These step-by-step instructions will guide you through the rebuilding process of your Mercury Triple Ram Trim and Tilt system using the Buckshot Racing #77 Seal and Rebuild Kit or Mercury OEM part numbers: 8116121 (NLA), 811612, 811612-A1, 811612-A2, and later 811612-A3. This guide covers removal, disassembly, seal replacement, and reassembly to restore proper function to your hydraulic system.
Tools & Materials Required
✔ Buckshot Racing #77 Seal and Rebuild Kit✔ Socket Set & Ratchet (Metric & SAE)✔ Wrench Set✔ Screwdrivers (Flathead & Phillips)✔ Needle Nose Pliers✔ Seal Pick or O-Ring Removal Tool✔ Hydraulic Fluid (Mercury or equivalent)✔ Brake Cleaner or Solvent✔ Lint-Free Shop Rags✔ Torque Wrench✔ Plastic Mallet✔ Thread Sealant (if needed)
Step 1: Safety Precautions
🔴 Ensure the boat is properly secured on a trailer or stand.🔴 Disconnect the battery to prevent accidental operation.🔴 Wear gloves and safety glasses to avoid injury.🔴 Work in a clean, well-ventilated area free from dirt and debris.
Step 2: Removing the Trim and Tilt Unit
Trim the outboard to its highest position and secure it using a support bracket or transom saver.
Disconnect the hydraulic lines leading to the trim and tilt system to prevent fluid spills.
Use a drain pan to catch excess hydraulic fluid.
Remove the mounting bolts securing the trim and tilt unit to the clamp bracket.
You may need to use penetrating oil if bolts are corroded.
Carefully lower the unit and remove it from the bracket.
Drain remaining hydraulic fluid from the system by tilting the unit into a drain pan.
Step 3: Disassembling the Trim and Tilt Rams
Remove the end caps from each hydraulic ram using a wrench or spanner tool.
Some models require a snap ring removal before the cap can be taken off.
Extend the rams manually by pulling them out of the cylinder.
Use compressed air if needed to force them out.
Use a seal pick to carefully remove old O-rings, backup rings, and dust seals.
Inspect the ram shafts and cylinders for wear, pitting, or damage.
If the ram is severely corroded, consider replacing it.
Step 4: Installing New Seals and O-Rings
Clean all components thoroughly using brake cleaner and a lint-free cloth.
Lubricate new O-rings and seals with hydraulic fluid or silicone grease before installation.
Install new O-rings and backup rings inside the end caps, ensuring they are seated properly.
Carefully slide the new seals onto the ram shaft without twisting or stretching them.
Reinstall the end caps and tighten them securely using a torque wrench (follow manufacturer specs).
Step 5: Reassembling the Trim and Tilt System
Insert the rams back into the hydraulic cylinder with a slow, even motion.
Reinstall snap rings or retaining rings to secure the end caps in place.
Reconnect the hydraulic lines ensuring the fittings are tightened securely.
Torque all mounting bolts to the manufacturer’s specifications.
Step 6: Refilling and Bleeding the Hydraulic System
Refill the hydraulic reservoir with Mercury or equivalent hydraulic fluid.
Cycle the trim and tilt system multiple times to purge air from the system.
Lower and raise the motor fully while checking the fluid level.
Check for leaks around the ram seals and fittings.
Top off hydraulic fluid as necessary.
Step 7: Final Checks and Testing
Reconnect the battery and power on the trim and tilt system.
Test operation by trimming the motor up and down multiple times.
Ensure smooth movement without hesitation or leaks.
Re-torque any fittings if necessary.
Maintenance Tips for Longevity
🔹 Flush the trim system with fresh water after saltwater use to prevent corrosion.🔹 Check hydraulic fluid levels regularly and top off as needed.🔹 Inspect for leaks and worn seals every season.🔹 Lubricate moving parts to prevent wear and ensure smooth operation.
By following these steps, your Mercury Triple Ram Trim and Tilt system will be restored to full working condition, ensuring smooth operation and reliability for your outboard motor. 🚤💨
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