1969 Evinrude 40 HP Big Twin, Big Twin Electric Lark Service Manual 4596, Page 70Get this manual
iRemove upper gearcase bearing, using bearing remover (Special Tool #309916) Drive propeller shaft oil seal out of the housing, using punchRemove "0" ring DISASSEMBLY OF ELECTRIC SHIFT GEARCASE
a Drain gearcaseRemove propeller nut, cotter and drive pins, thrust washer and propellerbRemove three screws attaching pump (impeller) housing to lower gearcaseDriveshaft and pump assembly may now be lifted from lower gearcaseSee Figure 6-16Remove seals, "0" ring, and water tube grommetscRemove the two lower gearcase stud nuts, the stud washer, and shift cable retainerA 916 inch deep socket is required to remove stud nutsDiscard the nuts, since they are not to be re-usedThese are self-locking nuts and lose their locking ability after being removedSee Figure 6-21dCarefully separate upper and lower gearcases about inches so that insulating sleeve over shift cable terminals can be slid back and terminals disconnectedSee Figure 6-22Completely separate upper and lower gearcase assembliesSet aside upper gearcase NOTE20 rollers are used in pinion bearingeRemove retainer screw and washer, and lift nylon coil lead retainer from lower gearcaseSee Figure 6-23Figure 6-19Shift Rod Bushing Punch