95966 Mercruiser BUSHING, COUPLING

Introduction
Table 1
Revision History
Revision Summary of Changes
02 Changed the drill one 10 mm hole to drill one 8.5 mm hole.
01 Changed the drill one 22.23 mm hole to drill one 19.75 mm hole . Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.This Special instruction describes the procedure for modifying the oil pan for additional oil sensor ports and installing the new sensor assemblies.Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Required Parts
Table 1 contains the new parts required for this change.
Table 2
New Part Number New Part Name Quantity
454-8550 Sensor Guard As 3
430-9455 Liquid Level Sensor Gp 3
6V-6317 Bolt 4
6V-3822 Bolt 1
6V-5815 Bolt 1
6V-5839 Washer 6
127-5447 Spacer 1
4P-4369 Spacer 2
115-3069 Connecting Clip Assembly 3
9S-4190 O-Ring Plug 1
238-5081 O-Ring Seal 1 Required Tools
Table 1 contains the tools required for this change.
Table 3
Tool Description Quantity
7/8-14-2B Tap 1
M10 x 1.5-6H Tap 1 Installation Procedure
Illustration 1 g06411883
(A) Oil PanThe following procedure modifies the oil pan to add additional oil sensor ports and 2 additional bracket mounting holes.
Illustration 2 g06411645
(D1) 388.7 mm (15.30 inch)
(D2) 260.3 mm (10.25 inch)
(D3) 320.7 mm (12.60 inch)
(D4) 345.7 mm (13.60 inch)
(D5) 385.7 mm (15.20 inch)
(A) Oil Pan
Drill one 19.75 mm (0.8125 inch) hole through oil pan (A) at dimension (D1) from the rear face of the oil pan and at dimension (D2) from the top of the pan.
Use the 7/8-14-2B tap to tap the hole through the oil pan at dimension (D1) from the rear face of the oil pan and at dimension (D2) from the top of the pan.
Drill one 19.75 mm (0.8125 inch) hole through oil pan (A) at dimension (D1) from the rear face of the oil pan and at dimension (D5) from the top of the pan.
Use the 7/8-14-2B tap to tap the hole through the oil pan at dimension (D1) from the rear face of the oil pan and at dimension (D5) from the top of the pan.
Drill one 8.5 mm (0.335 inch) hole to a depth of 31 mm (1.2 inch) at dimension (D1) from the rear face of the oil pan and at dimension (D3) from the top of the pan.
Use the M10 x 1.5-6H tap to tap the hole at dimension (D1) from the rear face of the oil pan and at dimension (D3) from the top of the pan to a depth of