8866A47 Mercruiser GEAR HOUSING ASSEMBLY (2.43:1 Ratio)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-6396     O-Ring Assembly Compound     1    
B     9S-3263     Thread Lock Compound     1    Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.Note: Only a portion of the items in the process are serviceable parts. All parts must be disassembled and assembled in order to obtain access to the serviceable parts.Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring seal may not have the same sealing properties as a new O-ring seals. Use Tooling (A) during the assembly procedure.Note: DO NOT mix parts from one pilot valve to another pilot valve. The Pilot valve will not operate properly if the parts are mixed.
Illustration 1 g00741704
Spool assembly (17) is installed in port (1) and port (3) in the pilot valve.Spool assembly (18) is installed in port (2) and port (4) in the pilot valve.Spring seat (7) is installed in port (1) and port (3) in the pilot valve.Spring seat (10) is installed in port (2) and port (4) in the pilot valve.
Illustration 2 g00741966
Install bushing (16) in valve body (9) .
Install new O-ring seal (21) on valve body (9) .
Illustration 3 g00741947
Install spring pin (24) in plate (25) .
Illustration 4 g00741941
Note: Make sure that spring pin (24) is installed in the correct location in the valve body.
Install plate (25) on the pilot valve.
Install washers (27) and bolts (28). Tighten the bolts to a torque of 21 2 N m (16 1 lb ft).
Illustration 5 g00741938
Note: Three different springs are available for the pilot valve. See Table 2.
Install spring (26) in the pilot valve.
Table 2
Spring    
165-9461 (1)    
190-7750 (2)    
190-7751 (3)    
( 1 ) Standard spring
( 2 ) This spring reduces the operating torque by seventy percent.
( 3 ) This spring reduces the operating torque by eighty percent.
Use the following procedure to assemble spool assemblies (17) and (18) .
Illustration 6 g00741935
Note: Spool (22) is assembled in port (1) and port (3) in the pilot valve. Spool (23) is assembled in port (2) and port (4) in the pilot valve.
Install washer (19) on the spool.Note: Spring (13) is installed on spool (22). Spring (15) is installed on spool (23) .
Install spring (13) or spring (15) on the spool.
Put the end of the spool in the slotted opening of seat (11). Install seat (11) .
Illustration 7 g00741926
Note: Spool assembly (17) is installed in port (1) and port (3) in the pilot valve. Spool assembly (18) is installed in port (2) and port (4) in the pilot valve.
Install spool assembly (18) in the pilot valve.
Illustration 8 g00741919
Install new seal (1) in plug (2) .