TABLE OF CONTENTS - Glm Products

1 TABLE OF CONTENTS . MERCURY/ MARINER / FORCE GEARCASE. Mercury / Mariner / Force Mercury / Mariner / Force Gearcase Exploded Views Section 1 Prop Shaft & Drive Shaft Components Section 5. Gearcase Components - , 4, , 6, , HP .. 6-7 Prop Shaft Identification .. 60. Gearcase Components - 6, 8, , 10, 15 HP .. 8-9 Bearing Carrier Components & Applications .. 61. Gearcase Components - 18XD, 20, 25 HP .. 10-11. Prop Shaft Components - 25, 30, 40, 50 HP (2 & 3-Cyl.) .. 62. 25 HP (4S), 30 HP (2-Cyl.), 40 HP, 50 HP (2 & 3-Cyl.)(2 & 4-Stroke) 12-13. Prop Shaft Components - 35-70 HP (2, 3 & 4-Cyl.) .. 63. Gearcase Components - 35-70 HP (2, 3 & 4-Cyl.) .. 14-15. Gearcase Components - 50, 55, 60 HP (3-Cyl.)(2-Stroke) .. 16-17 Prop Shaft Components - 50, 55, 60 HP (3-Cyl.) .. 63. Gearcase Components - 40, 50, 60 HP EFI (4-Cyl.)(4-Stroke) .. 16-27 Prop Shaft Components - 55, 60-120 HP (3 & 4-Cyl.)

2 63. Gearcase Components - 30-125 HP (3 & 4-Cyl.)(2 & 4-Stroke) .. 18-19 Prop Shaft Components - L4, L6 & V6 (65-225 HP).. 64. Gearcase Components - L4, L6 & V6 (65-225 HP) .. 20-21. Prop Shaft Components - V6 (200 DFI, 225 Carb., 225 & 250 EFI) .. 64. Gearcase Components - (200 DFI, 225 CARB, 225 & 250 EFI) .. 22-23. Upper Drive Shaft Identification (20 Transom) .. 65. Gearcase Components - 4-Stroke Verado .. 24-25. Drive Shaft Components - Pre-Load Pin Type Drive Shaft .. 66. Mercury / Mariner / Force Drive Shaft Components - Retaining Nut Type Drive Shaft .. 66. Gearcase seal & Bearing Kits Section 2. Drive Shaft Components - Non-Retaining Nut Type Drive Shaft 66. Gearcase seal Kits - Mercury & Mariner .. 28 Drive Shaft Components - Alpha Gearcase L4, L6, V6 (65-225 HP) .. 67. seal & Bearing Kits - Without Forward Bearing.

3 29. Drive Shaft Components - Late Alpha Gearcase V6 .. 67. Gearcase seal & Bearing Kits Applications .. 30-32. Gearcase seal Kits - Force .. 33 Mercury / Mariner / Force Gearcase seal Kits - Force Applications .. 33 Water Pumps Section 6. Mercury / Mariner / Force Water Pump Impeller Identification .. 70-71. Lower Gear Housing Gears Section 3 Water Pump Kits - 8, , 15, 40, 50, 60 EFI HP, 3-Cyl. 4-Stroke .. 72. Water Pump Kits - 25, 30, 40, 50 EFI HP, 3-Cyl. (1998 & Up) 4-Stroke . 73. Lower Gear Housing Gears - Inline 4 (40, 45, 50 HP) .. 36. Water Pump Kits - 40-275 HP, 3-Cyl., L4 & L6 4-Stroke .. 74. Lower Gear Housing Gears - 3-Cylinder 40, 50 HP .. 37. Lower Gear Housing Gears - 3-Cylinder 50, 55, 60 HP .. 38 Water Pump Kits - 15 HP & .. 75. Lower Gear Housing Gears - 3 & 4-Cyl. w/ 3 Jaw Rev. Clutch .. 39 Water Pump Kits - 15XD-60 HP w/ Metal Pump Housing 2-Stroke.

4 76. Lower Gear Housing Gears - 3 & 4-Cyl. w/ 6 Jaw Rev. Clutch .. 40 Water Pump Kits - 20-70 HP w/ Small Plastic Pump Hsg. 2-Stroke .. 77. Lower Gear Housing Gears - Inline 4 w/ 3 Jaw Rev. Clutch .. 41 Water Pump Kits - 65-225 HP w/ Large Plastic Pump Hsg. 2-Stroke .. 78. Lower Gear Housing Gears - Inline 4 w/ 6 Jaw Rev. Clutch .. 42 Water Pump Kits - 65-225 HP w/ Large Metal Pump Hsg. 2-Stroke 79-80. Lower Gear Housing Gears - Inline 6 (90-150 HP) .. 43 Water Pump Kits - 75-140 HP (Force & Chrysler Only) .. 80. Lower Gear Housing Gears - V6 135, 150 HP .. 44 Water Pump Kits Applications (Force & Chrysler Only) .. 80. Lower Gear Housing Gears - V6 160, 175, 200 HP w/o Drive Shaft Nut .. 45 Water Pump Kits 4-Stroke .. 81. Lower Gear Housing Gears - V6 150 (XR6, MAG III) 150 EFI, 150 DFI, 175 HP .. 46. Water Pump Kits .. 82-86. Lower Gear Housing Gears - V6 150 (XR4, MAG III) 175, 200, 200 EFI, 220 HP.

5 47. Lower Gear Housing Gears - V6 200, 225 ( DFI), 225, 250 ( EFI) HP .. 48 Mercur y / Mariner / Force Prop Hardware, Prop Wrenches, Tools & Anodes Lower Gear Housing Gears - V6 225, 250 ( Carb) .. 49. Section 7. Lower Gear Housing Gears Applications .. 50-51 Prop Hardware - 6-15 HP (1 & 2-Cyl.) .. 88. Prop Hardware - 8-25 HP (2-Cyl.) .. 88. Mercury / Mariner / Force Prop Hardware - 30-75 HP (2, 3 & L4-Cy.) .. 89. Gearcase Shift Components Section 4. Prop Hardware - 60-120 HP (Inline 4-Cyl.) .. 89. Shift Components - 25-50 HP (2 & 3-Cyl.) .. 54 Prop Hardware - 70-275 HP (L4 & V6) .. 89. Shift Components - 35-70 HP (2, 3 & 4-Cyl.) .. 54 Prop KIts & Hardware Applications .. 90. Shift Components - 50, 55, 60 HP (3-Cyl.) .. 55 Prop Wrenches .. 90. Shift Components - 50, 60-125 HP (3 & 4-Cyl.) .. 55 Service Tools .. 91-92. Shift Components - L4, L6 & V6.

6 56 Aluminum Anodes .. 93. Shift Components - V6 ( ) .. 56 Aluminum Prop Nut Anode Kits & Replacement Anodes .. 94. Shift Components Applications .. 57-58 Anodes Applications .. 94-96. TABLE OF CONTENTS . MERCURY / MARINER / FORCE POWERHEAD COMPONENTS. Mercury / Mariner / Force Mercury / Mariner / Force Pistons Section 8 Carburetor Kits and Fuel Pumps Section 12. GLM Exclusive Marine Pistons .. 98 GLM's Plastic Inline Fuel Filters .. 148. Piston Ring Coatings Comparison .. 98 Low Pick-up Water / Fuel Separator Mounting Bracket .. 149. Piston Designs (Crossflow, Loopcharged & Four-Stroke) .. 99 How to Choose the Correct Water / Fuel Separator .. 150. Inline 3-Cylinder DFI Pistons .. 100 Stainless Steel Brackets / Die Cast Aluminum Brackets .. 105. Water Separating Fuel Filter Kits .. 151. Inline 4-Cylinder Crossflow Pistons .. 101.

7 Carburetor Diaphragm and Gasket Kits .. 152-153. 2 & 3-Cylinder Loopcharged Pistons .. 102. Inlet Needles and Seat Assemblies .. 153. Inline 2, 3, 4 & 6-Cylinder Crossflow Pistons .. 103. Gaskets for Fuel System .. 154. 3-Cylinder Loopcharged Pistons .. 104 Check Valve Kits .. 155. Inline 3 & 4-Cylinder Loopcharged Pistons .. 105-107 Fuel Pump Diaphragm Kits .. 156. 60 V6 Loopcharged Pistons .. 108-111 Fuel System Components and Kits Applications .. 157-161. Inline 2, 3, 4 & 6-Cylinder Piston Kits & Rings Applications .. 112-113. Mercury / Mariner / Force 60 V6 Piston Kits and Rings Applications .. 114 Powerhead Gaskets Section 13. Mercury / Mariner / Force Head Gaskets - 1, 2, 3 & L4-Cylinder .. 164. Powerhead Bearings & Seals Section 9 Head Gaskets - Early Mariner 2-Cylinder .. 164. Head Gaskets - 60 V6 - Mercury & Mariner.

8 165. GLM's Needle & Caged Bearings .. 116-117. Head Gaskets - Force .. 165. Needle Bearing Identification .. 118. Powerhead Gasket Kits - Mercury & Mariner .. 166-168. Powerhead Bearings - Connecting Rod Bearings (Big End) .. 118 Powerhead Gasket Kits - Force .. 169. Powerhead Bearings - Center Bearings .. 119 Cylinder Head Seals .. 169. Bearing Applications .. 120-124 Cylinder Head O-rings .. 169. Head Gasket and Gasket Kit Applications .. 170-172. Crankshaft Bearings, Oil Seals & O-rings .. 125. Powerhead Mounting Gaskets - 2, 3, L4 & L6-Cylinder .. 173. Crankshaft Bearings, Oil Seals & O-rings Applications .. 126-129 Powerhead Mounting Gaskets - V6 .. 174. Crankcase Gaskets .. 174. Cylinder Block Cover Gaskets .. 174-175. Mercury / Mariner / Force Reed Block Gaskets .. 175. T her mostats Section 10 Transfer Port Cover Gaskets.

9 176. Baffle Plate - Exhaust Manifold Gaskets .. 176-177. Thermostats &Thermostat Kits .. 132-133. V6 Divider Plate Gaskets .. 177. Poppet Valve Kits .. 133. Water Jacket Cover Gaskets .. 178. Thermostat & Poppet Valve Kit Applications .. 134 Sound Attenuator Gaskets .. 178. Thermostat Housing Components .. 135-136 Miscellaneous Gaskets .. 178. Mercury / Mariner / Force Mercury / Mariner / Force Ignition and Electrical Section 11 Oil seal & O-ring Size Charts Section 14. Point Sets .. 138 Mercury / Mariner / Force Oil Seals Shaft & Bore Size .. 180. Condensers .. 138 Mercury / Mariner / Force O-Ring Size Chart .. 181. Tune-Up Kits .. 138. Coils .. 138. WARRANTY. Ignition System Applications .. 139 Limited Warranty of GLM Products , Inc.. 182. Solenoids .. 140 Warranty Service Procedure .. 183. Rectifier .. 140 GLM Products , Inc.

10 Warranty Claim Application .. 184. Power Trim Relay .. 140. Electrical System Applications .. 141-145. Mercury/Mariner/Force Gearcase Section 1. Mercury / Mariner / Force Gearcase Exploded Views Gearcase Components - , 4, , 6, , HP .. 6-7. Gearcase Components - 6, 8, , 10, 15 HP .. 8-9. Gearcase Components - 18XD, 20, 25 HP .. 10-11. 25 HP (4S), 30 HP (2-Cyl.), 40 HP, 50 HP (2 & 3-Cyl.) (2 & 4-Stroke) . 12-13. Gearcase Components - 35-70 HP (2, 3 & 4-Cyl.) .. 14-15. Gearcase Components - 50, 55, 60 HP (3-Cyl.)(2-Stroke) .. 16-17. Gearcase Components - 40, 50, 60 HP EFI (4-Cyl.)(4-Stroke) .. 16-17. Gearcase Components - 30-125 HP (3 & 4-Cyl.)(2 & 4-Stroke) .. 18-19. Gearcase Components - L4, L6, & V6 (65-225 HP) .. 20-21. Gearcase Components - (200 DFI, 225 CARB, 225 & 250 EFI) ..22-23. Gearcase Components - 4-Stroke Verado .. 24-25.