44xs and 25xs please help!

[Glenno]

Hi all,

I have recently fitted a 550 super sport (Australian class) motor to my current ten foot tunnel hull.

I dont know if the mid section and lower unit are off a 25xs or a 44xs, [B][U]PLEASE HELP! Pictures attached.

The lower unit was full of water after my first race day so its in need of some attention. So thats why I need to find out what it is.

Are the 25xs and the 44xs towers and lower units the same castings?
The shaft coming out of the lower unit seems rather thick for a 25hp and the gear ratio is 1 to 1. Can a 1 to 1 ratio be placed in the 25xs case or does that mean it a 44xs? Is the 25xs drive shaft thinner than the 44xs? How many splines at top?

Does any one have a lower unit that they are willing to sell or know where I can get some parts like prop shaft, bearings, seals, inpeller housing, inpellar, possibly the gears to fix mine?

Any healp with this would be really apreciated! I am of the water now because I dont want to further damage the lower unit.

Ps: the power head is a modded 30hp 3 cylinder yami.

Thanks heaps,
Glenno

[Glenno]

44xs and 25xs help please

Hi again,

If you have a lower unit for it please pm me!

Glenno

[pearson95m]

Glenno,
I’ll help answer some of your questions.

Its hard to tell from the pictures if the mid section is from a 44xs or 25xs. They are very similar to the eye, but different internal dimensions (I believe). If I’m not mistaken, the outside dimensions of the 25 and 44 mid’s are the same… however, they are slightly different on the inside. I am not positive about this.

From the picture it looks like your gearfoot is from a 44xs. One way you can tell for sure is by measuring the propshaft. If the propshaft is smaller than 5/8” then it’s a 25xs. Also, the driveshaft’s in the 44xs are larger than the 25xs. By the looks of it, you have a 44xs driveshaft and gearfoot.

Getting a gearfoot and parts for these are a little tough to come by. I suggest contacting Mark Wheeler. He has been involved with and has contacts of people making some of these items. Some of these things you can still get through Mercury, and others you’ll have to buy after market or find someone who can make them.

I hope this helps…

Josh

[ZUL8TR]

gear case leads

Here is gear case parts list for 25xs

http://www.crowleymarine.com/mercury...ts/1495_12.cfm

Here is gear case parts list for 44xs

http://www.crowleymarine.com/mercury...ts/1504_13.cfm

Based on part numbers of the gear case and the drive shaft they are different.

Note there are alot of NLA parts for the gear cases but there are parts available from others but limited I suppose. Here are some sources:

http://www.aeroliner-boats.com/index.html
This is David van Weele's site and he has a lot of bearings and seals for these type of gear cases.

Another is Jerry Wienandt who is very familiar with the 44xs and may have some gear case parts. His site name here is Trident. Here is his info

http://www.hydroracer.net/forums/member.php?u=1772

Another that is a resource for these type units is Ron Thomas, here is his email

Ron Thomas <birdfoot_23@yahoo.com>

Others hopefully will chime in

These gear cases are reletavily easy to work on if you are familiar with them and have some of the basic tools. For example do you have the outer cone cover nut R&R tool? Do you have the cartridge puller tool?

[trident]

44XS Gearcase

I have new replacement propshafts.

Frank Erion has new replacement gears.

Aeroliner has new replacement cones, cone nuts, driveshafts, water pump cartridges, etc.

Ron Thomas does excellent rebuild work.

Mark Schmerbauch does nice shaping of the 44XS cases.

Difference btween 44XS and 25XS tower is the upper casting which include the exhaust tuner pipe. Same clamp assy. Same lower casting, but drilled for whichever gearcase.

Hope this helps.

Jerry

[Top Gun 3-Z]

You have a pm

[Glenno]

44xs gear case help

Thanks every one for your help so far! Your all champions!

I have taken the prop shaft out of the lower unit. I was able to undo the cone nut with my hand (so it was not very tight) But it has been butchered at some stage around the two grab holes.

The gears look fairly bad to me, I will post some pics soon. Also the bearing thing (prop side of the water pump cartridge) looks maybee home made.

My main Question is how to remove the drive shaft and all related bearings and seals (drive shaft) from the lower unit?

Do I

1) undo the nut at the bottom of the drive shaft then slip the shaft out.
2) some how grab the bearing and seal and pull up vertically to remove them.
3) Also any tips on removing the prop shaft bearing at the nose cone end in the case would be really apreciated.

Any help is really apreciated,as I live in Australia and no one here knows anything about these awesome little lower units.

Also I have only diven and raced the motor once and I am stinging to get it back on the water.

Thanks heaps
Glenno

[ZUL8TR]

Gear case disassembly

1. Mount drive shaft in vise with gear case unit vertical and upside down, protect shaft with wood plates each side of the shaft

2. remove nut on drive shaft gear. There may be a bent tab washer so bend away the tabs, if not the nut could be the nylock type with no bent tab washer. Place box wrench on nut and rotate the case CW looking down while holding wrench.

3. remove drive shaft from vise. Place drive sfaft in vise but horizontal. Protect shaft. Take a rubber mallet and strike the top area of the case and the drive shaft should move out of the case with the top pilot with seal and the ball bearing. Note where the shims are and replace same way if you use the same prop shaft.

4. The pilot with seal and the ball bearing should easily slip off the drive shaft.

5. There are 2 needle roller bearings in the gear case, one needle roller bearing in the front of the gear case (Torrington GB98)that the prop shaft goes into you and the other is in the drive shaft bore (Torrington GB 912). Press and special tool needed to R&R.

6. To remove ball bearing from prop shaft a press is needed.

7. sounds like you need many new parts like gears, seals, bearings, maybe shims if you don't have the right combination to get the proper gear lash setting.

8. might want to have somebody rebuild it?

[Guest]

Quicksilver replacement parts

The below will take you to our web page and list the parts and prices. We also stock the bearings and seals.

Alan

http://aeroliner-boats.com/10.html

[Glenno]

44xs gear case help

Hi all,
Thanks for the info on how to dismantle the lower unit, It came apart very easily.

I am 37 years old and have been playing around with outboards (dismantling and rebuilding) for 2/3 my life but never worked on race stuff before, I have been racing stock 25hp class (full standard shifting lower unit) in Australia for about 6 years.

I have attached some pictures of the internals of the lower unit for your input.

Note:
1) The cracked bearing on the prop shaft (that was close to stuffing everything).
2) All the bearings look totally stuffed along with the prop shaft.
3) the rear lower unit bearing,seal carrier is definately home made to overcome the stuffed prop shaft.
4) The drive shaft looks good.

I will definately need to get in touch with you Alan and also someone who has prop shafts and inpellars.

I know I will need to maybe get some diferent shims as well to get lash correct, My best mate is also an outboard mechanic so he will be able to give his input on the rebuild as well.

I wish I was over in the states so I could send it off to you guys to get it sorted, but being over in Australia, I am going to have to learn to sort it.

Thanks all,

Glenno (addicted to club racing and getting others into the sport)

[ZUL8TR]

gear case rebuild

Frank Erion has new prop shafts, gears and impellors. Jerry Wienandt also has prop shafts. David (Alans brother) at Aeroliner has the needle roller bearings and ball bearings, seals, cone nut, inner cone piece with new GB98 roller bearings and seals, (might also need) pump cartridge.

For details on assembly contact Ron Johnson.

What are the condition of the threads in the gear case that receives the outer cone nut? If they are in poor condition that could be a problem. Usually the cone nut threads go bad first.

[Glenno]

44xs gear case help

Hi there,

The housing thread looks fine thankfully.
yep I definately need a new pump cartridge.

I will be in touch with all these guys early this week to sort out some parts.

How was the cracked bearing, fairly bad!

Glenno

[ZUL8TR]

case rebuild

My guess you have about $600 +/- plus Ship in parts for prop shaft, gears, all roller and ball bearings, cone nut, inner cone piece, seals, impellor, shims, water pump cartridge.

The inner cone that presses against the water pump cartridge is not what these cases came with.

[trident]

Gearcase

Glenno,

That's not the original cone at all!. Alan & David (Aeroliner) has new ones, very nice, and has the cone nut and water pump cartridge, also very nice. I buy mine from them. I do have prop shafts. Aeroliner also has drive shafts if needed.

I suggested to Alan that if you need all this stuff, maybe we we send the various parts to one supplier, to pool it into one shipment to you. It would take a little coordination, but with this site and the 'net, that should be easy...

Just a thought, if you're buying new gears and shaft, maybe someone here could press the gear on, before its shipped? I don't have tools or knowledge for that. Anyone?

Jerry

[lcp8410]

44xs and 25xs please help!

me too wanted to know u guy press the gear in without scratch a good shaft.