1969 Evinrude 40 HP Big Twin, Big Twin Electric Lark Service Manual 4596, Page 77Get this manual
kPress new upper pinion bearing into upper gear housing, using Special Tools378737 and308099Press against hardened (lettered) side of bflaringPosition washer with large hole in gearcase, then thrust bearing, and finally washer with small hole1Install lower gearcase pinion bearing outer race, using Special Tools #378737 and #308098, preSSing against lettered end of bearing onlySee Figure 6-47 Figure 6-45Installing Front Bearing Race
mInstall new upper gearcase bearing, using bearing installer (Special Tools #378737 and 309915) See Figure 6-42Install new oil retainer, using seal installer (Special Tools #378737 and 308103)nApply liberal coating of OMC Needle Bearing Assembly Grease, Part Number 378642, to outer race and rollers of lower pinion bearingPlace 20 rollers in position in outer raceoCoat "0" ring groove with Sealer 1000 to assure an oil-tight seal between upper and lower gearcase halves and place new "0" ring in position
Figure 6-46Installing Forward Coil gearHolding pinion gear in place, install propeller shaft and reverse gear assemblye Install reverse coil, carefully feeding blue lead through opening in gearcase Align lead with recess in gearcasefMake sure leads are correctly positioned and free of all obstructions, and that green lead is well protected by metal guardSecure leads in nylon retainer with washer and screwDo not overtighten screwCAP UPPER WASHER (LARGE HOLE) ,