76385 Mercury TILT LOCK ASSEMBLY (PORT)

Illustration 1 g00994344
Improper handling can damage the ceramic seal. If the shaft is bumped during installation, the ceramic seal that is internal to the pump may crack leading to a coolant leak from the weep hole. During installation, be careful not to make hard contact to the shaft. Insert the pump completely during installation. Do not allow the shaft to support the weight of the pump during installation.
(1) Spring Note: The seal installation tool is part of the replacement seal assembly. (2) Seal assembly For installation, remove spring (1) from the seal assembly. Lubricate the inside diameter of the seal assembly with 207-1600 Rubber Lubricant. Use the seal installation tool and hand pressure to install the seal assembly onto the shaft until the face of the seal assembly makes light contact with the face of the ceramic ring and rubber seal. Install the spring onto the seal assembly. (3) Ceramic ring and rubber seal Lubricate the outside diameter of the ceramic ring and rubber seal with 207-1600 Rubber Lubricant. Orient the polished face of the ceramic ring toward seal assembly (2). Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the bearing housing. (4) Locknut Torque ... 103 20 N m (75 15 lb ft)Torque for the locknut's set screws (not shown) ... 4 1 N m (35 9 lb in) (5) Roller bearing Bearing's outer diameter ... 63.987 to 64.000 mm (2.5192 to 2.5197 inch)Bore in housing for bearing ... 63.942 to 63.962 mm (2.5174 to 2.5182 inch)Bearing's inner diameter ... 34.988 to 35 mm (1.3775 to 1.3780 inch)Shaft's outer diameter for bearing ... 35.009 to 35.024 mm (1.3783 to 1.3789 inch) (6) Clip Orient the beveled side of the clip toward the shaft's spline. (7) Oil seal Install the oil seal into the bearing housing within two minutes after the seal is removed from the package. Install the oil seal dry. Do not lubricate the sealing lip. Orient the seal's cup toward the shaft's spline. Use the correct installation tool and use a slow, even motion to press the seal into the housing. (8) Impeller Lubricate the shaft with clean engine oil. Place the shaft onto a fixture that will absorb the load and press the impeller onto the shaft until the impeller's nose is flush with the end of the shaft. (9) Dimension from the bearing housing's flange to the end of the shaft ... 93.740 0.125 mm (3.6905 0.0049 inch) (10) O-ring seal Lubricate the bore for the O-ring seal with glycerin. (11) O-ring seal (not shown) Lubricate the bore for O-ring seal (10) with clean water or with engine coolant. (12) Plug Torque ... 170 15 N m (125 11 lb ft) (13) Cup plug Orient the cup plug according to the orientation in Illustration 1. Press the plug into the bore until the plug is flush with the bearing housing. (14) O-ring seal Lubricate the bore for the O-ring seal with glycerin.Maximum leakage per minute for the water side of the pump at 138 kPa (20 psi) of air pressure ... 20 cc (1.22 cu in)Maximum leakage per minute for the oil's side of the pump at 138 kPa (20 psi) of air pressure ... 24 cc (1.46 cu in)