COX CXO300 User manual

WATER PUMP
REPLACEMENT GUIDE
(VESSEL)
–––
CXO300 – designed
for purpose
coxmarine.com

- Trim PTT Up
1 Trim PTT up
Action Description
Raise PTT angle, high enough for the transmission assembly to clear.

- Remove Propeller Assembly
1 Remove propeller assembly.
Action Description
Un-screw the propeller securing fastener.
Remove and Discard the single use nut.
Remove the propeller and hub assembly.
Store the hub assembly safely, for future assembly.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Standard Tools 1/2" Ratchet
Hand tools Sockets and Extensions 1/2" 27mm 12 point deep chrome socket

WT 3269 - Remove propeller sacrificial anode
1
Action Description
Inspect anode for degradation and wear.
Record the orientation of the anode if needed.
Un-screw the bolt, reacting the anode within the transmission housing.
Remove anode, fastener and washer.
Store anode, fastener and washer safely for future assembly.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Standard Tools 5/8" Ring spanner

WT 3266 - Remove transmission (Including transfer pipes)
1
Action Description
Un-screw 3 retaining bolts/nuts and washers.
Tip if removing a 30" or 35" Transmission, the studs can be reacted using the appropriate size open ended
spanner across the flats.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Sockets and Extensions 16mm spanner
2
Action Description
Un-screw 3 retaining bolts/nuts and washers.
Tip if removing a 30" or 35" Transmission, the studs can be reacted using the appropriate size open ended
spanner across the flats.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Sockets and Extensions 16mm spanner

3
Action Description
Un-screw 2 retaining bolts/nuts and washers using a thin wall socket for access.
WARNING ensure the transmission is supported before removing the final fastener.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Standard Tools 3/8" Ratchet
Hand tools Sockets and Extensions 3/8" 4" chrome extension
Hand tools Sockets and Extensions 3/8" 16mm deep chrome socket

4
Action Description
WARNING Heavy - 2 person manual lift or use of specialist lifting equipment.
WARNING Spacer (30" and 35" only) may drop down, when transmission is being removed.
Info dowel pins locate the Transmission and the Spacer (If applicable) and can inhibit removal as they are slight
interference fit.
Remove transmission from outboard.
Store transmission safely, for future assembly.
5
Action Description
Remove input shaft sleeve and water transfer tube if attached to the transmission.
Tip if tubes are not with the transmission, they will be held in the midsection.
Visual Check for any degradation or damage to parts. Replace as necessary.
Store if the parts are in good condition, for future assembly.

- Remove water pump
1 Disconnect PTFE drain hose
Action Description
Disconnect the small plastic pipe from the FESTO fitting on the water pump gearbox.
Tip to release the FESTO fitting, push the pipe into the union, press down the union collar and keep depressed,
and simultaneously pull out the plastic pipe.

2 Remove water pump fasteners
Action Description
Un-screw the 3 M6 fasteners (Fig 1).
Un-screw the 2 dowel fasteners (Fig 2).
Store the fasteners safely, ready for future assembly.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Standard Tools 3/8" Ratchet
Hand tools Sockets and Extensions 3/8" 10mm shallow chrome socket
Hand tools Sockets and Extensions 3/8" 4" chrome extension
Hand tools Sockets and Extensions 3/8" 8mm shallow chrome socket

3 Remove water pump from transmission
Action Description
Navigate the PTFE hose through the water pump body grommet.
Remove the water pump assembly, sliding up and off the transmission drive shaft.

- Install new water pump
1 Offer new water pump into place
Action Description
Check that the small plastic pipe is fully home in the FESTO fitting, under the water pump.
Assemble the water pump sliding over, and down the transmission drive shaft.

2 Connect PTFE oil drain pipe
Action Description
Navigate the small plastic pipe through the water pump and into the FESTO fitting on the water pump gearbox.
Push the pipe securely into the FESTO collar and into the tighter resistance sealing position.
Tip the small plastic pipe should engage into the FESTO fitting by 15mm. Check that the fitting is securely holding
the pipe, with a pull test.

3 Torque water pump fasteners
Action Description
Tighten by hand the 2 dowel bolts (Fig1).
Tighten by hand the 3 M6 fasteners (Fig2).
Torque the 2 dowel bolts to 7Nm.
Torque the 3 M6 fasteners to 7Nm.
Tool Tool Type Tool Category Tool Code Tool Description
Hand tools Standard Tools 3/8" Digital torque wrench 6-130Nm
Hand tools Sockets and Extensions 3/8" 10mm shallow chrome socket
Hand tools Sockets and Extensions 3/8" 4" chrome extension
Hand tools Sockets and Extensions 3/8" 8mm shallow chrome socket

WT 6267 - Install transmission spacer (30" and 35" variants only)
1 Check for dowels and pip seal
Action Description
Check 2x dowels are located correctly and present. If not in the spacer, installed in the midsection.
Check the pip seal is in place for exhaust seal on the top face of the transmission spacer.

2 Install transmission spacer
Action Description
Ensure spacer correct orientation, with water pump cut out towards transmission.
Assemble transmission spacer over studs onto midsection.

WT 6258 - Install intermediate shift shaft
1 Install intermediate shift shaft
Action Description
Assemble Intermediate shift shaft through midsection and PTT swivel bracket bore.
Align the shaft onto the splines of the GSA arm in adapter plate.
Ensure the retaining clip (Cir Clip) is not pushed up into the adapter pate.

WT 6270 - Install input shaft sleeve to midsection
1 Install input shaft sleeve
Action Description
Ensure correct length input shaft sleeve (25",30" or 35").
Lubricate the O-rings inside the midsection, with a small amount of marine grease.
Insert input shaft sleeve into mid section ensuring it engages correctly through the O-rings.
Check the input shaft sleeve installed is the new flexible version and not the rigid aluminium tube.

WT 6271 - Install water transfer tube to transmission
1 Install water transfer tube
Action Description
Lubricate the O-rings inside the water pump, with a small amount of marine grease.
Insert water transfer tube into water pump.
Check the water transfer tube is engaged correctly and pushed past the O-ring.

WT 6312 - Install transmission
1 Make sure exhaust seal is present
Action Description
Check gasket is in place for exhaust seal on the top face of the transmission

2 Install transmission
Action Description
Adjust transmission into gear.
WARNING Heavy - 2 person manual lift or the use of specialist lifting equipment is required.
Lift transmission and install to the outboard, making sure water transfer pipe (water pump) and input shaft sleeve
(Midsection) are aligned with the corresponding locations.
Rotate the prop shaft to engage splines between input shaft and crankshaft adapter. Once aligned pull back
transmission enough to access gearshift shaft.
Adjust transmission back to neutral.
Push transmission gently, fully home onto the midsection dowels, ensuring intermediate shift shaft is correctly
engaged.
WARNING make sure splines in the intermediate shift shaft are correctly aligned. DO NOT force the transmission
home as it will damage the circlip on the GSA arm.