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Author Topic:   Mercury EFI, 60-HP, Water In Gear Case

richvi posted 06-22-2013 12:31 PM ET (US)
[For the second] time in [six years]...water has gotten into the lower unit gears [of a Mercury 60-HP outboard engine]. [In] November 2010 I paid $458 for repair. [The 60-HP Mercury outboard engine is] in the shop again. Is [the Mercury 60-HP outboard engine] prone to failure?
jimh posted 06-22-2013 04:44 PM ET (US)
Water intrusion into the lubrication of the gear case generally is via these paths:
--leakage at the propeller shaft seal
--leakage at the drive shaft seal
--leakage at the shift shaft seal
--leakage at the two gear case filler cap screws
The gear case filler cap screws are very likely to leak if they are not properly installed with new seals. It is sometimes seen that the seals or washers on these cap screws are not replaced when the gear case lubricant is refilled. Or, sometimes, two seals are inadvertently used, with an old one left in place and a new one added. Check these filler cap screws carefully. Clean out the seats for the seals. Install new seals and screws.
The propeller shaft seal is prone to damage if fishing line is wrapped up on the propeller shaft. If the propeller shaft is out of true and wobbles, it will wear the seal. And some models of outboard engines use rather cheap and low quality seals, leaving them prone to water intrusion.
When the water pump is serviced it is typical that not all the seals are replaced. Some mechanics or owners skimp on replacement of these components. Use OEM parts and replace all the seals in the water pump and drive shaft.

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Author	Topic: Mercury EFI, 60-HP, Water In Gear Case
richvi	posted 06-22-2013 12:31 PM ET (US) [For the second] time in [six years]...water has gotten into the lower unit gears [of a Mercury 60-HP outboard engine]. [In] November 2010 I paid $458 for repair. [The 60-HP Mercury outboard engine is] in the shop again. Is [the Mercury 60-HP outboard engine] prone to failure?
jimh	posted 06-22-2013 04:44 PM ET (US) Water intrusion into the lubrication of the gear case generally is via these paths: --leakage at the propeller shaft seal --leakage at the drive shaft seal --leakage at the shift shaft seal --leakage at the two gear case filler cap screws The gear case filler cap screws are very likely to leak if they are not properly installed with new seals. It is sometimes seen that the seals or washers on these cap screws are not replaced when the gear case lubricant is refilled. Or, sometimes, two seals are inadvertently used, with an old one left in place and a new one added. Check these filler cap screws carefully. Clean out the seats for the seals. Install new seals and screws. The propeller shaft seal is prone to damage if fishing line is wrapped up on the propeller shaft. If the propeller shaft is out of true and wobbles, it will wear the seal. And some models of outboard engines use rather cheap and low quality seals, leaving them prone to water intrusion. When the water pump is serviced it is typical that not all the seals are replaced. Some mechanics or owners skimp on replacement of these components. Use OEM parts and replace all the seals in the water pump and drive shaft.