Mercury 40 Force... Helpppppp

[mercurymang]

I have a '98 Mercury 40 Force. What was supposed to be a routine water pump impellar replacement went south when after discovering that the shifter shaft coupling nut was siezed onto the shaft. I tried to break it loose but of course I applied too much force and broke the plastic shifting mechanism arm that attaches to the shaft up in the bottom of the engine cowling. After quite a bit of work, I was able to get the shift lever out but now see that after I get it fixed(or get a new one), there will be virtually no way to reconnect it with the limited space there.
Question is does the cowling come off to allow access. I'm stumped as to how one would do this. Any help would be appreciated. This is my brother in laws boat and I was trying to help out and do some maintenance and now I have screwed it up.

 

[roscoe]

Re: Mercury 40 Force... Helpppppp

THats a tough one.
Yes, all the pieces and the cowl will come off, eventually.
Never tore one of those late model Force's down that far.

I think you are going to need a factory manual with step be step instructions.

Wish I could help.

 

[mercurymang]

Re: Mercury 40 Force... Helpppppp

Thanks Roscoe. Ya, I think it's time to get a manual.

 

[emoney]

Re: Mercury 40 Force... Helpppppp

Drawings here while you wait for manual
http://www.**********/parts/search/Merc/Force/1998/H040412UD/DRIVESHAFT HOUSING/parts.html

 

[roscoe]

Re: Mercury 40 Force... Helpppppp

http://www.crowleymarine.com/mercury-outboard/2532.cfm

 

[wickware]

Re: Mercury 40 Force... Helpppppp

Please send Pics attachments showing the actual matters you are mentioning.

 

[mercurymang]

Re: Mercury 40 Force... Helpppppp

Please send Pics attachments showing the actual matters you are mentioning.

This is not a great pic and I have taken the boat back to my brother in laws house. You can see the lever down at the bottom but you cant see what exactly is broken.

 

[mercurymang]

Re: Mercury 40 Force... Helpppppp

Ok, I have a manual on order. I sure hope it shows me how to do this. I can't believe they would make it that complicated to get to an are where there is a cotter pin.

 

[mercurymang]

Re: Mercury 40 Force... Helpppppp

Finally got my manual in yesterday ($80). Although it doesn't have anything in it about replacing the shift shaft, it does show how to remove the motor which is what I think I will need to do in my case. It looks fairly straight forward but the book is not detailed so i'm not sure if there is a gasket in there. Has anyone ever removed a motor on one of these or something fairly similar?

 

[mercurymang]

Re: Mercury 40 Force... Helpppppp

FYI. I removed the motor which allowed me access to the shift shaft. As it turns out, the shift rod thread nut was rusted and siezed which caused the intitial problem.