7 MercruiserSpecialTools

Throughout this publication, "Warnings" and "Cautions," accompanied by the
international HAZARD symbol ! , are used to alert the technician to special

instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe these safety alerts carefully.
These safety alerts alone can not eliminate the hazards they signal. Strict compliance
to these special instructions when performing the service, and common sense
operation are major accident prevention measures.
90-866948 1106
Safety Alerts and Notices
! WARNING
WARNINGindicates a potentially hazardous situation that, if not avoided, could
result in death or serious injury.
IMPORTANT: Indicates information or instructions that are necessary for a particular

step or action.
NOTE: Indicates information that helps in the understanding of a particular step or

action.
Approved Practices and Procedures

! CAUTION
Avoid personal injury or property damage. Personal safety is dependent upon using
proper service procedures, the correct tools and appropriate parts. The procedures
in this manual are safe and effective when performed properly. Some of the
procedures require special tools, specifically designed for the purpose. If part
replacement is required, use only replacement parts that are manufactured or sold
by Mercury Marine. Anyone who chooses to use procedures, tools or parts not
recommended by Mercury Marine assumes full responsibility for the results.
IMPORTANT: Use of procedures, tools, or parts not recommended by Mercury
Marine may void the Mercury Marine Limited Warranty.
This manual is written to aid our dealers and company service personnel in the proper
installation or service of our products. Persons who are not familiar with these or
similar products produced by Mercury Marine, and who have not been trained in the
recommended servicing or installation procedures should have the work performed
by an authorized Mercury Marine dealer technician. Improper installation or servicing
of this product could result in damage to the product or personal injury.
This document details safe service and diagnostic procedures. Mercury Marine
cannot caution against all potentially hazardous service methods. For safety
reasons, follow procedures as described in this document.
2006 Mercury Marine
CAUTIONindicates a potentially hazardous situation that, if not avoided, may

result in minor or moderate injury or property damage. It may also be used to alert
against unsafe practices.
MerCruiser Special Tools Catalog
! CAUTION
Manual Revisions and Current Information

Mercury Marine reserves the right to make changes to this manual without prior notification.
Information contained in this document supersedes all information issued before the
publication date of this manual. Refer to dealer service bulletins; operation, maintenance,
and warranty manuals; and installation manuals for other pertinent information concerning
the products described in this manual.
Related Service Bulletin List

Use the following table to record any future service bulletins that affect or add to the
information in this manual. List the bulletin numbers and affected sections or pages in this
manual for your reference.
Bulletin Type Service Bulletin Bulletin Description/Title
Section/Page
Affected
Copyright and Trademark Information

Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
2006, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury
Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, SportJet, KPlanes, MerCathode, RideGuide, SmartCraft, Zero Effort,
M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered
trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered
service mark of Brunswick Corporation.
TABLE OF CONTENTS
Section 1 - Alpha Sterndrive Tools
Alpha Sterndrive Tools............................................2
Alpha Sterndrive Tool Application Chart..........2
Section 2 - Bravo Sterndrive Tools

Bravo Sterndrive Tools..........................................16
Bravo Sterndrive Tool Application Chart........16
Section 3 - TR/TRS Sterndrive Tools

TR/TRS Sterndrive Tools......................................38
TR / TRS Sterndrive Tool Application Chart...38
Section 4 - Gasoline Engine Tools

Gasoline Engine Tools..........................................44
Gasoline Engine Tool Application Chart.........44
EFI/MPI Engine Tool Application Chart..........45
ECM/PCM Engine Tool Application Chart......46

Gasoline Engine and EFI/MPI Tools..............46
CDS System Kits and Components...............53
Section 5 - Lubricants/Sealants/Adhesives
LSA Table..............................................................56
Section 6 - Tool Manufacturers

Tool Manufacturers................................................60
90-866948 NOVEMBER 2006
Page i
Page ii
90-866948 NOVEMBER 2006
Table of Contents
Alpha Sterndrive Tools......................................... 2
90-866948 NOVEMBER 2006
Alpha Sterndrive Tool Application Chart.........2
Page 1
Alpha Sterndrive Tools

Alpha Sterndrive Tool Application Chart
Page 2
Part No.
Description
Alpha One Gen II MC1, RMR Alpha One
9112037
Shift Cable Tool
9114311A2
Drive Shaft Bearing Preload Tool
9117256
Bearing Retainer Wrench
9118605A2
Bearing Adapter Installation Tool
9131107T
Shift Shaft Bushing Tool
9131108T
Oil Seal Driver
9131229A7
Bearing Removal and Installation Tool

Assembly
9133489
Needle Bearing Driver
9133491
9133492T
9133493T
Bearing Cup Driver
9134379T
Bearing Cup Driver
9134569A1
Slide Hammer Puller
9136577T
Bearing Cup Driver
9137240A1
Snap Ring Pliers
9137241
Universal Puller Plate
9137299Q2
Lube Gun
9138053A4
Power Steering Gauge Kit
9138277A2
Tab Washer Pliers
9138756
Ujoint Adapter
9138918T
Bearing Cup Driver
9138919
Swivel Pin Puller
9143506T
Drive Shaft Bearing Retainer Wrench
9138918T
Bearing Adapter
9143693A2
Transom Cutout and Drill Fixture
9144110T
Seal Driver
9144357Q2
Flushing Device
9145497A1
Bellows Expander Tool
9146086A1 / 9185716
Puller Jaws Assembly / Puller Bolt
9152915A6
Trim Pump Test Gauge Kit
9178473
Backlash Indicator
1254048
Belleville Washer
9156048T
Pinion Gear Shimming Tool
9156775T
Drive Shaft Adapter
9158222A1
Dial Indicator
9160523
Shimming Tool, Drive Gear
9160526T
Shimming Tool, Driven Gear
9161067A3
Pinion Nut Wrench
9161069T
Bearing Carrier Retainer Nut Wrench
X
X
90-866948 NOVEMBER 2006

Part No.
Description
Alpha One Gen II MC1, RMR Alpha One
9161077T
Propeller Shaft Adapter
9163209
Torch Lamp
9166274
Torque Wrench, lbin.
75104A7
Shift Shaft Tool
9178310
Hinge Pin Tool
9178473
Backlash Indicator
91805057A2
Bushing Installation Tool
91805475A1
Alignment Tool Assembly
91806908A1
Power Steering Adapter
91806908A1
Seal and Bushing Installation Kit
91807944T
Needle Bearing Installation Tool,

Reverse Gear
91808053T
Bearing Cup Driver
9183155
Dial Indicator Adapter Kit
91809815A1
Shift Shaft Stabilizer
91815850
Forward Gear Assembly Tube
91816242
Puller Jaw
91816246
Guide Plate
91816244
Reverse Gear Needle Bearing Driver
91816245
Needle Bearing Remover
91817569T
Carrier Seal Driver
91817570T
Upper Drive Shaft Housing Seal Driver
91818162
Sleeve Installation Tool
91818169T
Sleeve Removal Tool
91821571A1
Water Pump Alignment Pins
91821709T
Spanner Wrench
9183155
Dial Indicator Adapter Kit
91854377
Shimming Tool, Driven Gear
918775281
MCM Tool Overlay Kit
9189897
Dial Indicator Holding Tool
9195639
Pipe Tap
Shift Cable Tool
X
9112037
Installs and removes shift cable into the bell housing of the
transom assembly.
10815
90-866948 NOVEMBER 2006
Page 3

9114311A2
Preloads the drive shaft bearing when checking pinion height

and backlash.
24271
9114311A2
Installs and torques the Ujoint retainer nut.

10482
Bearing Cup and Adaptor Installation Tool
9591
Shift Shaft Bushing Tool
9118605A 2
Installs the forward gear bearing race on a standard gearcase.
Presses the reverse gear bearing adapter into the gear housing
on a counterrotating gearcase.
9131107T
Aids in the removal and installation of the shift shaft bushing on
Alpha One excluding Gen II.
9906
Oil Seal Driver
9131108T
Installs bearing carrier oil seals.
8883
Page 4
90-866948 NOVEMBER 2006

Bearing Removal and Installation Kit
2966
Bearing Driver
9131229A7
Installs and removes the bearings in all gearcases.
9131229A7 tool assembly includes the following components:
1124156 Hex Nut
1234961 Washer
9115755T Bearing Carrier
9129310 Plate
9129610 Pilot Plate
9130366T1 Mandrel
9131229 Puller Shaft
9132325T Driver Head
9132336 Driver Needle Bearing
9136379 Puller/Head Gear
9136571T Pilot Washer
9137292 Roller Bearing
9137311 Driver Head
9137312 Driver Head
9137323 Driver Head Rod
9137324 Pilot Washer
9137350T Pilot Mandrel
9138628T Puller/Driver Head
9152394 Head Pull Rod
9133489
Installs the small roller bearing into the gimbal housing.
10769
9133491
9443
Installs the needle bearing in the forward gear. Removes and

installs the seals and bearing in the gimbal housing.
9133492T
Removes and installs the lower swivel pin bearing in the gimbal
ring.
10789
Bearing Cup Driver
9133493T
Installs the upper driveshaft bearing cup into the driveshaft

housing.
10764
Bearing Cup Driver
9134379T
Installs the driveshaft bearing cup into the gear housing.

10765
90-866948 NOVEMBER 2006
Page 5

Slide Hammer
9134569A 1
6761
Bearing Cup Driver
Aids in the removal of various drive components. Use with puller

jaws (9134570).
9136577T
Installs the forward gear bearing cup into a the gear housing of
the with a bearing cup outside diameter of 89 mm (3.500 in.).
10766
Snap Ring Pliers
9137240A1
Removes the snap ring located at the gimbal housing bearing.

24278
9137241
Removes bearings from gears and the driveshaft.
8505
Grease Gun
9137299Q 2
Aids in the lubrication of key areas on the drive and transom.

Allows easy access to grease fittings.
8120
Power Steering Test Gauge Kit
9138053A05
Tests the power steering system pressure.
10804
Tab Washer Pliers
9138277A2
Bends the propeller tab washers off of the tab nut.

10827
Page 6
90-866948 NOVEMBER 2006

Ujoint Adaptor
9138756
Supports the yoke when disassembling the Ujoint.

20661
Bearing Cup Driver
9138918T
Installs the bearing cup in the top cover of the driveshaft
housing.
10767
Puller Head
9138919
Removes the swivel pin from the gimbal rings.

10806
Driveshaft Bearing Retainer Wrench
9143506T
Removes and installs the threaded driveshaft bearing retainer.
9520
Seal Driver
9143591T
Installs the upper driveshaft oil seal.

10812
9143693A 2
Cuts and drills the boat transom for sterndrive installation.
9182
90-866948 NOVEMBER 2006
Page 7

Seal Driver
9144110T
Installs the oil seals in the water pump base on older Alpha
product.
10814
Flushing Device
9144357Q 2
Attaches to the water intakes; provides a fresh water

connection when flushing the cooling system or operating the
engine.
9192
9145497A1
Aids in the removal and installation of the exhaust bellows.
10483
Puller Jaws Assembly

Puller Bolt
9146086A1
9185716
Removes the bearing carrier.
9514
Power Trim Test Gauge Kit
9152915A6
Tests circuit pressures for various trim pumps.

3753
Backlash Indicator Rod
9153459
Aids in checking gear backlash.

10452
Belleville Washer
1254048
Use with the Pinion Nut Adapter (9161067A3) and a propeller

nut to check the reverse gear backlash.
10772
Page 8
90-866948 NOVEMBER 2006

Pinion Gear Locating Tool
9156048001
Measures pinion gear height.
ob01627
Driveshaft Holding Tool
9156775T
Provides a wrench surface to turn the driveshaft. Also used to
hold driveshaft for pinion gear installation.
9448
Measures distance, movement, and runout; used for drive

system assembly and engine setup.
9479
70
80
90
60
50
40
10
30
9158222A1
20
Dial Indicator
Drive Gear Shimming Tool
9160523
Measures the Ujoint pinion gear clearance.

10819
Driven Gear Shimming Tool
9160526T
Aids in measuring the upper driven gear clearance.

10820
Pinion Nut Wrench
9161067003
ob01639
Holds the pinion nut when removing the pinion gear and
driveshaft.
9161069T
Installs and removes the bearing carrier retainer nuts.
ob01615
Propeller Shaft/Driveshaft Adapter
9161077T
Provides a wrench surface to turn the propeller shaft.

10805
90-866948 NOVEMBER 2006
Page 9

Torch Lamp
9163209
Heats surfaces to aid in the removal and installation of

interference fit engine components.
8776
Puller Head
9163616T
10678
Torque Wrench, lb. in.
Removes the upper swivel shaft on gimbal rings.
9166274
Dialtype torque wrench that sets torque from 9 to 150 lb. in.;
3/8 in. drive.
10829
Shift Shaft Lever
75104A7
Assists in shifting the gear housing when the gear housing is
separated from the driveshaft housing.
10818
Hinge Pin Tool
9178310
Removes and installs the hinge pins.

10672
9178473
9450
Bushing Installation Tool
91805057A2
10773
Installs the upper shift shaft bushings into the transom

assembly.
91805475A 1
Used to align the engine to the standard Bravo transom
assembly for sterndrive installation.
9183
Page 10
90-866948 NOVEMBER 2006

Power Steering Adapter Kit
91806908A02
Adapts power steering test gauge (9138053A05) to test power

steering control valves.
10803
Seal and Bushing Installation Tool
91806928A1
Installs the shift shaft bushings in the Alpha One Gen. II drives
with serial number 0F094775 and above.
10811
Needle Bearing Installation Tool
91807944T
Aids in the installation of the needle bearing in the reverse gear
of a counterrotating gearcase.
10792
Bearing Cup Driver
91808053T
Aids in the installation of a new smaller outside diameter top

cover bearing.
10768
Shift Shaft Slide Stabilizer
91809815A1
Holds the Alpha shift shaft slide in the proper position as the
sterndrive is installed onto the bell housing studs
4729
Forward Gear Assembly Tube
91815850
Removes and installs the forward gear and bearing adapter
assembly for counter rotation gearcases.
11577
Puller Jaws
91816242
Use with either the twoprong or threeprong puller on all drives.
10681
90-866948 NOVEMBER 2006
Page 11

Guide Plate
91816243
Centers the rod used to drive in the forward gear bearing on a
standard rotation gearcase, and the reverse gear bearing on a
counter rotation gearcase.
4481
Reverse Gear Needle Bearing Driver
91816244
Installs the needle bearings into the reverse gear of a
counterrotating gearcase.
10810
Needle Bearing Removal Tool
91816245
Removes the needle bearings from the back adapter of a
counterrotating gearcase.
10793
Carrier Seal Driver
91817569T
Removes and installs the bearing carrier seals. Installs seals in
the driveshaft seal carrier.
9481
Upper Driveshaft Housing Seal Driver
91817570T
Install the seals in the upper driveshaft housing.

10833
91818162
Installs the aluminum sleeve into the Ujoint bellows.

10823
Sleeve Removal Tool
91818169T
Removes the aluminum sleeve from the Ujoint bellows.

10824
Water Pump Alignment Pins
91821571A 1
Aligns the water pump during installation.
9482
Page 12
90-866948 NOVEMBER 2006

Trim Cylinder End Cap Tool
91821709T
Allows easy removal of the trim cylinder end caps. Required if
tilt limit spacers are to be installed or if the trim in limit spacer
is to be removed (to allow additional trim in range).
10691
Dial Indicator Adapter
9183155
Dial indicator holding fixture.
2999
Driven Gear Shimming Tool
91854377
10821
Seal Driver
Use to shim the driven gear on the Alpha One Gen. II starting
with Serial Number 0L100009 and above. Can be Identified by
the letters 'A, B, C.'
91864497
Installs double lip seal in driveshaft housing.

25951
MCM Tool Overlay Kit
918775281
MCM Tool Overlay Kit (sheet numbers 1020) contains 11
overlay sheets and hooks indicating locations for all the
Mercury MerCruiser gasoline engine and sterndrive active
service tools
24523
9189897
Secures the dial indicator to the gear housing when checking
backlash.
ob01631
Pipe Tap
9195639
Taps the bell housing for shift cable installation.
10802
90-866948 NOVEMBER 2006
Page 13
Notes:
Page 14
90-866948 NOVEMBER 2006

Table of Contents
Bravo Sterndrive Tools....................................... 16
90-866948 NOVEMBER 2006
Bravo Sterndrive Tool Application Chart.......16
Page 15
Bravo Sterndrive Tools

Bravo Sterndrive Tool Application Chart
Page 16
Part No.
Description
Bravo One
Bravo Two
Bravo Three
Blackhawk
9112427
Shift Cable
Adjustment
Tool
9117256
Bearing
Retainer
Wrench
9117257
Bearing Carrier
Retainer Tool
9117262A1
Shift Cable
Anchor
Adjustment
Tool
9117273
Bushing
Removal Tool
9117275A1
Bearing and
Seal
Installation
Tool
9117301T1
Clutch
Assembly
Stand
9117302
Shift Handle
Tool
9131106T
Bearing Cup
Driver
9131229A7
Bearing
Removal and
Installation
Tool Assembly
9134569A1
Slide Hammer
Puller
9137241
Universal
Puller Plate
9137299Q2
Lube Gun
9138053A4
Power Steering
Gauge Kit
9138756
Ujoint Adapter
9142840T
Drive Shaft
Pinion Gear
Shimming Tool
9143559T
Clamp Plate
9143578A1
Bushing /
Bearing / Seal
Driver
9143579
Tapered Insert
Tool
90-866948 NOVEMBER 2006

Part No.
Description
Transom
9143693A2 Cutout and Drill
Fixture
Bravo One
Bravo Two
Bravo Three
Blackhawk
9144357Q2
Flushing
Device
9145497A1
Bellows
Expander Tool
9152915A6
Trim Pump
Test Gauge Kit
9153459
Backlash
Indicator Rod
9155916
Oil Seal Driver
9155918
Bearing Driver
9158222A1
Dial Indicator
9161069T
Bearing Carrier
Retainer Nut
Wrench
9161077T
Propeller Shaft/
Driveshaft
Adapter
9163209
Torch Lamp
9163616T
Puller Head
9163626
Bearing Cup
Driver
9163638T
Bearing Driver
9166274
Torque
Wrench, lbin.
9176675T1
Reference
Electrode
9178310
Hinge Pin Tool
91805347
Bearing Driver,
Bearing
Adapter
91805352T
Bearing Driver,
Outer Propeller
Shaft Bearing
91805356
Bearing Carrier
Tool
91805358T
Seal Driver,
Outer Propeller
Shaft
91805372
Seal Driver,
Bearing Carrier
Seal
91805374
Bearing Carrier
Tool
918053741
Bearing Carrier
Tool
91805382T
Bearing
Retainer Tool
90-866948 NOVEMBER 2006
Page 17
Page 18
Part No.
Description
Bravo One
Bravo Two
91805451
Driveshaft Bolt
Tightening Tool
91805453
Driveshaft
Race Tool
91805454
Driver Handle
91805455
Driveshaft
Retaining Nut
Tool
91805456T
Bearing
Adapter Tool
91805457T1
Propeller Nut
Tool
91805458
Vertical Guide
Tool
91805462T
Shimming Tool
91805466
Pinion
Inspection Tool
91805470
Front Bearing
Guide
91805471T
Needle Bearing
Installation
Tool
91805472
Needle Bearing
Removal Tool
91805473
Guide Insert
91805474
Vertical Shaft
Service Tool
91805475A1
Alignment Tool
Assembly
91805481
Backlash
Indicator Rod
91805482
Backlash
Indicator Rod
91805485
Vertical Driver
91805573T
Holding Fixture
91806192
Spline
Backlash Tool
91806908A1
Power Steering
Adapter
91813653T
Seal Driver
91816242
Bravo Three
Blackhawk
X
X
Puller Jaw
91818162
Sleeve
Installation
Tool
91818836A1
Drill Bushing
Tool Kit
91821709T
Spanner
Wrench
9183155
Dial Indicator
Adapter Kit
X
X
X
90-866948 NOVEMBER 2006

Part No.
Description
Bravo One
Bravo Two
Bravo Three
Blackhawk
91840965A1
Integrated
Transom
Alignment
Assembly
9184996T1
Flushing Kit
91862064A1
Seal Removal
Tool
91862546
Retention
Sleeve
Removal Tool
91863738
Driveshaft
Retaining Tool
91864220
Driver Head
91881150Q1
Dual Water
PickUp Gear
Case Flush
Seal Kit
91883983
MCM Tool
Board Overlay
Update Kit
9189865
X
X
Bearing Seal
and Cup Driver
9189867T
Bearing Driver
9190244A1
Puller/Drive
Assembly
9190338A1
Puller Bar
9196512
Gear Case
Pinion
Shimming Tool
Power Steering Pump Pulley Remover
Kent Moore J25034C

Removes the pulley on the power steering pump on Saginaw
pumps only.
18598
Power Steering Pump Pulley Remover
Kent Moore J212391

Removes the pulley on the DHB power steering pumps and
water pumps with smaller shafts.
25952
Expanding Rod
SnapOn CG404
12538
90-866948 NOVEMBER 2006
Aids in the removal of gears and bearings; use with SnapOn

CG40A6.
Page 19

Collet
SnapOn CG40A6
Aids in the removal of gears or bearings; use with SnapOn
CG404.
12534
Collet
SnapOn CG40A10
Aids in the removal of bearings; use with expanding rod.
21601
Expanding Rod
SnapOn CG454
Aids in the removal of the upper swivel shaft lower bearing in
the gimbal housing. Use with SnapOn Collet (CG4515).
17771
Collet
SnapOn CG4515
10774
Hex Nut
Aids in the removal of the upper swivel shaft lower bearing in

the gimbal housing. Use with SnapOn Expanding Rod
(CG454).
1124156
A 5/8 in. x 18 in. hex nut that aids in the removal and installation
of various engine components. May use with Puller Shaft
(9131229); also included in the Bearing Removal and
Installation Kit (9131229A 7).
18650
Washer
1234961
Use on the threaded puller rod between the nut and plate when
removing bearings.
10834
Shift Cable Adjustment Tool
9112427
9186
Bearing Retainer Wrench
Attaches over the shift cable, and aids in proper shift cable
adjustment at the shift plate.
9117256
Removes and installs the ujoint bearing retainer nut.

10482
Page 20
90-866948 NOVEMBER 2006

Bearing Carrier Retainer Tool
9117257
Loosens and tightens the bearing carrier retainer nut on Bravo

Two.
10465
Shift Cable Anchor Adjustment Tool
9117262A1
91-17262
Use to set the shift cable adjustments after shift cable

installation. Includes the following components:
9117262A1 Core Wire Locating Tool
9117263 Shift Cable Anchor Adjustment Tool
91-17263
10687
Bushing Removal Tool
9117273
Aids in the removal of the shift shaft bushing.
10485
Bearing and Seal Installation Tool
9117275A1
Installs the shift shaft bushings and oil seal.

10461
Clutch Assembly Stand
9117301T1
Holds the clutch assemblies for servicing.
10515
Shift Handle Tool
9117302
10688
Hex Nut
Positions and removes the shift shaft.

1124156
A 5/8 in. x 18 in. hex nut which aids in the removal and
installation of various engine components. May use with Puller
Shaft (9131229); also included in the Bearing Removal and
Installation Kit (9131229A 7).
18650
Puller Plate
9129310
18600
90-866948 NOVEMBER 2006
Aids in the removal and installation of the gimbal bearing, as

well as various bearings in the gear housing. Also included in
the Bearing Removal and Installation Kit (9131229A 7).
Page 21

9131106T
311
06
Bearing Cup Driver
Installs the driven gear bearing cup.

8882
Puller Shaft
9131229
18604
Bearing Removal and Installation Kit
A 5/8 in. x 18 in. (15.875 mm) long threaded rod which aids in
the removal and installation of various engine components.
Also included in the Bearing Removal and Installation Kit
(9131229A 7).
9131229A7
Installs and removes the bearings in all gearcases.
9131229A7 tool assembly includes the following components:
1124156 Hex Nut
1234961 Washer
9115755T Bearing Carrier
9129310 Plate
9129610 Pilot Plate
9130366T1 Mandrel
9131229 Puller Shaft
9136379 Puller/Head Gear
9136571T Pilot Washer
9137292 Roller Bearing
9137311 Driver Head
9137312 Driver Head
9137323 Driver Head Rod
9137324 Pilot Washer
9137350T Pilot Mandrel
9138628T Puller/Driver Head
9152394 Head Pull Rod
2966
Slide Hammer
9134569A 1
6761
Pilot Washer
Aids in the removal of various engine components. Use with

puller jaws (9134570).
9136571T
Used in pinion gear and pinion bearing installation.

ob01619
9137241
8505
Page 22
90-866948 NOVEMBER 2006

Grease Gun
9137299Q 2
Aids in the lubrication of key areas on the engine. Allows easy

access to grease fittings.
8120
Driver Rod
9137323
25431
Aids in the removal and installation of various bearings and

bearing races
9138053A05
10804
Ujoint Adapter
9138756

20661
Driveshaft Pinion Gear Shimming Tool
9142840T
Assists in determining the driveshaft pinion gear shims.
10586
Clamp Plate
9143559T
Installs onto the gear housing while separated from the

driveshaft housing and holds a preload while checking the the
gear backlash and bearing preload.
10486
Bushing/Bearing/Seal Driver
9143578A1
Installs the transom assembly bushings, bearings, and seals.

10484
90-866948 NOVEMBER 2006
Page 23

Tapered Insert Tool
9143579
Removes and installs the tapered insert retainer into the water
inlet hose.
9197
9143693A 2
9182
Flushing Device
9144357Q 2

engine.
9192
9145497A1
Aids in the removal and installation of the exhaust bellows.
10483
Puller Jaws Assembly

Puller Bolt
9146086A1
9185716
Removes bearing carrier and bearing races.
9514
9152915A6

3753
9153459

10452
Page 24
90-866948 NOVEMBER 2006

Oil Seal Driver
9155916
Installs the bearing carrier oil seals.
10848
Bearing Driver
9155918
Aids in the removal and installation of the bearing carrier needle

bearings.
10476

70
80
90
60
50
40
10
30
9158222A1
20
Dial Indicator
9479
9161069T
Installs and removes the bearing carrier retainer nuts on Bravo
One.
ob01615
Propeller Shaft/Driveshaft Adapter
9161077T
Provides a wrench surface to turn the propeller shaft or the
driveshaft.
10805
Torch Lamp
9163209

8776
Puller Head
9163616T
10678
Bearing Cup Driver
Removes the upper swivel shaft on gimbal rings.
9163626
Installs the bearing cup into the bearing carrier.

10473
90-866948 NOVEMBER 2006
Page 25

Bearing Driver
9163638 1
Removes and installs the lower driveshaft pinion bearing.
10477
9166274
Dial type torque wrench that sets torque from 9 to 150 lb. in.;
3/8 in. drive.
10829
Bearing Cup Driver
9167443T
Installs the driveshaft bearing cup into the gear housing, and
the bearing cup into the bearing carrier.
10838
Reference Electrode
9176675T 1
Senses and electrical current in the water when testing the

MerCathode system. Use to check hull potential.
9188
Hinge Pin Tool
9178310

10672
Outer Propeller Shaft Bearing Driver
91805352T
Installs the roller bearing into the outer propeller shaft.

10479
Bearing Carrier Tool
91805356
Aids in the installation of the bearing carrier needle bearing.
10469
Page 26
90-866948 NOVEMBER 2006

Outer Propeller Shaft Seal Driver
91805358T
Installs the seals in the outer propeller shaft.

10684
Bearing Carrier Seal Driver
91805372
Aids in the installation of seals into the bearing carrier.
10683
91805374
Aids in the removal and installation of the outer propeller shaft
bearing carrier on the Bravo Three. Also used with Bearing
Retainer Tool (91805382T) to remove propeller shaft retainer
nut.
10470
918053741
Removes and installs the driveshaft bearing carrier on the

Bravo Three.
10471
Driveshaft Retaining Tool
91805381
Used to hold the bearings and the lower driveshaft while

checking backlash.
10843
Bearing Retainer Tool
91805382T
Removes and installs the outer propeller shaft bearing retainer.
10481
90-866948 NOVEMBER 2006
Page 27

Driveshaft Race Tool
91805453
Aids in the installation of the lower driveshaft bearing race.

10587
Driver Handle
91805454
10590
Driveshaft Retaining Nut Tool
Use with Front Bearing Guide (91805470) for installation of the

front bearing.
91805455
Removes and installs the lower driveshaft retaining nut.
10588
Bearing Adapter Tool
91805456T
Removes and installs the bearing adapter.
10459
Propeller Nut Tool
91805457T 1
Aids in the removal and installation of the front propeller nut.

10677
Shimming Tool
91805462T
Aids in measuring the pinion height.

10689
Pinion Inspection Tool
91805466
10675
Front Bearing Guide
Draws the driveshaft into the bearing taper to facilitate the

pinion height measurement.
91805470
Guides the installation of the front bearing into the drives.

10701
Page 28
90-866948 NOVEMBER 2006

Needle Bearing Installation Tool
91805471T
Installs the pinion gear needle bearings into the lower driveshaft
bores.
10673
Needle Bearing Removal Tool
91805472
Aids in the removal of the pinion gear needle bearings.

10674
Guide Insert Tool
91805473
Inserts into the Bearing Cup Driver (9131106T) when installing
the front driven gear bearing cup.
20864
91805475A 1
9183
91805481
Indicates the inner propeller shaft backlash.

10453
91805482
Indicates the outer propeller shaft backlash.

10455
Vertical Driver
91805485
10854
Spline Backlash Tool
Use with various drivers to remove the drive bearings.

91806192
Measures the propellershafttogearspline backlash on

Vblocks.
10692
90-866948 NOVEMBER 2006
Page 29

91806908A02

10803
Seal Driver
91813653T
Installs the Ujoint oil seal into the bearing carrier. Also used to
pilot the puller rod for the installation of the gear housing needle
bearing.
10852
Puller Jaws
91816242
Use with either the twoprong or threeprong puller on all drives.
10681
Guide Plate
91816243
Centers the rod used to drive in the forward gear bearing on a
standard rotation gearcase, and the reverse gear bearing on a
counter rotation gearcase.
4481
91818162
Installs the aluminum sleeve into the Ujoint bellows.

10823
Trim Cylinder End Cap Tool
91821709T
Allows easy removal of the trim cylinder end caps. Required if
tilt limit spacers are to be installed or if the trim in limit spacer
is to be removed (to allow additional trim in range).
10691
Dial Indicator Adapter
9183155
Dial indicator holding fixture.
2999
Page 30
90-866948 NOVEMBER 2006

Bearing Carrier Oil Seal Installer
91840385
Installs the needle bearing and oil seals into the bearing carrier.
10698
Bearing Carrier Installation Tool
91840388
Protects the seals when installing the bearing carrier onto the
propeller shaft.
9518
91840393
Installs the bearing carrier retainer nut on heavyduty propeller

shafts.
9449
Propeller Shaft Tool Kit
91840393A1
Aids in the installation of the bearing carrier retainer with a

heavyduty propeller shaft installed on the lower unit.
10702
ITS Alignment Tool
91840965A1
Used to align the engine to the integrated or standard Bravo

transom assembly for sterndrive installation.
15539
Flushing Kit
91849996T 1
Use for flushing gearcases with low water inlets.

9195
Seal Removal Tool
91862064A 1
Aids in the removal of the bearing carrier oil seals.

10685
90-866948 NOVEMBER 2006
Page 31

Spanner Wrench for L18 Ujoint Bearing
Retainer
91862219A1
Removes and installs the driveshaft bearing retainer.

10705
Bearing Installation Tool
91862530
Aids in the installation of the needle bearing and outer radial

bearing.
10855
Steel Bearing Adapter Socket
91862531
Removes and installs the steel bearing adapter.
10706
Retention Sleeve Removal Tool
91862546
Removes the aluminum sleeve from the Ujoint bellows of all

the Bravo sterndrives, serial number 0L999999 and below.
10851
Driveshaft Retaining Tool
91863738
Holds the bearings and the lower driveshaft while checking

backlash.
10843
Needle Bearing and Outer Race Installation

Tool
91864220
Aids in the installation the needle bearing and the outer radial
bearing on new style gears in the older Bravo drives (1999 and
earlier).
10458
Page 32
90-866948 NOVEMBER 2006

Dual Water Pickup Flush Gearcase Seal Kit
91881150K 1
Blocks off the front water inlet holes on the dual water inlet
gearcases.
9194
Seal Driver Tool
91865050
Aids in the removal and installation of the Ujoint oil seal of the
bearing retainer nut.
10775
Gear Lash Flag 27/32
91865080
27/32
Aids in checking the gear lash for 27/32 tooth gears in the
driveshaft housing.
10799
91865081
driveshaft housing.
27/29
10800
91865082
23/30
driveshaft housing.
10872
Stub Shaft for Bravo X Series
91865083
10795
Stub Shaft for Standard Bravo
Replaces the Ujoint assembly during the shimming process of

the driveshaft housing.
91865084
10782
Clamp Block and Handle Tool
Replaces the Ujoint assembly during the shimming process of

91865085
Used to move the stub shaft when reading the gear lash on the
driveshaft housing.
10779
Adapter Rod Tool
91 865086
Holds the measuring tools for shimming the driveshaft housing.
10464
90-866948 NOVEMBER 2006
Page 33

Dial Indicator Holding Block
91865097
Secures the dial indicator tool in proper location when shimming
10781
Pinion Gear Shimming Tool
91865114
Measures the pinion (drive) gear depth of the driveshaft
housing.
10778
Driven Gear Clamping Tool
91865115
Prevents driven gear movement when measuring the gear lash
of the driveshaft housing.
10472
91865116
16/19
driveshaft housing.
10844
SnapRing Driver
91866107
Aids in the removal of the cross bearing snap rings. Part of the
Cross Bearing Removal and Installation Kit (91866107A01).
21565
Cross Bearing Mandrels
91866108
Aids in the removal and installation of the bearing caps on the
cross bearings.
21572
Cross Bearing Press
91866109
Aids in the removal and installation of the bearing caps on the
cross bearings.
21566
DMT 2004 Digital Multimeter
Measures RPM on spark ignition (SI) engines, ohms, amperes,

AC and DC voltages; records maximums and minimums
simultaneously, and accurately reads in high RFI environments.
H z TEMP
mA
A
V Hz
mV
IG
OFF
IP
TEMP
mA
COM
91892647A01
Hz
4516
Page 34
90-866948 NOVEMBER 2006

Bearing Seal and Cup Driver
9189865
Aids in the installation of the bearing carrier seals and bearing

cup.
10467
Bearing Driver
9189867T
Aids in the installation of the driveshaft needle bearings.

10478
Puller/Drive Assembly
9190244A1
Removes and installs the driveshaft housing bearings and
sleeves. Assembly includes the following and can be purchased
separately:
9190777T1 Puller Jaws
9190774 Puller Guide
9190775 Puller Bolt
9190244T Driver Guide
10849
Puller Bar
9190338A1
Aids in the removal of the bearing carrier.
10457
Pulley Pusher Installer
9193656A1
Installs the pulley onto the power steering pump.
10047
Gearcase Pinion Shimming Tool
9196512
Aids in measuring the gearcase pinion height.

10670
Plug
92238609
Aids in bleeding the in/down circuit on the remote trim pump.
8862
90-866948 NOVEMBER 2006
Page 35
Notes:
Page 36
90-866948 NOVEMBER 2006

Table of Contents
TR/TRS Sterndrive Tools.................................... 38
TR / TRS Sterndrive Tool Application Chart

......................................................................38
90-866948 NOVEMBER 2006
Page 37
TR/TRS Sterndrive Tools

TR / TRS Sterndrive Tool Application Chart
Part No.
Description
TR
TRS
9134569A1
Slide Hammer Puller
9137241
9138053A4
Power Steering Gauge

Kit
9138277A2
Tab Washer Pliers
9138756
Ujoint Adapter
9143693A2
Transom Cutout and Drill

Fixture
9144357Q2
Flushing Device
9152915A6
Trim Pump Test Gauge

Kit
9153459
9155916
Oil Seal Driver
9155918
Bearing Driver
9155919
Bearing Driver
9158222A1
Dial Indicator
9163209
Torch Lamp
9163619T
Seal / Bearing Driver
9163620A1
Bearing Nut Wrench and

Drive Shaft Socket
9163625T
Bearing Holder
9163626
Bearing Cup Driver
9163638T
Bearing Driver
9166274
Torque Wrench, lbin.
9167441
Gear Housing Pinion

Gear Shimming Tool
9167443T
Bearing Cup Driver
9168891T
Bearing Driver
9178310
Hinge Pin Tool
91805475A1
91806192
Spline Backlash Tool
91806908A1
Power Steering Adapter
9189897
Dial Indicator Holding

Tool
9198171T
Driveshaft Housing Gear

Shimming Tool
Slide Hammer
X
X
X
X
9134569A 1
6761
Page 38
Aids in the removal of various engine components. Use with

puller jaws.
90-866948 NOVEMBER 2006

9137241
8505
9138053A05
10804
Tab Washer Pliers
9138277A2
Bends the propeller tab washers off of the tab nut.

10827
Ujoint Adapter
9138756

20661
9143693A 2
9182
Flushing Device
9144357Q 2

engine.
9192
90-866948 NOVEMBER 2006
Page 39

9152915A6

3753
9153459

10452
Oil Seal Driver
9155916
Installs the bearing carrier oil seals.
10848
Bearing Driver
9155918
Aids in the removal and installation of the bearing carrier needle

bearings.
10476
Driver Head
9155919
Removes bearings and seals; installs needle bearings into the

bearing carrier.
10476

70
80
90
60
50
40
10
30
9158222A1
20
Dial Indicator
9479
Torch Lamp
9163209

8776
Page 40
90-866948 NOVEMBER 2006

Seal / Bearing Driver
9163619T
Installs the driveshaft bearing cup and Ujoint oil seal in the
drive shaft housing of the TR and TRS sterndrives. Also installs
the TR drive unit propeller shaft bearing cup.
10865
Bearing Nut Wrench and Driveshaft Socket
9163620A1
Remove and installs the upper driveshaft bearing nut.

10861
Bearing Holder
9163625T
Supports the drive gear bearing when removing and installing

the Ujoint nut.
10860
Bearing Cup Driver
9163626
Installs the bearing cup into the bearing carrier.

10473
Bearing Driver
9163638 1
Removes and installs the lower driveshaft pinion bearing.
10477
9166274
3/8 in. drive.
10829
Gear Housing Pinion Gear Shimming Tool
67441
Determines the pinion gear clearance in the TRS gear

housings.
10864
90-866948 NOVEMBER 2006
Page 41

Bearing Cup Driver
9167443T
Installs the driveshaft bearing cup into the gear housing, and
the bearing cup into the bearing carrier.
10838
Bearing Driver
9168891T
Removes lower driveshaft bearing from the gear housing of the

TRS sterndrives.
10859
Hinge Pin Tool
9178310

10672
91805475A 1
9183
91806908A02

10803
9189897
Secures the dial indicator to gear housing when checking
backlash.
ob01631
Driveshaft Housing Gear Shimming Tool
9198171T
Determines the driveshaft housing drive gear clearance on the

TR and TRS sterndrives.
10862
Page 42
90-866948 NOVEMBER 2006

Table of Contents
Gasoline Engine Tools........................................ 44
Gasoline Engine Tool Application Chart.......44
EFI/MPI Engine Tool Application Chart......... 45
ECM/PCM Engine Tool Application Chart..... 46

Gasoline Engine and EFI/MPI Tools.............46
CDS System Kits and Components..............53
90-866948 NOVEMBER 2006
Page 43
Gasoline Engine Tools

Gasoline Engine Tool Application Chart
Page 44
Part No.
Description
GM
Ford
4 Cyl (3.7L)
9114822
Oil Pump Alignment

Tool
9118078
Fuel Fitting
Connector
9124697
Piston Ring
Expander
9135547
Engine Coupler
Wrench
9138053A4
Power Steering
Gauge Kit
9142447
Microfiche Viewer
(120v)
9142460
Microfiche Viewer
(240v) International
9152024A1
Remote Starter
Switch
9152344
Flywheel Holder
9159339
Tachometer / Dwell
Meter
9163209
Torch Lamp
9163998A1
Spark Chamber
Assembly
9166273
Rocker Stopper
9166274
Torque Wrench,
lbin.
91805475A1
Alignment Tool
Assembly
91805918A1
Fuel ShutOff Tool
91806141A1
Probe Assembly
91806141A2
Probe Assembly
91806794A1
Installation Jig
91806901
Fuel Pressure Tee
91806908A1
Power Steering
Adapter
91809711
ES Torx Driver
91809929
Oil Pump Pickup

Installer
91809938
Oil Pump Pickup

Installer
91815234
Dyno Model 4000
91818812A1
Ignition Timing
(EST)
91828363A1
Tool Drill Fixture
91830230T
Spark Air Gap Tool
X
X
X
X
X
X
X
90-866948 NOVEMBER 2006

Part No.
Description
GM
Ford
4 Cyl (3.7L)
91854009A3
DMT 2000A
Tachometer /
Multimeter
91861540A1
DDT Adapter
Harness (Carb
Thunderbolt V)
9186197
Idle Mixture Socket
91863375A1
Alignment Hook
918775281
MCM Tool Overlay

Kit
91881833A2
Fuel Pressure
Gauge Kit
91883502
Air Line Cutter
91883983
MCM Tool Overlay

Update Kit
9193656A1
Pulley Pusher
Installer
9199379
Portable Timing
Light
9199750A1
DVA / Multimeter
Kit
EFI/MPI Engine Tool Application Chart

Part No.
Description
9118078
Fuel Fitting
Connector
91803135
Fuel
Pressure
Gauge
Adapter
5.0L
5.7L 350
6.2L
454 7.4L
502
91803999
Mercury
MerCruiser
DDT
Cartridge
v2.0 (MEFI)
91805747A
2
Timing Tool
(MEFI)
91805918A Fuel ShutOff

1
Tool
91806901
Fuel
Pressure Tee
91822560A
2
DDT Harness
Assembly
(MEFI)
91881833A
2
Fuel
Pressure
Gauge Kit
9199379
Portable
Timing Light
9199750A1
DVA /
Multimeter Kit
90-866948 NOVEMBER 2006
4.3L
Page 45
ECM/PCM Engine Tool Application Chart

Part No.
Description
4.3L MPI
5.0L MPI
350 MPI
Horizon
6.2L MX MPI
Horizon
496 / 8.1L MPI
91803135
Fuel
Pressure
Gauge
Adapter
91805918A1
Fuel
ShutOff
Tool
91822560T12
DDT
Adapter
Harness
(555)
91822560A13
DDT
Harness
Assembly
(555)
DMT 2000A
Tachometer
91854009A3
/ Multimeter
Kit
91880118A2
Mercury
MerCruiser
DDT
Cartridge
v1.2 (555)
91881833A2
Fuel
Pressure
Gauge Kit
9199379
Portable
Timing Light
9199750A1
DVA /
Multimeter
Kit
Gasoline Engine and EFI/MPI Tools

Oil Pump Alignment Tool
9114822
Use to align the oil pump during installation of the 4cylinder

Mercury Mercruiser (224) cid engines only.
10878
Fuel Fitting Connector
18078
10871
Page 46
Installed between the fuel line and the carburetor on 2barrel

MerCab and 4barrel Weber carburetors.
90-866948 NOVEMBER 2006

Piston Ring Expander
9124697
Expands piston rings for removal and installation.

6255
Engine Coupler Wrench
9135547
Installs and removes the engine coupler and torques the bolts
on the couplers that mount directly to the crankshaft; 1/2 in.
drive.
10869
9138053A05
10804
Microfiche Viewer (120v)
9142447
Views the microfiche parts lists.

11194
Microfiche Viewer (240v) International
9142460
Views the microfiche parts lists.

11194
Remote Starter Switch
9152024A1
Provides a remote starter button to crank the engine when

performing service procedures.
10882
Flywheel Holding Tool
9152344
Holds or turns the flywheel while making engine repairs, also

used to torque the flywheel or the engine coupler.
4738
90-866948 NOVEMBER 2006
Page 47

Service Tachometer/Dwell Meter
F
9159339
Aids in checking engine RPM (010,000); also checks the dwell

on breaker point ignition systems.
13472
Torch Lamp
9163209

8776
Spark Gap Tester
9163998A 1
Provides a visual indication of spark/coil efficiency.

13488
Rocker Stopper
9166273
Plugs the oil holes in the rocker arms to eliminate oil spray while
adjusting the valve lash.
10884
9166274
3/8 in. drive.
10829
Fuel Pressure Gauge Kit
91803135
Allows an older fuel pressure gauge to attach to either GM or

Mercury MerCruiser Schrader valve.
10943
91805475A 1
Used to align the engine to the Standard Bravo Transom
Assembly for sterndrive installation.
9183
Page 48
90-866948 NOVEMBER 2006

Timing Jumper Plug
91805747A2
Locks the electronic spark trigger ignition system in base timing
mode to set the initial ignition timing; also used as a jumper lead
for testing various circuits.
20654
Fuel ShutOff Tool
91805918A1
Used to perform fuel system pressure tests.

20657
Probe assembly
91806141A1
11198
Probe Assembly
Measures SAVregulated emissions on early models with a test

port mounted to the side of the exhaust elbow.
91806141A2
11199
Installation Jig
Measures SAVregulated emissions on models with a test port

mounted to the top of the exhaust elbow.
91806794A02
Locates the engine mounts when installing engine.

9187
Fuel Pressure Tee
91806901
The Fuel Pressure Tee has a Schrader valve that can be used
on MerCarb, Weber, or TBI models.
10873
91806908A02

10803
ES Torx Driver
91809711
11192
90-866948 NOVEMBER 2006
Removes the screws that hold the solenoid on Delco PG260

starter motors.
Page 49

Oil Pump Pickup Installer
91809929
Installs the 5/8 in. (16 mm) diameter oil pickup tube and screen
into the engine's oil pump.
11196
Oil Pump Pickup Installer
91809938
Installs the 3/4 in. (19 mm) diameter oil pickup tube and screen
into the engine's oil pump.
11197
Dyno Model 4000
91815234
Connects to the propeller shaft on sterndrive models and

operated the engine simulating a loaded condition while the
boat is on a trailer. Dyno maximum hp is 575 hp.
11191
Ignition Timing Cable
91818812A 1
13427
DDT Harness Assembly (MEFI)
Locks the electronic spark trigger ignition system in base timing

mode to set the initial ignition timing; also used as a jumper lead
for testing various circuits.
91822560A2
Harness connects to DDT Scan Tool Kit. Use with MEFI 1, MEFI
2, and MEFI 3 ECM models.
10945
Adapter Harness
84822560A13
Data link harness between engine and Computer Diagnostic
System (CDS).
5826
Tool Drill Fixture
91828363A1
Aids in the mounting of the following Panel Mount Controls:

Commander300, 3000 Classic, Commander 2000.
24885
Page 50
90-866948 NOVEMBER 2006

Spark Air Gap Tool
91830230T
Checks engine spark.
24886
DMT 2000A Tachometer / Multimeter Kit
91854009A3
Measures RPM on both 2cycle and 4cycle marine engines,

records the maximums and minimums simultaneously, and will
read accurately in high RFI enviroments.
10867
Idle Mixture Socket
9186197
10874
Alignment Hook
Turns the idle mixture screws on Rochester 4barrel

carburetors.
91863375A 1
Assists during engine alignment.
9190
TKS Carburetor Mixture Adjusting Tool
91866201
Adjusts idle mixture screw on TKS MerCarb.

25739
MCM Tool Board Overlay Kit
918775281
MCM Tool Overlay Kit (sheet numbers 1020) contains 11
overlay sheets and hooks indicating locations for all the
Mercury MerCruiser gasoline engine and sterndrive active
service tools
24523
90-866948 NOVEMBER 2006
Page 51

Fuel Pressure Gauge Kit
91881833A03
Tests the fuel pump pressure; can be used to relieve fuel

pressure.
rms32
Air Line Cutter
91883502
Prevents collapsing when cutting the air lines for the water drain
system on 496/8.1 and Mercury MerCruiser models equipped
with the airactuated water drain system.
24887
MCM Tool Board Overlay Update Kit
91883983
Updates the original MCM Tool Board Overlay Kit 91877528.

This sheet has 12 additional tools for the Bravo XR, XZ, and
Bravo Three sterndrives.
24888
Pulley Pusher Installer
9193656A1
Installs the pulley onto the power steering pump.
10047
Timing Light
9199379
Allows a technician to check ignition timing.

11561
DVA/Multimeter Kit
9199750A 1
Tests the electrical and ignition systems; consists of a VOA

meter with builtin direct voltage adapter.
3460
Page 52
90-866948 NOVEMBER 2006
CDS System Kits and Components

Computer Diagnostic System (CDS)
4520
Breakout Box
Order through SPX

Monitors all electrical systems for proper function, diagnostics,
and calibration purposes. For additional information, pricing, or
to order the Computer Diagnostic System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA 18003452233
Canada 8003452233
Europe 49 6182 959 149
Australia (03) 95446222
SPX P/N MM46225
Connects to the Propulsion Control Module (PCM) to test

engine circuits and components without probing wires. May be
used with a Computer Diagnostic System (CDS).
5974
SmartComms Interface Box
SPX P/N MM46944
Interface between the computer and engine ECM or PCM. Can

also be programmed to function as a standalone water test
data recorder.
25405
Terminal Test Probe Kit
SPX P/N MM46523
Test probes adapt test meter leads to harness connections

without damaging harness terminals. May be used with a
Computer Diagnostic System (CDS).
7915
Water Test Trigger Cable
SPX P/N MM46952
Used for manually triggering a recording during a water test

session when an engine problem occurs.
25459
90-866948 NOVEMBER 2006
Page 53

AC/DC Adapter for SmartComms Interface
Box
SPX P/N MM46953
Used to set up a SmartComms Interface Box for a water test

session or to power up the box to download water test data
when no 12 v DC source is available.
25458
PCMCIA Card and Cable Kit
SPX P/N MM47095

For serial connection to the DMT 2004 Digital Multimeter or the
Electronic Dual Input Pressure Gauge.
25460
Extension Cable
84825003A1
Data link extension harness (3.05 m [10 ft.]) between the

adapter harness and the Digital Diagnostic Terminal or
Computer Diagnostic System (CDS).
4012
DMT 2004 Digital Multimeter
91892647A01
Measures RPM on spark ignition (SI) engines, ohms, amperes,

AC and DC voltages; records maximums and minimums
simultaneously, and accurately reads in high RFI environments.
H z TEMP
mA
A
V Hz
mV
IG
OFF
IP
TEMP
mA
COM
Hz
4516
Digital Pressure Meter
91892651A01
Connects to the fuel system/manifold and can be used in

conjunction with Computer Diagnostic System (CDS).
5786
DTS Command Module Breakout Box
91898254
Connects inseries with connectors at the command module.

25457
Page 54
90-866948 NOVEMBER 2006
Table of Contents
LSA Table........................................................... 56
90-866948 NOVEMBER 2006
Page 55
LSA Table
Tube Ref No.
Page 56
Description
Where Used
Part No.
Obtain Locally
Needle Bearing Assembly

Lubricant
92-802868A1
Dielectric Grease
92-823506-1
Loctite 271 Threadlocker
92-809819
Loctite 567 PST Pipe Sealant
92-809822
10
Loctite 277
Obtain Locally
12
Loctite Master Gasket Kit
92-12564-2
14
2-cycle Premium Outboard Oil
92-802813A1
19
Perfect Seal
92-34227-1
25
Liquid Neoprene
92-25711-3
27
Bellows Adhesive
92-86166Q1
33
Loctite 680 Retaining

Compound
92-809833
34
Special Lubricant 101
92-802865A1
36
P80 Rubber Lubricant
Obtain Locally
42
U-joint and Gimbal Bearing

Grease
92-802870A1
44
HI-Pressure Grease
Obtain Locally
51
92-809818
62
Cyanacrylate Adhesive
Obtain Locally
66
92-809821
67
Loctite 290
Obtain Locally
68
Loctite 609
Obtain Locally
74
Loctite 405
Obtain Locally
79
MerCruiser 4-cycle 25W40

Engine Oil
92-802837A1
80
SAE Engine Oil 30W
Obtain Locally
82
Premium Gear Lubricant
92-802846A1
86
Loctite 262
Obtain Locally
87
High Performance Gear

Lubricant
92-802854A1
91
Engine Coupler Spline Grease
92-802869A1
94
Anti-Corrosion Grease
92-802867A1
90-866948 NOVEMBER 2006
Tube Ref No.
Description
Where Used
Part No.
95
2-4-C Marine Lubricant with

Teflon
92-802859A1
98
Optimol White T Grease
92-847206
99
Isopropyl Alcohol
Obtain Locally
110
4 Stroke 10W30 Outboard Oil
92-802833A1
113
Loctite Moly Paste

(Molybdenum Disulfide Grease)
Obtain Locally
114
Power Trim and Steering Fluid
92-858074K01
115
Premium Plus 2-cycle TC-W3

Outboard Oil
92-802824A1
116
RTV 587 Ultra Blue Silicone

Sealer
92-809825
117
Loctite 7649 Primer N
92-809824
119
Storage Seal Rust Inhibitor
92-802878-56
120
Corrosion Guard
92-802878-55
121
15W40 4-cycle Diesel Engine

Oil
92-877695K1
122
Extended Life Antifreeze/

Coolant
92-877770K1
123
Marine Engine Coolant
92-813054A2
124
Fuel System Treatment &

Stabilizer
802875A1
125
Heat Transfer Compound
92-805701
126
Liquid Gasket
92-808137
127
T442 Sealant
92-862258
128
Loctite 5900 Ultra Black RTV

Silicone Sealant
92-809826
129
Loctite Gasket Remover
92-809828-1
130
Sealer Kit, Two Part Epoxy
92-65150-1
131
Loctite 5920 Ultra Copper Hi

Temp RTV Silicone
Obtain Locally
132
Alpha 2000 HD with Moly
Obtain Locally
133
CT-C30A Lubricating Grease
Obtain Locally
134
Loctite 380
Obtain Locally
135
Three Bond 1217F
Obtain Locally
136
Lubriplate SPO 255
Obtain Locally
137
Three Bond Adhesive TB-1530
Obtain Locally
138
Synthetic Power Steering Fluid

SAE 0W-30
92-858002K01
90-866948 NOVEMBER 2006
Page 57
Tube Ref No.
139
Page 58
Description
Synthetic Blend 4-Stroke
Outboard Oil 25W-40
Where Used
Part No.
92-883722K01
90-866948 NOVEMBER 2006

Table of Contents
Tool Manufacturers............................................. 60
90-866948 NOVEMBER 2006
Page 59
Tool Manufacturers
ColePalmer Instrument Company
8003234340
8475497600
8472472929 FAX
8475491700 International FAX
Fluke Corporation
P.O. Box 9090
Everett, WA 98206-9090
800-443-5853
Kent-More Tools/SPX Corporation
(J-Tools)
29784 Little Mack
Roseville, MI 48066
800-345-2233
Fax 810-578-7375
OTC Tools/SPX Corporation
655 Eisenhower Drive
Owatonna, MN 55060
800-533-0492
Fax 800-283-5665
Rinda Technologies
4563 N. Elston Avenue
Chicago, IL
773-736-6633
Fax 773-736-2950
SPX Service Repair
2800 Park Drive
Owatonna, MN 55060
800-344-4013
Stephens Instruments
111 Greenwood Avenue
Waukegan, IL 60079-9375
847-336-9375
Fax 847-662-6808
Page 60
90-866948 NOVEMBER 2006

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Throughout this publication, "Warnings" and "Cautions," accompanied by the

international HAZARD symbol ! , are used to alert the technician to special

Safety Alerts and Notices

IMPORTANT: Indicates information or instructions that are necessary for a particular

NOTE: Indicates information that helps in the understanding of a particular step or

Approved Practices and Procedures

2006 Mercury Marine

CAUTIONindicates a potentially hazardous situation that, if not avoided, may

MerCruiser Special Tools Catalog

Manual Revisions and Current Information

Related Service Bulletin List

Copyright and Trademark Information

Alpha Sterndrive Tool Application Chart..........2

Section 2 - Bravo Sterndrive Tools

Bravo Sterndrive Tool Application Chart........16

Section 3 - TR/TRS Sterndrive Tools

TR / TRS Sterndrive Tool Application Chart...38

Section 4 - Gasoline Engine Tools

ECM/PCM Engine Tool Application Chart......46

Section 6 - Tool Manufacturers

90-866948 NOVEMBER 2006

90-866948 NOVEMBER 2006

Section 1 - Alpha Sterndrive Tools

Section 1 - Alpha Sterndrive Tools

90-866948 NOVEMBER 2006

Alpha Sterndrive Tool Application Chart.........2

Section 1 - Alpha Sterndrive Tools

Alpha Sterndrive Tools

Alpha One Gen II MC1, RMR Alpha One

Shift Cable Tool

Drive Shaft Bearing Preload Tool

Bearing Retainer Wrench

Bearing Adapter Installation Tool

Shift Shaft Bushing Tool

Oil Seal Driver

Bearing Removal and Installation Tool

Needle Bearing Driver

Needle Bearing Driver

Needle Bearing Driver

Bearing Cup Driver

Bearing Cup Driver

Slide Hammer Puller

Bearing Cup Driver

Snap Ring Pliers

Universal Puller Plate

Power Steering Gauge Kit

Tab Washer Pliers

Bearing Cup Driver

Swivel Pin Puller

Drive Shaft Bearing Retainer Wrench

Transom Cutout and Drill Fixture

Bellows Expander Tool

Puller Jaws Assembly / Puller Bolt

Trim Pump Test Gauge Kit

Pinion Gear Shimming Tool

Drive Shaft Adapter

Shimming Tool, Drive Gear

Shimming Tool, Driven Gear

Pinion Nut Wrench

Bearing Carrier Retainer Nut Wrench

90-866948 NOVEMBER 2006

Section 1 - Alpha Sterndrive Tools

Alpha One Gen II MC1, RMR Alpha One