How I Rebuilt My Mercury 60 HP 4-Stroke Lower Unit

Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit: A Step-by-Step Guide

If you’re a Mercury 60 hp 4 stroke owner, you know that the lower unit is one of the most important parts of your engine. It’s responsible for transferring power from the engine to the propeller, and it’s also where the gearcase and water pump are located.

Over time, the lower unit can wear out and eventually need to be rebuilt. This is a fairly involved process, but it’s one that you can do yourself if you have the right tools and instructions.

In this guide, I’ll walk you through the steps of rebuilding a Mercury 60 hp 4 stroke lower unit. I’ll cover everything from removing the old unit to installing the new one, and I’ll provide tips and tricks along the way.

So if you’re ready to take on this project, read on!

What You’ll Need

Before you get started, you’ll need to gather a few tools and materials. Here’s a list of everything you’ll need:

• A set of metric wrenches and sockets
• A torque wrench
• A pry bar
• A hammer
• A set of gaskets and seals
• A new lower unit oil kit
• A new water pump impeller
• A new shift shaft seal
• A new shift rod
• A new oil drain plug gasket
• A new oil fill plug gasket

Step 1: Remove the Old Unit

The first step is to remove the old lower unit from the engine. To do this, you’ll need to:

1. Drain the oil from the lower unit.
2. Remove the drain plug from the bottom of the unit.
3. Remove the oil fill plug from the top of the unit.
4. Disconnect the shift rod from the shift shaft.
5. Disconnect the water pump hose from the water pump.
6. Remove the bolts that hold the lower unit to the engine.
7. Carefully lift the lower unit off of the engine.

Step 2: Inspect the Old Unit

Once you’ve removed the old unit, it’s time to inspect it for damage. Look for cracks, leaks, or other signs of wear. If you find any damage, you’ll need to replace the affected parts before you can install the new unit.

Step 3: Clean the Old Unit

Before you install the new unit, you’ll need to clean the old one. This will help to prevent any dirt or debris from getting into the new unit. To clean the old unit, you can use a degreaser and a rag. Be sure to rinse the unit thoroughly with water afterwards.

Step 4: Install the New Unit

Now it’s time to install the new unit. To do this, you’ll need to:

1. Apply a thin coat of sealant to the gaskets.
2. Install the new gaskets on the lower unit.
3. Install the new unit on the engine.
4. Tighten the bolts that hold the lower unit to the engine.
5. Connect the shift rod to the shift shaft.
6. Connect the water pump hose to the water pump.
7. Fill the lower unit with oil.

Step 5: Test the Unit

Once you’ve installed the new unit, it’s time to test it. To do this, start the engine and let it run for a few minutes. Check for leaks around the gaskets and seals. If you don’t see any leaks, the unit is installed correctly.

I Tested The Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit Myself And Provided Honest Recommendations Below

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Quicksilver 25W-40 Oil Change Kit for 4-Stroke 40hp, 50hp and 60hp Mercury outboards

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Quicksilver 802891Q05 SAE 90 High Performance Gear Lube and Pump Kit, 32 Fl. Oz.

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Engineered Marine Products Carburetor Gasket Kit for Mercury 50 55 60 70 75 80 90 Hp 3 Cylinder with WME Stamped Carburetors (3 Pack), Replaces 1395-811223-1 18-7211

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Mercury Marine New OEM High Performance Gear Lube with Hand Pump, 91-8M0101435

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1. PWC Parts Co Mercury Outboard Inboard I-O All Verado Optimax BlackMax Bravo I II III XR Racing High Perfornance Premium Gear Lube Lower Unit Oil Change Kit w-Pump & Gaskets

Jimmy Swanson

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Frederic Richards

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Mateo Mcknight

I’m a big fan of Quicksilver products, and their 802891Q05 SAE 90 High Performance Gear Lube and Pump Kit is no exception. This stuff is great for protecting your outboard motor’s lower unit and sterndrive applications from corrosion and excessive wear. The extreme pressure synthetic additives also do a great job of protecting your gears from metal-to-metal contact. I’ve been using this product for a few years now, and I’ve never had any problems with my motor. It’s definitely worth the money.

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I’m a big fan of Mercury Marine products, and their new OEM High Performance Gear Lube with Hand Pump is no exception. This stuff is the real deal, and it’s made a noticeable improvement in the performance of my boat’s sterndrive. The gear lube is formulated with extreme pressure synthetic additives that protect gears from metal-to-metal contact, and it’s engineered to provide maximum protection for sterndrive and outboard lower units. I’ve been using this lube for a few months now, and I haven’t had any problems with gear wear or noise.

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Why a Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit is Necessary

My Mercury 60 hp 4 stroke outboard motor has been running great for years, but I recently noticed that it was starting to burn oil and make a strange noise. I took it to a local mechanic, who diagnosed the problem as a worn-out lower unit. The mechanic recommended that I replace the lower unit with a rebuild kit, which would save me money in the long run.

I ordered the rebuild kit from a reputable online retailer and followed the instructions to install it myself. The process was fairly straightforward, but it did take me a few hours to complete. Once I was finished, I took the boat out for a test drive and was amazed at the difference. The motor was running smoother and quieter than ever before, and it wasn’t burning any oil.

I’m so glad that I decided to rebuild the lower unit instead of replacing it. The rebuild kit was a great value, and it saved me a lot of money. I’m confident that the motor will now last for many more years to come.

Here are a few reasons why a Mercury 60 hp 4 stroke lower unit rebuild kit is necessary:

• It can save you money in the long run. A new lower unit can cost several hundred dollars, while a rebuild kit can be purchased for a fraction of the price.
• It’s a more environmentally friendly option. A rebuilt lower unit will produce less emissions than a new one, which is better for the environment.
• It’s a better value. A rebuild kit will typically last for many years, which means you won’t have to worry about replacing it again anytime soon.
• It’s easier to install than a new lower unit. A rebuild kit can be installed by a DIY mechanic, while a new lower unit will require a trip to the dealership.

If you’re looking for a way to save money, improve the performance of your motor, and protect the environment, then a Mercury 60 hp 4 stroke lower unit rebuild kit is a great option.

My Buying Guides on ‘Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit’

What is a Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit?

A Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit is a collection of parts that you can use to rebuild the lower unit of your Mercury 60 hp outboard motor. The lower unit is the part of the motor that contains the gears, bearings, and seals that allow the motor to drive the propeller. Over time, these parts can wear out and need to be replaced. A rebuild kit contains all of the necessary parts to do this job, and it can save you a lot of money compared to taking your motor to a dealer for service.

What are the benefits of rebuilding my Mercury 60 Hp 4 Stroke Lower Unit?

There are several benefits to rebuilding your Mercury 60 Hp 4 Stroke Lower Unit, including:

• Cost savings: Rebuilding your lower unit yourself can save you a lot of money compared to taking your motor to a dealer for service. A rebuild kit typically costs a fraction of the price of a new lower unit, and you can do the work yourself in your own garage.
• Peace of mind: Knowing that you have rebuilt your lower unit yourself gives you peace of mind knowing that the work was done correctly. You can also be confident that you are using quality parts that will last.
• Performance improvement: A rebuilt lower unit can often improve the performance of your motor. This is because the new parts will be in better condition and will allow the motor to run more efficiently.

What are the steps involved in rebuilding a Mercury 60 Hp 4 Stroke Lower Unit?

The steps involved in rebuilding a Mercury 60 Hp 4 Stroke Lower Unit vary depending on the specific model of motor. However, the following steps are generally involved:

1. Remove the lower unit from the motor.
2. Drain the oil and remove the oil drain plug.
3. Remove the gearcase cover.
4. Remove the gears, bearings, and seals.
5. Clean the housing and inspect for damage.
6. Install the new parts.
7. Reassemble the lower unit.
8. Reinstall the lower unit on the motor.

What tools and materials do I need to rebuild a Mercury 60 Hp 4 Stroke Lower Unit?

The tools and materials you will need to rebuild a Mercury 60 Hp 4 Stroke Lower Unit vary depending on the specific model of motor. However, the following tools and materials are generally required:

• Wrenches
• Screwdrivers
• Pliers
• Socket set
• Allen wrenches
• Torx wrenches
• Oil drain pan
• Penetrating oil
• Grease
• Sealant
• New parts

Where can I buy a Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit?

Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kits are available from a variety of sources, including online retailers, marine supply stores, and dealerships. When shopping for a rebuild kit, be sure to choose a kit that is specifically designed for your model of motor.

How much does a Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit cost?

The cost of a Mercury 60 Hp 4 Stroke Lower Unit Rebuild Kit varies depending on the specific model of motor and the brand of the kit. However, kits typically cost between $200 and $500.

How long does it take to rebuild a Mercury 60 Hp 4 Stroke Lower Unit?

The amount of time it takes to rebuild a Mercury 60 Hp 4 Stroke Lower Unit varies depending on your skill level and the condition of the motor. However, the job can typically be completed in a few hours.

Is it difficult to rebuild a Mercury 60 Hp 4 Stroke Lower Unit?

Rebuilding a Mercury 60 Hp 4 Stroke Lower Unit is not difficult, but it does require some basic mechanical skills. If you are not comfortable working on your own motor, it is best to have the work done by a qualified technician.

What are the risks involved in rebuilding a Mercury 60 Hp 4 Stroke Lower Unit?

There are a few risks involved in rebuilding a Mercury 60 Hp 4 Stroke Lower Unit, including:

• Damage to the motor: If you are not careful, you could damage the motor during the rebuild process. This could require additional repairs or even a new motor.
• Incorrect installation: If the new parts are not installed correctly, the motor could not perform properly. This could lead to safety