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Author Topic:   Mercury Gearcase Removal

howlingdogsteve posted 05-04-2010 08:22 PM ET (US)
I removed the gear case on my 2006 Mercury 90 HP Four Stroke for the first time not long ago. Changed the water pump, pressure tested etc.
Now I'm about to put it back together.
Thing is the extreme prying of the lower leg took its toll on the aluminum gearcase housing. Should I just bolt it all back together as is, or, try to smooth out the gouges and rough spots on the lip? Also, should I use any kind of sealant between the upper and lower housings?
Thanks
Steve

howlingdogsteve posted 05-07-2010 09:07 PM ET (US)
Any advice on this would be welcomed.
Marlin posted 05-07-2010 09:41 PM ET (US)
Hopefully it's not chewed up too badly. I'd probably take a fine file and smooth it out a little, and maybe repaint the edge black. No sealant needed - water's supposed to be in there. I found with my 115 that the main problem getting it apart was some corrosion of the speedometer tube at the front of the gearcase. I lubed that up nicely with teflon grease, and 3 years later the lower unit came back off very easily. Recommend you do the same.
-Bob
10000 Lakes posted 05-07-2010 10:23 PM ET (US)
If you want to do this correctly use HYLOMAR sealant around the speedo connection. This sealant is made in Germany and used in Mercedes,BMW for sealing. Nothing better!
howlingdogsteve posted 05-09-2010 11:21 AM ET (US)
Thanks for the replies.
I suspect I'll need to take 1/32 of material off the edges to square things up.
Anybody know if that will mess up any tolerances?
Steve

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Author	Topic: Mercury Gearcase Removal
howlingdogsteve	posted 05-04-2010 08:22 PM ET (US) I removed the gear case on my 2006 Mercury 90 HP Four Stroke for the first time not long ago. Changed the water pump, pressure tested etc. Now I'm about to put it back together. Thing is the extreme prying of the lower leg took its toll on the aluminum gearcase housing. Should I just bolt it all back together as is, or, try to smooth out the gouges and rough spots on the lip? Also, should I use any kind of sealant between the upper and lower housings? Thanks Steve
howlingdogsteve	posted 05-07-2010 09:07 PM ET (US) Any advice on this would be welcomed.
Marlin	posted 05-07-2010 09:41 PM ET (US) Hopefully it's not chewed up too badly. I'd probably take a fine file and smooth it out a little, and maybe repaint the edge black. No sealant needed - water's supposed to be in there. I found with my 115 that the main problem getting it apart was some corrosion of the speedometer tube at the front of the gearcase. I lubed that up nicely with teflon grease, and 3 years later the lower unit came back off very easily. Recommend you do the same. -Bob
10000 Lakes	posted 05-07-2010 10:23 PM ET (US) If you want to do this correctly use HYLOMAR sealant around the speedo connection. This sealant is made in Germany and used in Mercedes,BMW for sealing. Nothing better!
howlingdogsteve	posted 05-09-2010 11:21 AM ET (US) Thanks for the replies. I suspect I'll need to take 1/32 of material off the edges to square things up. Anybody know if that will mess up any tolerances? Steve