Car Fix DIY Videos

Buy only the Mercury 40HP seal kit here: https://www.boats.net/product/mercury/823547A2?utm_source=youtube&utm_medium=video&utm_campaign=description_atf_BDN

See how to replace the output seals on your Mercury 40 HP 2-stroke in this video from Boats.net. Click the link above for a seal kit for this unit. It includes the seals and the O-ring you’ll need for this job in addition to more seals for other areas of the lower unit.

We’ll start with the prop already removed, and then we’ll drain the lower unit oil. Then, we’ll remove the bearing carrier housing and the prop. There are two seals you’ll need to replace, and John will show you how to get the old seals out and get the new ones pressed in. Then we’ll replace the O-ring on the housing and get everything put back together.

See this diagram for a better look at the lower unit and prop shaft assembly: https://www.boats.net/catalog/mercury/outboard-by-hp/40hp/0g760300-thru-0t979999-usa-cat-90-803018-2-cyl/gear-housing-propeller-shaft-2-00-1-gear-ratio?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN

Read how to do this job step by step: https://www.boats.net/blog/mercury/40hp/output/seal/replacement/2/stroke?utm_source=youtube&utm_medium=video&utm_campaign=BDN-description-blog-link

VIDEO HIGHLIGHTS:
Draining the lower unit – 0:53
Removing the bearing carrier – 1:30
Removing the old seals – 2:25
Replacing the seals – 3:38
Replacing the O-ring – 5:08
Reinstalling the bearing carrier and prop shaft – 5:30

Find Mercury outboard parts here:
https://www.boats.net/catalog/mercury/outboard-by-hp?utm_source=youtube&utm_medium=video&utm_campaign=description_btf_BDN

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In the video we’re working with a 2002 Mercury 40 HP 2-stroke outboard motor, but you may have similar steps for your Mercury outboard. If you’re not sure whether these steps apply to your motor, leave a comment and we’ll get back to you.