Re: trouble lower unit removal merc 40hp 2004
That engine is a model number 1A40412DD.
Parts listing:
http://www.crowleymarine.com/mercury-outboard/6995.cfm
Service Manual P/N: 90-883064R02
http://1manual.com/Mercury manuals/Service Manual PDFs/FourStroke/883064/cover.pdf
You must have Adobe Acrobat reader installed to use this manual. If you scroll down to the lower part of the opening page, you will see the various engine components in red. Click on the one you want and when the first page opens, click on the "Save As" icon at the top LH corner of the page and you can save it to your computer.
Look under4 "Gear Housing, Non Bigfoot" page 6A-12 for Removal Instructions.
When ready to install, page 6A-46 for Installation Instructions.
You should do just fine with these and if you have any problems, come back to the site and ask as there will be someone here to help you.
Gerry