94-5 494Printed in U.S.A. - 1 -
No. 94-5
Water Pump Base Replacement - 30/40
Mariner and Mercury
19941/230/40
Serial Number
US 0G053314 thru 0G071765
Outboards listed, may have had the lower seal in the
water pump base damaged during manufacturing.
Damage to this seal could, after prolonged operating
time allow water to enter the gear housing causing
damage.
OWNER NOTIFICATION:
Astherewereonlyasmallnumberofregisteredunits
atthetimethisproblemwasdetected,acustomerlet-
ter will not be issued.
Please contact the owners of any affected outboards
thatyour dealership mayhave delivered andarrange
to have the water pump base replaced.
CORRECTION:
IMPORTANT:Removeanyburrsonthedriveshaft
using 320 grit carborundum cloth prior to remov-
ing the water pump impeller.
1. Remove the gear housing assembly and disas-
semble the water pump components to gain ac-
cess to the water pump base. Refer to 30/40 Ser-
vice Manual 90-826148.
2. Withthegearhousingsecuredintheuprightposi-
tion, remove the vent plug.
IMPORTANT: Protect the gasket surfaces of the
water pump area of the gear housing with a shop
towel when removing the water pump base.
3. Use a locking pliers to pull, or two screw drivers
to pry the water pump base out of the gear hous-
ing (Figure 1).
b
a
a - Water Pump Base
b - Vent Plug
Figure 1. Water Pump Base Removal
NOTE: If you are not able to remove the water pump
base as described, remove the water pump base
along with the drive shaft as outlined in the service
manual.
4. Apply a light coating of 2-4-C Marine Lubricant
with Teflon (92-825407A12) onto a new o-ring
and install the o-ring into the groove around the
replacement water pump base (Figure 2).
52825
a
b
a - O-Ring
b - Water Pump Base
Figure 2. O-Ring Installation.
