Re: cost to replace Alpha 1 drive shaft seal
Instructions for seal replacement
http://www.amarket.com/merseal.htm
REPLACEMENT OF OUTDRIVES YOKE AND SEAL MERCRUISER
1) Start by removeing the upper drive from the lower gearcase
2) Rremove the oil from the drive. Take top drive from bottom drive.
3) Remove the large covernut with covernut wrench or use a 1/2" bar through the nut and u-joint to loosten it.
4) Remove the top cover of the outdrive to relieve vaccuum on drive and pull complete u-joint section from front of drive.
5) Mount the u-joint in a vice with the nut up and remove the nut with 15/16 socket wrench.
6) Remove the complete assembly of parts from the yoke and place the nut and washer aside and place the stack gear down on the bench and unstack the parts one at a time until you come to the carrier with the seal in it. Clean it with parts washer. Guard the shim set behind the bearing assy.
7) With the lip downward drive the seal out with screwdriver and hammer. Place the new seal over the bore and press down with a 2x4 piece and hold it under pressure and straight. While under pressure have someone else hit the 2x4 with a large hammer on the wood right over the seal and the seal should sink into place, flush with top of carrier.
8) Clean all of the parts and restack the parts back up to the cover nut.
9) Go back to the U-Joint section and remove the cross and bearings from the assembly, discard all but the center yoke and long engine side yoke.
10) Rebuild the U-Joint using 2 new bearings and youk from kit, Be sure the clips are completely set around the caps and that you do not let any needles fall inside the caps, if the caps do not close enough for the snaps to install this is probably the problem.
REPAIR KIT
11) Lubricate the U-Jooints
12) place the stack of parts over the spline of the yoke and tighten it up, a new nut and washer is provided. Check that the word nut goes on the nut side..
13) Lubricate between the lips of the large seal before assembly
14) Remove the driven ear and shaft by lifting it out of the cap opening. Change the two seals in the base of the empty housing, remove them upward with a screwdriver
15) Replace the seals using a scocket that fits on the upper seal, and drive the lower in from the bottom with a flat surface until flush.
16) Greese the seals, and drop the cleaned driven gear and shaft in from the top, clean the cap and replace it with a new 'o' ring on it. use lube on screws.
17) Be sure that the shims that were behind the yoke assy are replaced using the large black one to hold the others in.
19) Drive the assembly into place and tap on the tip of the assy to be sure it is completely seated, then tighten covernut. Do not rely on covernut to pull it tight. Don't forget the large 'o' ring around the assy it must be installed.
20) The Shiming should not have changed but the unit should turn effortlessly and you should feel no gap between the gears. There is however a small unfeelable gap that must be there. To check rotate the shaft back and forth rapidly about one inch and you should hear a tapping indicating a light backlash.
23) Replace bottom of drive and fill with oil..
Good luck on how ever you do it! Help is always here when you ask!