815822A30 Mercruiser GEAR HOUSING ASSEMBLY

Start By:a. install body retaining pinsb. remove muffler groupc. release air reservoirs pressure 1. Mark and identify two hose assemblies (4) for installation purposes. Disconnect two hose assemblies (4) from cylinder (3).2. Loosen nut (1) off plate (2) and remove bolt (5) and the washer that secure cylinder (3) to the box assembly. Set cylinder (3) with nut (1) and bolt (5) still attached, out of the way. 3. Remove eight bolts (7) and the washers that secure plate (2) to box assembly (6). Remove plate (2). 4. Remove two bolts (8) and the washers and position Tool (A) on the locks and reinstall two bolts (8) as shown. Attach a lifting sling through Tool (A) as shown and secure the sling to a suitable lifting device. 5. Remove four bolts (9) and the washers that secure box assembly (6) to the machine. 6. Remove exhaust diverter (10) with cylinder (3) attached, from the machine. The weight of exhaust diverter (10) and cylinder (3) is approximately 65 kg (145 lb). The following steps are for the installation of the exhaust diverter. 7. Remove and clean any adhesive that remained on cross beam (11) during the removal process. 8T-9013 High Temperature Adhesive/Sealant is used between the cross beam and the exhaust diverter. Prior to applying 8T-9013 High Temperature Adhesive/Sealant, the exhaust diverter must be installed using Steps 9 through 14 to check for the proper stroke. Refer to the topic "Adjusting For Proper Stroke" in this module. After the correct stroke has been obtained, remove the exhaust diverter and reinstall the exhaust diverter starting with Step 8 of this procedure. 8. Apply 8T-9013 High Temperature Adhesive/Sealant to the surface of cross beam (11) as shown. 9. Remove and clean any adhesive that remained on exhaust diverter (10) during the removal process. Install exhaust diverter (10) with cylinder (3) attached, to the machine. The weight of exhaust diverter (10) and cylinder (3) is approximately 65 kg (145 lb). 10. Install four bolts (9) and the washers that secure box assembly (6) to the machine. 11. Remove two bolts (8) and the washers and remove Tool (A). Reinstall two bolts (8) and the washers as shown. 12. Put plate (2) in position on box assembly (6). Install eight bolts (7) and the washers that secure plate (2) to box assembly (6). 13. Put cylinder (3) in position on the box assembly and install bolt (5) and the washer. Tighten nut (1) after bolt (5) has provided 2 1 mm (.0787 .0393 in) clearance between components.14. Connect two hose assemblies (4) from cylinder (3)15. After installation of the muffler group and removal of the body retaining pins, start the machine to recharge the air reservoirs.End By:a. install mufflerb. remove body retaining pinsDisassemble & Assemble Exhaust Diverter
Start By:a. remove exhaust diverter 1. Remove nut and bolt (2) and the washers that secure cylinder (3) on lever (1). Remove cylinder (3). 2. Remove nut and bolt (4) that secures lever (1) on the shaft. Remove lever (1). 3. Remove woodruff key (5) from shaft (6). Check the condition of woodruff key (5) for wear or damage and replace if necessary.
There is spring pressure behind the housing assembly. When bolts ((7) are removed, spring force will be released. To prevent possible personal injury use caution while holding in position when bolts (7) are slowly and evenly being removed.
4. To release the spring pressure, hold the housing assembly and slowly and evenly remove six bolts (7) and the washers. Remove 12 locks (8). 5. Remove housing (9) and six springs (10). Check the seal ring (not shown), located on pipe (12) for wear or damage and replace if necessary.6. Remove four bolts (11) and remove pipe (12) from the box assembly. 7. Remove cotter pin (13) and clevis pin (14) that secure plate assembly (15) on lever (16). Remove plate assembly (15). 8. Remove bolt (18) and slide lever (16) off shaft (6).9. Remove shaft (6) from the box assembly. Check the condition of shaft (6) and woodruff key (17) for wear or damage and replace if necessary. For the assembly of the exhaust diverter, reverse the disassembly procedure.End By:a. install exhaust diverter