Unable to drop lower gearbox on 40hp, 1972 merc 402

aceallenk

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Mar 30, 2011
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New to this engine (1972, 40hp, 402 thunderbolt) and want to change the cooling system impeller. I loosened the one nut (thats all there is) from each side, and took the one off in very back, This has loosened the lower unit off on the front side but still seems to be solid on the back side above the propeller. I,m thinking that the trim fin above the propeller is holding the lower unit up solid. My question is how do you remove this trim fin? there is a hole directly above this fin but unable to get a socket (1/4" or 3/8" drive) through the hole that is big enough to remove what might be a 9/16 nut. On the fin itself there are no nuts or bolts to remove or loosen this. Any suggestions
 

merc850

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Re: Unable to drop lower gearbox on 40hp, 1972 merc 402

At different times they used a 5/16 Allen head bolt instead of a hex head. Just loosen the trim tab and remove it, there will be another nut under it holding LU on. Just make sure to replace the Allen bolt before you start to reinstall LU. Grease the studs to prevent galling.
 

aceallenk

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Re: Unable to drop lower gearbox on 40hp, 1972 merc 402

Thanks guys. It was a 12 point bolt, used a 7/16 socket with 3/8 ratchet, worked great and lower is on the bench.
 

bktheking

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Re: Unable to drop lower gearbox on 40hp, 1972 merc 402

I remember allen, never 12 point, probably replaced by someone.
 

Moody Blue

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Re: Unable to drop lower gearbox on 40hp, 1972 merc 402

Of the four Merc motors I've had (actually 3 Merc, 1 Mariner) all had the 12 point bolt. Wonder if it's a year thing or hp dependent?
 

bktheking

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Re: Unable to drop lower gearbox on 40hp, 1972 merc 402

Could be, merc did weird and strange things as we all know.
 
M

Maxz695

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Re: Unable to drop lower gearbox on 40hp, 1972 merc 402

my 40 HP 402 2 cyl has a 9/16 nut under the trim tab 1979 the 888 alpha drive i rebuilt had a hex allen type screw
 
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