Powerhead removal

[Bill kubiak]

Got my lifting eye and tomorrow I plan to pull the powerhead. and see what is wrong or damaged in my upper mounts and to fix that missing stud.
Does anyone have any idea what the weight of a 40 hp 4 cyl powerhead is?

 

[Faztbullet]

About 100lbs

 

[Bill kubiak]

Thank you, I got it off and found many surprises, one good and several bad
The missing Powerhead stud was just a missing stud and not broken off, so I can replace that with a new stud and glue it in there with some good thread locker.
The left or port motor mount was missing it's locknut and all the washers,
The Starboard or right motor mount Cover was loose as a goose, all it's washers and lock nut are in place but lots of play
I think the rubber mounts may have decayed from fuel leaking over the years and is probably shrunk in size
The thru bolts that go from the steering arm and into the driveshaft housing and thru the mounts appear to have rusted and become fused to the steering arm and I have no idea how to break them loose
How do you remove the exhaust adapter plate from the driveshaft housing? I see no screws, the only bolts are the two on each side that hold the upper motor mount covers of the motor mounts that are inside of the driveshaft housing.
I need to raise the motor up to remove the lower unit to get the driveshaft out of the way but I have everything disconnected and cannot find my Giant Screwdriver to relieve the pressure to do it manually.
I am looking at the two battery cables and the two wires from the electric trim and wondering how to make it work . Any ideas on anything so far?

BTW this is a 1998 Merc 40 Hp, 4 cylinder, two stroke, and yes I have the manual but it does not show me how to do anything above

 

[Bill kubiak]

Got Er Done, I was bent over to pick up a flashlight when I stood up I bumped the adapter plate with my shoulder and it just popped loose, took it off checked the motor mounts they looked fine, I tightened up the bolts on the covers gootentite, found I had the exact fine thread SS nut and washer I needed for the missing mount part, bolted everything down and tomorrow I will go the the store to get the missing stud. Gonna clean everything now and then paint the rusted steering arm part with Rustolium, put it all together over the weekend and go fishing next week.

 

[Bill kubiak]

Job is done, and it is running fine.
The only stud I could find was either 1 1/2 inch or 2 inch long, what I actually needed was a 1 3/4 inch long stud. Leave to Mercury to make something that you cannot get a part for, I used the shorter stud with a few drops of Blue thread locker which I had and 15 minutes after I installed that stud it was impossible to remove,, I solved the length problem by not screwing that stuff down till it bottomed out. I counted the turns it took, 10 turn to bottom, so I screwed it in 7 turns until it matched the opposite stud.
The most difficult part about the re-assembly was getting the engine controls and wiring thru the rubber mounts and laid out so it made sense.
Thank you for all the guys and gals that helped with their suggestions in about 5 post's I made about this motor.