3.0 sportmaster rebuild

[CPC]

Just bought a boat with a 2015 300xs last weekend and have put a few hours on the boat before the lower unit locked up at 55-60 mph. I changed the fluid when I got it and the old fluid had some milky oil in it. That said I have not worked on one of these lower units and thinking about tackling the job. I have rebuilt a few of my bravo 1 and xr drives. Is there a good service manual available for these lower units?

Local shops are 1-4 weeks out from being able to look at it.

Any tips on rebuilding these lowers would
be helpful.


thanks

[wolfgangb]

Yes there is: Mercury #90-842009. Starting model year 2005. Covers Sport Master, Torque Master, and Fleet Master Gearcases (post introduction of large bearing on fwd gear).
Seeing that you have rebuilt Merc LUs before, the mistakes in the shimming section will be evident to you. Good luck!
Regards, Wolfgang (South Africa)

[Chaz]

Tools and service manual will get you thru it, if you have done Merc lower units before.

With the 3.0 / 3.2L sporties, you'll want to get a "driveshaft seal holder" and "shift shaft seal holder" from MAD / EFI .. the stock parts are *&%** junk .. :smiletest:

While you have it apart, you can also fit 3 prop shaft seals in the carrier. I put them in:
First one "in" to hold oil. Second and third, "out".
(I use-ta put the first two, in, to hold oil .. but they did such a good job that the outside seal never saw a bit of oil .. dried / burned up pretty quick)

https://madefi.com/shop/ols/products/sportmaster-billet-upgrade-kit-loaded-with-seals-93db4914-e304-4577-a91c-2993d4ce101e?olsFocus=false

[CPC]

Tools and service manual will get you thru it, if you have done Merc lower units before.

With the 3.0 / 3.2L sporties, you'll want to get a "driveshaft seal holder" and "shift shaft seal holder" from MAD / EFI .. the stock parts are *&%** junk .. :smiletest:

While you have it apart, you can also fit 3 prop shaft seals in the carrier. I put them in:
First one "in" to hold oil. Second and third, "out".
(I use-ta put the first two, in, to hold oil .. but they did such a good job that the outside seal never saw a bit of oil .. dried / burned up pretty quick)

https://madefi.com/shop/ols/products/sportmaster-billet-upgrade-kit-loaded-with-seals-93db4914-e304-4577-a91c-2993d4ce101e?olsFocus=false


thanks for the information. I am going to look for the manual and order it.

[H2OPERF]

[ the mistakes in the shimming section will be evident to you. Good luck!
Regards, Wolfgang (South Africa)[/QUOTE] shouldn't we get a class action refund for the errors??? I read that several times before i said yea thats f...ed up. It takes quite a few special tools to do it , many can be home made but some not so easy.

[wolfgangb]

Well, there is also a hidden disclaimer in the Manual, which says roughly: "if you have completed assembly of the unit and it does not work (i.e. turn) YOU have done something wrong".
When shimming, switch off cellphone, be patient, and record everything, so you do not confuse yourself. For pinion height, make sure that the propshaft is well centered (!!!), use 10 to 12" feeler gauge, and a 600 Lumen headlamp. Make sure that your glasses (if you are wearing any) do not hit the cav plate.