remove bearing (28) from manifold.Assemble Oil Pump
1. Install bearing (1) in manifold with tool (A). The installed bearing in the manifold must be .030 in. (0.76 mm) below the machined surface of the manifold. 2. Lower the temperature of two shafts (2) and install in manifold. 3. Install plunger (5), spring (4) and plug (3) in manifold. 4. Lower the temperature of shaft (6). Install the key in the shaft and install the shaft in gear (7) with a press until the gear makes contact with the shoulder on the shaft. 5. Put a thin layer of SAE 30 oil on the shaft assembly and bearing. Install shaft assembly (8) in manifold. 6. Install two bearings in each gear (9) with tooling (A) and a press. Install the bearings until they are even with the surface of the gear. 7. Put a thin layer of SAE 30 oil on gears (9). Install the two gears on manifold shafts.8. Install two O-rings (12) and O-ring (10) on manifold. Install manifold (11) on manifold (13). 9. Install two bearings in housing with tooling (A). Make an alignment of the oil hold in bearing (14) with the oil hole in housing. Install larger bearing even with housing surface. 10. Put housing assembly (15) in position on oil pump and install nine bolts.
TYPICAL EXAMPLE11. Put key in shaft assembly and install gear (16). Put 9S3263 Thread Lock on the thread of bolt. Install washer and bolt. Tighten bolt to a torque of 18 2 lb.ft. (24 3 N m). 12. Install bearing in cover (17) with tool (A). Bearing is installed even with the edge of cover. 13. Heat gear (18) to a temperature of 275°F (135°C). Install shaft assembly in cover. Use a press and tool (A) to install shaft assembly on gear (18). Install shaft assembly until shaft shoulder is even with the edge of gear.14. Inspect cover gasket (19) and make a replacement if necessary. 15. Install gasket (19) and cover (17) on the oil pump. 16. Use tooling (A) and a press to install bearing (20) in retainer (21). 17. Put retainer assembly (22) in position on manifold and install two locks and five bolts.18. Install pipe on oil pump.end by:a) install oil pump