96765 Mercruiser HOSE, Reservoir To Exchanger

start by:a) remove floor plate (see VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY section)1. Disconnect bracket (3) and move the hose assemblies away from the fan drive pump. 2. Disconnect hose assemblies (1), (2) and (4) from the fan drive pump.3. Install tooling (A) on the top of the inside of the cab. Install a nylon strap around the fan drive pump. 4. Remove the nuts that hold fan drive pump (5) in place. Use tooling (A) to remove the fan drive pump. The weight is 75 lb. (34 kg).Install Fan Drive Pump
1. Make sure the O-ring seal is in position between the fan drive pump and the pump drive. Install fan drive pump (1). 2. Connect hose assemblies (2), (3) and (4) to the fan drive pump.3. Connect bracket (5). end by:a) install floor plate (see VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY section)Disassemble Fan Drive Pump
start by:a) remove fan drive pump
Be very careful not to damage the pump parts during disassembly.
1. Remove servo valve (1) from the pump. 2. Remove plug (2) and spool (3) from the valve body.
There is spring force behind guide (7).
3. Remove guide (7) from the valve body. 4. Remove cap (6), spring (5) and cap (4) from the valve body. 5. Remove cap (8) from cap (9).6. Remove bolt (11) from cap (9).7. Remove cap (9) from guide (7).8. Remove follower (10). Remove washers (12) and (13). 9. Remove plate assembly (14) from the pump housing. 10. Remove piston (15).11. Use tool (B) to remove bearing (16) (if worn or damaged). 12. Remove piston block assembly (17).13. Put identification on the pistons and by the openings in the cylinder block so the pistons will be installed in their original cylinders.14. Remove the pistons. 15. Remove spider (19) and spider pivot (18).
There is spring force behind ring (20).
16. Use a press and tooling (C) to put spring (21) in compression. Use tool (D) to remove ring (20). Slowly remove the force from the spring. Remove the spring from the cylinder block. 17. Remove pins (23) and pin keeper (22) from the cylinder block. 18. Use tool (D) to remove ring (24) from the housing. 19. Use a soft hammer to remove shaft (25) from the housing. 20. Remove seal (27) and washer (26) from the shaft. 21. Use tool (E) to remove rings (28) and (30) from the shaft.22. Remove races (29) and bearing (31). 23. Use tool (D) to remove ring (32) from each side of the housing.24. Remove covers (33) from each side of the housing. 25. Remove O-ring seals (36), races (35) and bearings (34) from each side of the housing. 26. Remove swashplate (37) from the housing. Remove the pin and the button (not shown) from the swashplate. 27. Remove collar (38) and the spring from the housing.28. Use tooling (B) and a press to remove bearing (39) from the housing.Assemble Fan Drive Pump
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. Be very careful not to cause damage to the parts of the pump during assembly. Put clean engine oil on all parts that move before the pump is assembled. 2. Use a press and tooling (A) to install bearing (1) in the housing. The bearing must be installed with the end numbers on it toward the outside of the pump and .078 in. (1.98 mm) below the seat of the counterbore. 3. Put spring (2) and collar (3) in position in the housing. 4. Put the pin and the button (not shown) in position on swashplate (4). Put the swashplate in position in the housing. The numbers on bearings (5) must be toward the inside of the housing. 5. Install bearings (5) and races (6) in each side of the housing. 6. Put O-ring seals (7) and covers (8) in position on each side of the housing.7. Use tool (B) to install rings (9) in the housing.8. Use tool (C) to install the ring on the shaft. 9. Put race (10), bearing (11) and race (12) in position on the shaft.10. Use tool (C) to install the other ring on the shaft. 11. Put the shaft in position in the housing.
The lip of seal (14) must be installed toward the inside of the housing.
12. Install washer (13) and seal (14) in the housing. Use tool (B) to install the ring (not shown) in the housing. 13. Put pin keeper (16) in compression and install it in the splines of the cylinder block.
Pins (15) must be installed in the special grooves in the cylinder block.
14. Install three pins (15) with the head end toward the inside of the cylinder block. 15. Put washer (17) and spring (18) in position in the cylinder block. 16. Use a press and tooling (A) to put spring (18) in compression. Use tool (B) to install ring (19) in the cylinder block.