2021 Suzuki 150hp, 175hp and 200hp Lower unit failure analysis and rebuild.

I've seen at least 7 of these lower units fail abruptly with under 400 hours on them.
Every single time the pinion gear has been completely annihilated in one way or another.
I'm curious if anyone else has had issues with these 2021 and 2022 Suzuki DF150, DF175 and DF200 lower units?

Here are a few of the things I used in this video:

Some of the OEM parts needed:
57300-96850 Gearset
57500-87861 Reverse gear shim set (Clutchdog Side)
57500-87852 Reverse gear shim set (Bearing carrier side)
09181-60005 thru 09181-60013 Pinion gear/ Driveshaft shims (Various sizes)
09181-75008 thru 09181-75019 Forward gear shims (Various sizes)

0:00 Intro
0:42 Pinion failures
2:33 Disassembly
4:30 Clean metal shavings out
4:54 Gear marks
7:43 Glue needle bearings in with grease
8:59 Shim talking
12:35 Install needle bearing, pinion and driveshaft
13:55 Prop shaft
15:55 Reverse bearing
20:00 Reverse gear
21:42 Test by hand
22:53 "Thats all there is to it"

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[trythistv]

Here are a few of the things I used in this video:


Some of the OEM parts needed:
57300-96850 Gearset
57500-87861 Reverse gear shim set (Clutchdog Side)
57500-87852 Reverse gear shim set (Bearing carrier side)
09181-60005 thru 09181-60013 Pinion gear/ Driveshaft shims (Various sizes)
09181-75008 thru 09181-75019 Forward gear shims (Various sizes)



(Purchasing items from links displayed on my channel or website may earn me a commission for referring you, this is done at no cost to you and helps me continue making videos like this one)

[jeremygrindle]

I’ve got 5 rental boats that just so happen to be 2021 models. This is my third season with them and I couldn’t tell you how many of these I’ve had to rebuild, yes some were due to renters hitting rocks and such but I would dare to say each one has been rebuilt at least twice if not three times. And at $800+ per gear set plus other parts it isn’t cheap, not including down time. Thanks for the video, I’ve been saying that there must’ve been a factory or material issue. I had 2019 models before these and the only time I had an issue was when a renter hit something in the water and then it was only a bent prop shaft. Never had to change a gear set until these ‘21 models.

[gaetanobuttari]

Great video but I have a question, if you don't mind? Is the spring and bearings in the Suzuki DF200 prop shaft pinned behind the clutch dog to keep pressure into the forward gear? Or does the shift shaft pull the clutch dog into forward and reverse? What's the purpose of the spring behind the shifting rod if it's not pushing it forward or reverse? I put my lower unit in after replacing the prop shaft and Carrier bearing and when i ran the boat it worked perfectly going forward but hard shifting into reverse and only had throttle no reverse movement?

[fishermansfriend]

Hello from Finland. I have 2018 APX df 175. No problem so far 800 hour on it. My friend say that in Norway this AP model engines lower unit is going to broke very often. They are rental use for fisherman tourists, and they shift the gear forward to reverse accidentally too high speed. Reason to this is that there is no neutral lock position in remote control unit!

Could this be reason this problem only? or is it year of manufacture...

Another question for you. I have df 50, 2012 year model. Bearing carrier in lower unit pulled out when my motor is trimmed up in shore. The reason is that raining snow and water filled the hole in middle of propeller and drive shaft. Then came minus 15 celsius and water freezes there and expand ice pullet that bearing carrier out.
I bought new bearing carrier and install it, but there seems to be too much end play in drive axle, maybe about 1 mm. i test drove it and it will leak oil from gearbox. I see it on the water.
Do you know how this is possible?

And can You make video of these big Suzuki valve clearance adjustment?
I hope you understand because my english is not perfect :)

[jarad]

Thank you so much for making the video. I have one that needs rebuilding. Do you happen to have the number for the Timpken barons?

[IsaiahPikuyak]

Hello I have never worked on lower unit and I lost my manual and I ordered pinion gears through oem parts my outboard is suzuki df70a

[pmxmotorsportllc]

I have a lower unit for 2018 df250z counter rotating, that i need to replace the upper driveshaft since the splines are damaged, I have the new driveshaft, I was wondering if removing the carrier bearing and replacing the driveshaft would be enough, since i don't want to get to deep taking everything apart, the only step that scares me the most is checking for play on all the parts, since i don't have a gauge for it. Great video.

[khkeel]

Thanks for the video! Could this be from accidentally putting the engine in reverse while going forward? I did this to my engine to avoid hitting something and now I have a knocking sound while idling in neutral. It abruptly stalled the engine. I’m hoping my gears don’t look like those.

[danbowers]

What year is the motor you are working on in the video?

[reyrod]

What about the thin pin that’s at the bottom of the shift rod? What purpose does it serve cause I pulled mine out of a locked up lower and pin broke, but the way you took it off it looked like there was no pin.

[bricezama]

I have a new DF150 four stroke, about 14hours on it. Yesterday on my way, i hit some swell and i accidentally hit the throttle from forward into neutral then into reverse all at once. The propeller still had forward movement on it. The engine immediately beeped and shut off. Should i open the lower unit to ensure that no damage was done, or is there a fail safe mechanism that was responsible for shutting off the engine to avoid damage?