Mercury Outboard Thunderbolt 500 50 HP Part 1 - Inspection and disassembly

Doing a complete tear down and rebuild of a Mercury Thunderbolt 500 50 HP engine.


Thunderbolt 500 engine

Rectifier 114-2986

Swithchbox. 333-3213A3

STARTER
Part # 50-38890A1 Electric Starter motor

SOLENOID
Part # 11-25661 Starter Solenoid

Carburator
Sierra 18-7068 Carburetor repair kit (Wuffle Marine $14.99)

Seals
26-29476 OIL SEAL, LOWER END CAP Quicksilver 18-2016
30-20080 (saying its replaced by 30-63742T) BALL BEARING, LOWER END CAP - Quicksilver # 18-1154

Special Tools
Part # C-91-34377A1 Tool for Lower Unit
Part # C-91-23033 Shift Shaft Bushing Tool
Part # C-91-74241 Cover nut tool
Kano kroll for breaking parts apart.

BELT
10-20140 TIMING BELT

LOWER UNIT
Part# 26-23300 OIL SEAL WATER PUMP BASE
Part# 26-26782 OIL SEAL WATER PUMP BASE
Part# 26-24590 OIL SEAL, SHIFT SHAFT BUSHING (LOWER)
Part# 26-31249 OIL SEAL, SHIFT SHAFT BUSHING (UPPER)
Part# 26-56788 OIL SEAL, BEARING CARRIER (DOUBLE LIP)
Part # 43-55607 GEAR, PINION - DRIVE SHAFT
Part # 31-38146A1 ROLLER BEARING ASSEMBLY, TAPERED - DRIVE SHAFT
Part # 31-38356A1 TAPERED ROLLER BEARING ASSEMBLY
Part # 52-47586 RATCHET, SLIDING CLUTCH (HAS BEEN REPLACE BY 52-92911T)
Part # 31-62091 BEARING, ROLLER - DRIVE SHAFT
Part # 43-55608 FORWARD GEAR ASSEMBLY
Part # 43-55609 REVERSE GEAR ASSEMBLY
Part # 25-25439 "O" RING, SHIFT SHAFT BUSING
Part # 23-55419A1 BUSHING ASSEMBLY, SHIFT SHAFT
Part # 26-24590 OIL SEAL, SHIFT SHAFT BUSHING (LOWER)
Part # 26-31249 OIL SEAL, SHIFT SHAFT BUSHING (UPPER)

AUTOMATICE CHOKE
Part # 54283A2 PLUNGER AND LINK ASSEMBLY, CHOKE SOLENOID
ELECTRIC

SHIMS & “O” Rings
Part # 15-20082A1 AR SHIM, UPPER END CAP TO CYLINDER BLOCK AND CRANKCASE (MERCURY DEALER)
Part # 15-20085A1 AR SHIM, LOWER END CAP TO CRANKCASE AND CYLINDER BLOCK (MERCURY DEALER) MARINE ENGINE IS $48.33
Part # 25-20081 (QTY 2) "O" RING, UPPER & LOWER END CAP

EXHAUST PLATE & HOUSING
Part # 46109 PLATE, BAFFLE - EXHAUST MANIFOLD
Part # 46112 COVER, EXHAUST MANIFOLD
Part # 27-37725 Power head to exhaust plate
Part # 27-38501 Gasket, Exhaust Extension Plate

CYLINDER HEAD GASKETS
Part # 27-37816 GASKET, CYLINDER BLOCK COVER
Part # 18-4353 gasket set replaces 27-72486A32


GASKETS
Part # 27-37725 (QTY 1) GGASKET, POWERHEAD TO EXHAUST EXTENSION PLATE
Part # 27-46110 REPLACED BY 27-85491-3 (QTY 1) GASKET, CYLINDER BLOCK TO BAFFLE PLATE
Part # 27-38501 (QTY 1 ) GASKET, EXHAUST EXTENSION PLATE TO DRIVE SHAFT HOUSING
Part # 27-46111 (QTY 1) REPLACED BY 27-854924
GASKET, BAFFLE PLATE TO EXHAUST COVER

REEDS
Part # 34-56704A1(QTY 4) REED SET, MATCHED - MAIN BEARING (Check with NASHVILLE MARINE)
Part # 34-20053 (QTY 1) REED STOP, REED VALVES (Check with NASHVILLE MARINE)
Part # 17-20033 (QTY 2) DOWEL PIN, CRANKCASE TO CYLINDER BLOCK

PISTON RINGS
Part # 39-27841A12 RING, PISTON SET (ebay $53.74)

IMPELLER
Part # 47-65959 IMPELLER, WATER PUMP
Part # 27-32771 GASKET, WATER PUMP BASE TO GEAR HOUSING
Part # 26-23300 OIL SEAL, WATER PUMP BASE
Part # 26-26782 OIL SEAL, WATER PUMP BASE
Part # 25-26855 "O" RING, WATER PUMP BASE
Part # 25-20273 RING, RUBBER - CENTRIFUGAL SLINGER
Sierra kit 18-3507

Part # 27-32769 GASKET, LOWER - WATER PUMP BASE TO WATER PUMP BODY


REMOTE CONTROL:
Part #17-20009 PIN, DETENT - CONTROL HOUSING NEUTRAL WARM-UP LEVER
Part # 24-35210 SPRING, DETENT PIN
Part # 24-35227 SPRING, DETENT PIN TENSION
Part # 19-20011 WELCH PLUG, DETENT PIN AND SPRING RETAINING