809160 Mercruiser SET SCREW

1. Remove upper drive shaft guard (1). Drain the hydraulic oil from the flywheel housing. 2. Disconnect hose (2) and two clips (3). Disconnect elbow (4) from the retarder housing. 3. Disconnect the breather line (not shown) at the top of the retarder. Remove air compressor supply line and elbow (5) and discharge line (6). 4. Fasten tooling (A) to top of retarder housing. Fasten a hoist to tooling (A). 5. Remove bolts (7) from the housing, and lower the retarder out the bottom. Weight of the retarder is 135 kg (300 lb.).Install Retarder
1. Check the O-ring seal around the housing, and if damaged, use a new seal fro replacement.2. Fasten tool (A) to retarder, and fasten a hoist to tool (A). Lift retarder (1) up from the bottom, and put it in position on flywheel housing. Install the bolts that hold the retarder in position.3. Connect the line to the breather at the top of the retarder. Install the air compressor discharge line and supply line and elbow. 4. Install elbow (4) to the bottom of the retarder. Install two clips (3) and hose (2) to the retarder.5. Install the upper drive shaft guard.END BY:a. install retarder control valveb. install drive shaftc. install exhaust crossover manifold and mufflerDisassemble Retarder
START BY:a. remove retarder 1. Remove two bolts (3), lock (2), plate (1) and gear (4). 2. Remove bolts (5) from stator (6). 3. Install two 3/8"-16 NC forcing screws (7). Tighten the screws evenly to loosen the stator from the retarder housing.4. Remove the forcing screws, and install two 3/8"-16 NC forged eyebolts. Fasten a hoist to the stator, and remove the stator. Weight of stator is 60 lb. (27 kg). Remove the O-ring seal from the stator. 5. Remove rotor (8). 6. Remove snap ring (9) from the rotor. 7. Remove bearing (10) and retainer (11). Use pry bars as shown. 8. Remove ring (12) from the carrier. Remove the carrier only if necessary. 9. Install tooling (A) in the ring groove of the carrier. Remove carrier (13). 10. Turn rotor as shown. Remove snap ring (15) and two rings (14) from the carrier.11. Remove carrier only if necessary. Use same procedure as in Step 9. 12. Install two 3/8"-16 NC forged eyebolts (16). Fasten a hoist to the housing. Remove housing (17) from the yoke assembly. Weight of the housing is 130 lb. (59 kg). 13. Turn the housing as shown. Remove bolts (18). Remove cage (19) from the housing. Remove the O-ring seal from the cage. 14. Remove seal (20) from the cage. 15. Remove the bearing from the cage with tool (B).
Remove the race from the bore toward the inside of the housing as shown.
16. Remove race (21) from the housing. Remove O-ring seal (22). 17. Remove bolts (25), lock (23), retainer (26) and O-ring (not shown). Remove shaft (24) from yoke (27). 18. Remove race (28) from the yoke with tool (C).Assemble Retarder
1. Check seals and O-rings for damage. If damaged, use new parts for replacement. Heat race (1) in oil to a maximum temperature of 275°F (135°C), and install on yoke (2). 2. Put shaft (7) in position in the yoke. Install O-ring seal (5), retainer (4), lock (6) and bolts (3). Bend lock correctly against bolt heads.
Make sure the race is installed against the counterbore of the housing.
3. Lower the temperature of race (8), and install the retarder housing. Install O-ring seal (9) in the retarder housing. 4. Install the bearing in cage (10) with tool (A). 5. Install the lip-type seal in the cage with tool (A). Install the lip-type seal until it makes contact with the counterbore and the lip is toward the bearing. 6. Install O-ring seal (11) in the cage. Install cage (10) on retarder housing (12). Install the four bolts that hold the cage in position on the housing. 7. Install 3/8"-16 NC forged eyebolts (13) in retarder housing (12). Fasten a hoist to the housing, and install on the yoke assembly.
Carriers must be assembled correctly on the rotor.
8. Heat the carrier with two ring grooves in oil to a maximum temperature of 275°F (135°C). Install carrier (14) on rotor (15). 9. Install the rings on the carrier with tool (B). 10. Install snap ring (16) that holds the carrier in position.11. Turn the rotor as shown. Heat the carrier with one ring groove in oil to a maximum temperature of 275°F (135°C), and install on the rotor. Install the ring on the carrier with tool (B). 12. Install retainer (17) on the rotor. 13. Install bearing (18) on the rotor. 14. Install snap ring (19) that holds the bearing in position on the rotor. Hoist is used for easy installation only. 15. Install two 3/8"-16 NC forged eyebolts (20) in the rotor. Fasten a hoist to the eyebolts, and install rotor (15) in position on the shaft. 16. Install two 3/8"-16 NC guide bolts (21) in the retainer and two guide bolts in the retarder housing. Install O-ring seal (24). Install two 3/8"-16 NC forged eyebolts (22) in the stator, and install stator (23) in position on the retarder housing with a hoist.17. Install the six bolts that hold the retainer to the stator, and tighten the bolts to a torque of 45 7 lb.ft. (36 5 N m). 18. Install gear