896892A40 Mercury BLACK MAX PROPELLER, 9.5 Pitch Aluminum

1. Loosen the bolt that holds yoke (1), and back it out 63 mm (.25 in.).2. Fasten tooling (C) to yoke (1), and tighten the screw to remove the yoke from the tapered shaft on the drive gear. 3. Use two 3/8"-16 NC forcing screws (3) to remove cage (2).
Gear (4) and the bearings are free to move out of the flywheel housing. Carefully remove gear (4) and the bearings so it does not fall and cause personal injury and component damage.
4. Remove gear (4) and bearings. 5. Use tooling (D) to remove two bearings (5) from gear (4). 6. Remove O-ring seal (8).7. Use tool (F) to remove lip-type seal (7).8. Use tooling (E) to remove bearing cup (6) from cage (2). 9. Use tooling (E) to remove bearing cup (9) from the flywheel housing. 10. Disconnect power take-off output shaft bearing lubricant supply hose (10). Cover the openings.11. Remove two bolts (11). 12. Fasten tooling (A) and a hoist to flywheel housing (13). The weight of flywheel housing (13) is 209 kg (460 lb.).13. Remove all the bolts that hold the flywheel housing, and move it off the locating dowels.14. Install two 5/8"-18 NF × 8 in. (203 mm) long guide pins (12) through the crankshaft gear into the crankshaft. 15. Use tooling (D) to remove crankshaft gear (14). 16. Remove O-ring seal (15) from crankshaft gear (14). 17. Inspect sleeve (16) on the crankshaft rear flange. Remove the sleeve only if it requires replacement.Install Flywheel Housing
1. Install sleeve (1) on the crankshaft rear flange. Be sure the beveled edge on the outside diameter is to the outside. See crankshaft rear seal installation for the tooling and procedure for installing sleeve (1). After installation, the dimension from the edge of the sleeve to rear face of the crankshaft is 1.5 0.5 mm (.06 .02 in.). 2. Install new O-ring seal (2) in crankshaft gear (3). Put clean engine oil on the O-ring seal. 3. Install two 5/8"-18 NF × 8 in. (203 mm) long guide pins (5) into the crankshaft rear flange.4. Align dowel (4) with the dowel on crankshaft gear (3), and install crankshaft gear (3) on guide pins (5).5. Use two flywheel bolts each with three washers to pull crankshaft gear (3) onto the crankshaft.6. Remove the bolts used to install the crankshaft gear. 7. Thoroughly clean the mating surfaces of flywheel housing (6) and the cylinder block. Put the clean gasket in position on the dowels on the cylinder block. Do not use any adhesive to hold the gasket.8. Fasten tooling (B) and a hoist to flywheel housing (6), and carefully put it in position on the dowels. 9. Be sure the dampers are in place for the bolts at sequence location 13 and 11. The dampers are installed with the spring opening toward the cylinder block.10. Tighten bolts numbered 1 through 7 in numerical sequence to a torque of 135 13 N m (100 10 lb.ft.).11. Tighten bolts numbered 8 through 18 in numerical sequence to a torque of 55 7 N m (40 5 lb.ft.).12. Retighten bolts numbered 1 through 7 in numerical sequence to a torque of 135 13 N m (100 10 lb.ft.).13. Retighten bolt numbered 8 through 18 in numberical sequence again to a torque of 55 7 N m (40 5 lb.ft.).14. Trim the gasket even with the bottom of the flywheel housing. 15. Be sure bolts (7) are installed.16. Remove the protective covers, and connect power take-off output shaft bearing lubricant supply hose (8). 17. Lower the temperature of bearing cup (9), and install it in the flywheel housing until the cup contacts the bottom of the bore. 18. Heat two bearings (10) to 135°C (275°F), and install them on gear (11) until the bearings contact the shoulders on the gear. 19. Use a press and tool (C) to install bearing cup (12) into cage (14). Install it against the bottom of the bore.20. Use tool (D) to install lip-type seal (13) into cage (14). Install the lip-type seal with the spring-loaded lip in the direction shown. Put clean engine oil on the lip of the seal.21. Install new O-ring seal (15), and put clean engine oil on it. 22. Put gear (11) in position in the flywheel housing. 23. Install cage (14). Tighten the nut on the stud to a torque of 27 4 N m (20 3 lb.ft.). 24. Be sure the tapered shaft on gear (11) and the bore of yoke (16) are clean.25. Install yoke (16), nut (17) and the washer. Tighten nut (17) to a torque of 650 50 N m (480 37 lb.ft.).END BY:a. install crankshaft rear seal and wear sleeveb. install starting motorc. install air compressord. install exhaust crossover manifoldf. install engineDisassemble Flywheel Housing
START BY:a. remove flywheel housing 1. Remove three bolts (1) and washer (2) from the idler gear shaft.
The bearings and spacer in the flywheel housing will fall when the gear is removed. Hold the bearings and spacer in position when the gear is removed.
2. Remove shaft (3) with a soft hammer. 3. Remove O-ring seal (4) from shaft (3). 4. Remove the bearing cups, spacer and ring from idler gear (5). Drive out the outer bearing cup, and remove the spacer and ring. Remove the inner bearing cup with tooling (A) and a press.Assemble Flywheel Housing
1. Install the ring and spacer in the gear. The spacer must be installed so it is in the center of the gear. Lower the temperature of the bearing cups (1), and install in the idler gear (2). 2. Install the O-ring seal (4) on the idler shaft (3). Put clean engine oil on the O-ring seal.3. Install the bearings, spacer and gear in the flywheel housing. 4. Install shaft (3) in the flywheel housing. 5. Put washer (5) in position on the idler shaft. Install three bolts.END BY:a. install flywheel housing