Mercury Outboard Lower Unit Repairs Video Playlist
Here at Boats.net, we’ve published multiple videos and articles related to all kinds of boat and outboard maintenance, repairs and troubleshooting.
Boats.net specializes in selling outboard parts, but we’ve also published many outboard maintenance and repair videos and articles. For this playlist, we’ve compiled a list of our videos dedicated to Mercury outboard lower unit removals, remounts and maintenance.
Mercury Tracker 25 Lower Unit Removal
Watch the video above to learn how to remove the lower unit from a Mercury 25 outboard. Removing the gearcase or lower unit on an outboard is an essential first step for an overhaul, replacing the driveshaft seals and the water pump. See how to remove the gearcase on a Mercury 25 Tracker, starting with the cowling, then the starter. This model requires releasing the shift shaft before unbolting the lower unit.
Mercury Tracker 25 Lower Unit Installation
Watch the video above to see how to reattach the gearcase on a Mercury Tracker 25. See how to install the lower unit while paying attention to details like preparing the bolts with threadlocker and having them within reach before picking up the unit. Plus making sure both the shift shaft and the motor are in the neutral position so the shift shaft lines up. Once you get the lower unit bolted up, you’ll reconnect the shift shaft and get the starter reattached.
Mercury Tracker 25 Gearcase Pressure Test
Watch the video above to see how to pressure test the lower unit on a Mercury Tracker 25 outboard. This requires draining the lower unit oil first, then using a gearcase pressure tester to determine if the seals on the Mercury outboard are holding on up.
Mercury Tracker 25 Gearcase Oil Change
Watch the video above to learn how to change the gearcase lube in a Mercury 25 outboard. It’s a simple yet essential task to keep the lower unit working properly. We replace the gearcase lube in this outboard by removing the vent and drain plugs. Next, we use a Mercury gear lube pump to push fresh gear lube into the lower unit. You’ll know the gearcase is full when you see oil spilling out of the vent opening at the top. When it's full, we replace the vent and fill plugs and it's ready to go.
Mercury Tracker 40 Lower Unit Removal - 4-Stroke
Watch the video above to see how to remove the lower unit from a Mercury 40 four-stroke outboard. It’s a simple procedure that opens the door to addressing a variety of issues that may be affecting the gearcase. We remove the cowling and disconnect the shift shaft, then we show you how to unbolt the lower unit so you can remove it.
Mercury Tracker 40 Lower Unit Remounting - 4-Stroke
Watch the video above to see how to remount the lower unit on a Mercury 40 outboard motor. Before mating the lower unit to the motor, grease the splines on the drive shaft and the water tube to make it easier to remove the gearcase next time. You’ll also see how to replace the trim tab and connect the shift shaft.
Mercury 40HP Outboard Gearcase Lube Change - 4-Stroke
Watch the video above to see how to change the lower unit oil in a Mercury 40HP four-stroke outboard. It starts by opening the vent and drain bolts to get the old gearcase lube out. We pressure test this Mercury 40 outboard using a gearcase pressure tester to check the lower unit for leaks in the seals at the prop shaft and drive shaft. Next, we refill the lower unit with fresh oil using a gearcase lube pump specific to Mercury so that it fits the fill opening. You’ll know the gearcase is full when you see lube running out of the vent opening at the top.
Related: Mercury 40HP Outboard Gearcase Oil Change & Pressure Test
Mercury Tracker 40 Gearcase Removal - 2-Stroke
Watch the video above to see how to remove the gearcase from a Mercury Tracker 40 two-stroke outboard. This procedure is necessary for replacing the water pump and upper seals on this Mercury outboard. The shift shaft on this unit is in two pieces. We get those separated, and then unbolt the lower unit.
Mercury Tracker 40 Gearcase Remount - 2-Stroke
Watch the video above to see how to reinstall the lower unit on a Mercury Tracker 40 outboard. The gearcase on this Mercury Tracker needed to be removed to get to the water pump and the upper seals. See how to remount the lower unit on a Tracker outboard, starting with a bolt in hand before guiding the lower unit into place and bolting it back on.
Related: How to Remount the Gearcase on a Mercury 40HP 2-Stroke Outboard
Mercury 40HP Outboard Lower Unit Oil Change - 2-Stroke
Watch the video above to see how to change the gearcase lube in a Mercury 40HP outboard. This job requires a Mercury gear lube pump with the correct fitting. See how to drain out the lower unit oil, then how to do a pressure test on the gearcase. After the pressure test, we fill the unit back up with fresh lower unit oil.
Mercury 200 Lower Unit Removal
Watch the video above to see how to remove the lower unit from a Mercury 200HP outboard. This job doesn’t require any special tools or parts, but you should have an assistant when it comes time to drop the lower unit. You’ll see the trick of how to do this on your own when you remove the gearcase mounting bolts. We remove the cowling and the side chaps, and then drain the gearcase oil before dropping the lower unit.
Mercury 200 Lower Unit Remount
Watch the video above to see how to reinstall the gearcase onto a Mercury 200 XL Verado outboard. We did a lot of work on the lower unit on this outboard. See how to reattach the lower unit, which has an extension, so getting the extension positioned was the first step. Next, we greased the drive shaft and got the lower unit installed on our Mercury 200 outboard. You’ll also see how to replace the anode.
Mercury 200 Lower Unit Pressure Test
After replacing the input, output and shift shaft seals on our Mercury 200 outboard, we needed to check if it sealed up correctly. Watch the video above to see how to do a gearcase pressure test on a Mercury 200 XL Verado, using a gearcase pressure tester to make sure the lower unit is properly sealed before re-installing it on the powerhead.
Mercury 200 Lower Unit Oil Change
Watch the video above to learn how to change the lower unit oil in a Mercury 200 outboard. See how to find where the vent and drain bolts are located, and then how to use a hand pump to push the gearcase lube into the unit from the drain opening. You should change the gearcase oil on a Mercury 200XL Verado after every 100 hours of use or once a year.
