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Suzuki DF20a Gearbox

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Post Options Post Options   Likes (0) Likes(0)   Quote Nathan Quote  Post ReplyReply Direct Link To This Post Topic: Suzuki DF20a Gearbox
    Posted: 24 Jan 2024 at 3:37pm
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I had a little mishap with the outboard. It fell on to the road. It actually survived pretty well. 

I need to replace the gear box housing. Ive got a new one. It has the rear bearing pressed in. I now need to strip the old one and install the gearbox, shaft etc into the new housing.

How difficult is this job. Doable for an amateur?
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Post Options Post Options   Likes (0) Likes(0)   Quote Mc Tool Quote  Post ReplyReply Direct Link To This Post Posted: 25 Jan 2024 at 9:50am
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you tube is your friend Smile any service info you can get will help . Should be straight forward job  , but you will need to know some specific technique  so plan to not get it done in one sitting as you may need to seek advice as the issues arrive.  
Before you start I would find out things like  , will you need to use a puller , big circlip pliers , are there likely to be corrosion issues  preventing disassembly ( you tube )
You may not find your exact model  ( its there ) on you tube but something close model-wise may have the same gear case , other than that ,dont force anything ( other than pressing a bearing )
 Yep  an amateur can do this Wink

Oh , and you aint the only one  to drag an outboard Embarrassed .......wasnt a good day
I wish I was young again .... Id be heaps smarter than this time
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Post Options Post Options   Likes (0) Likes(0)   Quote Nathan Quote  Post ReplyReply Direct Link To This Post Posted: 26 Jan 2024 at 10:36am
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Thanks, yeah some great vids online. Its looking doable.
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Post Options Post Options   Likes (0) Likes(0)   Quote Nathan Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 2024 at 11:41am
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An update on this. Proved to be mostly straightforward:
- Drained the oil.
- Prop and bearing housing came off in one piece easily.
- Water pump undone and then shaft lifted out.
- Pinion gear dropped off (no nut) and then rear bearing lifted out.
- Then reverse the process.

Only a couple of snags. A little spacer that sits behind the push rod fell out without me realising which meant first attempt reinstall failed as gears wouldnt engage. A slow look at the parts diagram and then a frantic search of the bench solved that problem. Also a slow look at the parts diagram at the placement of washers and shims.
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Post Options Post Options   Likes (0) Likes(0)   Quote FlawOne Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 2024 at 9:47pm
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Your lucky! My Mercury 50hp gear case has been a real pain. First the bearing carrier bent all the hooks I made up then then the pinion nut was so tight to crack it took two people. Don't know why they made it so hard to change the shaft seals on my model.
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Post Options Post Options   Likes (0) Likes(0)   Quote Mc Tool Quote  Post ReplyReply Direct Link To This Post Posted: 10 Feb 2024 at 10:19am
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Originally posted by FlawOne FlawOne wrote:

. Don't know why they made it so hard to change the shaft seals on my model.

probly so you would have to go to a dealer w/shop Wink
I wish I was young again .... Id be heaps smarter than this time
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