Watch the video above and follow the steps below to learn how to remove the lower unit (gearcase) from a Mercury 40HP 2-Stroke outboard.
Tools Needed – Mercury 40HP 2-Stroke Gearcase Removal
- Ratchet and extensions
- 13mm, 15mm sockets
- 16mm wrench
- 10mm wrench (x2)
NOTE: We removed the lower unit from a Mercury Tracker 40HP 2-stroke motor, but the steps are the same or similar for most small-to-medium sized Mercury outboards.
Removing Mercury 40HP 2-Stroke Lower Unit
Step 1. Disconnect the shift shaft by using two 10mm wrenches to loosen and remove the shift shaft coupling nut (located just below the mount halfway down the driveshaft housing).
Step 2. Remove the 13mm trim tab bolt and the trim tab itself.
Step 3. Remove the 15mm lower unit mounting bolt and washer within the trim tab housing.
Step 4. Remove three of the four 16mm lower unit mounting bolts.
Step 5. Support the lower unit so it won’t drop, then remove the last 16mm lower unit mounting bolt.
Step 6. Let the lower unit drop down carefully, away from the outboard and you’re done.
NOTE: You may have to rock the lower unit from side to side until it’s free from its mounting dowels.
As noted, the steps for removing the lower unit from a Mercury 40 2-Stroke outboard are the same or similar for most small-to-medium sized Mercury motors. However, if you want to see the gearcase removed on a 4-stroke model, watch the video above to see how to remove the lower unit on a 2003 Mercury Tracker 40HP 4-Stroke engine.