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OMC electric shift gear-head rebuild (how to series)

OMC Stringer sterndrive lower gearcase step by step rebuild
electric shift gear-head assembly

  • Gear-head rebuild help for 8 or 10 bolt swivel housings
  • Prop shaft bearing retainer (gear-head) years 1967-1971
  • Swivel housing does not need to be separated from gearcase for this repair
  • Two oil seals and bearing will be removed
  • Three oil seal and one bearing will be installed
  • Electric shift step by step pictures of outdrive rebuild

How to series for Electric shift outdrive
Forward-reverse coil repair
Clutch spring and swivel housing rebuilt
Shift cable removal and adjustment *400 *800 series years 1978-1985

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By author Trish Dougherty

680 Loctite is used on this bearing retainer (gear-head-assembly) to install 3 seals when rebuilding 1971 to 1977 OMC stern drive.

87620 Electric shift lower seal kit needed for rebuild
87620 Electric shift lower kit needed for rebuild

P/N 87620 Electric shift lower kit needed for rebuild OEM 981797.

*Note for this rebuild of 3 prop shaft seals, one will need to be purchased separately for a total of 5 units if you are changing seals in the swivel housing.

Johnson gasket sealing compound to reseal o-ring

Johnson gasket compound

P/N 508235 Evinrude Johnson gasket compound is for o-ring on gear-head and swivel gasket $12.29

68015 Loctite used installing OMC seals on rebuild

68015 Loctite

P/N 680 Loctite retaining compound 3.4 oz or (10 ml.) use on outside of new seals being installed. Gear-head unit that are found to have .010 or more play will require coating the inside of the bearing retainer area and let compound dry overnight. Then coat and install 24hr latter. $29.89

OMC outdrive showing sand blasted gear-head area
OMC outdrive showing sand blasted gear-head area

Sandblast or wire brush lower unit outdrive area, so not particles fall into stern-drive when we pull gear-head assembly out.

A Clean out screw hole with 13/64 drill
A Clean out screw hole with 13/64 drill

Clean out screw hole with 13/64 drill.

B Drill out 5/8 inch deep
B Drill out 5/8 inch deep

Drill out 5/8 inch deep.

C Tap size is 1/4 inch 20 n.c
C Tap size is 1/4 inch 20 n.c

Tap size is 1/4 inch 20 national coarse thread.

D Re-tap about 1/2 inch deep
D Re-tap about 1/2 inch deep

Re-tap about 1/2 inch deep.

E 7/16 wrench required
E 7/16 wrench required

7/16 wrench required.

F Only 2 bolt holes required
F Only 2 bolt holes required

Only 2 bolt holes required.

G
G

Remove the 4 screws from gear head assembly.

H
H

Remove old o rings.

I Install new o rings from seal kit P/N 87620
I Install new o rings from seal kit P/N 87620

Install new o rings P/N 87620.

J Remove gear-head with bearing carrier puller
J Remove gear-head with bearing carrier puller

Remove gear-head with bearing carrier puller.

K Can allso just pry out just holding screw
K Can allso just pry out just holding screw

Can allso just pry out just holding screw.

L Remove by hand after 3/8 of an inch
L Remove by hand after 3/8 of an inch

Remove by hand after 3/8 of an inch.

M
M

Can now remove screws.

N Notice groove on water seal area of drive shaft

Notice groove on water area of drive shaft .

O
O

Notice groove on oil seal area the lower part of drive shaft .

Wire brush bearing retainer
Wire brush bearing retainer

Remove o-ring and clean old gasket compound from unit with fine wire brush

Machine new oil seal area to 1.500 inches
Machine new oil seal area to 1.500 inches

Lathe will be required to machine front face to hold extra oil seal. Machine new oil seal area to 1-1/2 inch, you can be over by up to .007 if using 680 and .003 with 609 green Loctite retaining compound. Note Loctite products are listed under tools if you need to purchase this item.

Remove old bearing and seals
Remove old bearing

Remove old seals and bearings by pushing on bearing. Then sandblast or wire brush old gasket compound off gear-head assembly. Note Johnson gasket retaining compound is listed under tool if required.

Clean bearing and seals of any 680 loctite
Clean bearing and seals of any 680 loctite
381849 Used gear head assembly OEM 381849
381849 Used gear head assembly OEM 381849