96 Merc 150 EFI gearcase leak issue: Can anyone answer this??

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M GO BLUE

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Aug 27, 2009
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Georgetown, TN
I went down tonight to get the boat ready for a sauger-stalking tomorrow, and notice that there was a significant puddle of g/c lube on the shop floor. it appears to be coming from a weep-hole located forward of the shift linkage in the housing. I have combed over the manual and can't find any info on this weep hole, and am concerned about running it until I can determine what is causing the leak?? Anyone have any answers??
 

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That would be the shift shaft seal. Very common problem this time of year. You have water in your lube and it is freezing and pushing oil out the weakest link and that would be the shift shaft seal. That weep hole is to allow water to drain out and it so happens the shift linkage is there as well. It is not a big deal to replace. You can get the seal for around $10 or a new bushing with seal for arond $20. </p>

Bushing</p>

http://www.boats.net/parts/detail/merc/M-77631A%202.html</p>

Seal</p>

http://www.boats.net/parts/detail/merc/M-76384.html</p>
 
All:

I appreciate the guidance! I am gonna drop the lower unit this evening and put it on the stand...

James: Does this bushing/seal require a sealant on the mating surfaces during installation??
 
The seal is rubber coated and needs to go in dry. It requires a special tool to remove the bushing. You are welcome to use mine.
 
Appreciate the offer, James. I will go ahead and pull the gearcase off, verify that the shift-seal is the leaker, and order the new parts. When they get here, I'll give you a shout to see what would be a good time to snag the tool...
 
OK guys, here we go-Thought I'd share this (and ask a few more questions):

I dropped the gearcase this evening, and found that, indeed, it is the shift shaft seal that appears to have given up the ghost (as everyone predicted; see pics). Parts (and tools) are on the way to repair this, and appears to be a straight-forward repair. However, this is when I started noticing some things that "bothered" me:

1). When I got the gearcase removed from the mid-section, the water-pickup tube cam out with it! Now, in my days as a "blue" motor guy, I never saw this! Is this as simple as removing the tube from the waterpump and re-inserting into the powerhead fitting?

2). The alignment sleeve for the pickup-tube to waterpump has melted onto the pickup tube. (I was aware that this would happen after I removed/trashed the exhaust-can and modified the exhaust tuner). What is the easiest way to get this off the pickup tube? I was thinking torch emoHoppingmad

3). A quick look into (up) the midsection, and I noticed that the driveshaft seal didn't come with the driveshaft when I dropped the gearcase. I am thinking just re-aligning it in the hole before I reinstall the driveshaft/gearcase?? The thought of pulling the powerhead and having to wait for more gaskets is giving me heartburn emoVomit
 

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You will simply cut the alignment tube off and install a new one. Simply insert the water tube back in the adapter. It has the same seal as the inside of the water pump housing. It is not big deal. The seal is driven into the bottom of the crank and does not use a "O" ring like the "BLUE" motors. Also on the "BLUE" motors the water tube is attached to the adapter plate and does not come off. That is one of the reasons you can not do that mod on them. Hope this has cleared up a few things!!!
 
Excellent! I was hoping that was the case! I hope to be stalking the elusive Sauger-animal again...I'll let you know how the build-back goes. Appreciate it James. emoBeer emoToast
 

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