Mercruiser Alpha bellow replacement question

chrisg00

Cadet
Joined
Mar 27, 2010
Messages
13
Okay, sorry for asking more questions. I am 99% done with replacing all the bellows boots. I have a 1989 alpha one drive. Replaced the hose, u-joint bellows, cable bellows is on the cable but not secure yet (figure it's the easiest one to get to), and the exhaust bellows is attached to the transom end only at this point. How the h*ll do you get the other end on the drive or even vise-versa? I had the exhaust booon the drive end and couldn't get it on the transom end. So I pulled it out and put it on the transom end and now am having a h*ll of a time keeping it on the drive end, keeps sliding off.
Do you have to glue it on the same as the u-joint bellows? I'm assuming the cable boot needs to be glued as well? I noticed there wasn't any glue on the old cable boot or exhaust boot, thats why I ask.
Thanks
 

ken_23434

Petty Officer 1st Class
Joined
Jul 28, 2008
Messages
313
Re: Mercruiser Alpha bellow replacement question

Exhaust bellows does not need adhesive.

To get it stretched to install it, you pretty much need the "bellows tool". It grabs the bellows from the inside and holds it so you can stretch it backwards and expand it to pull it over the part where it attaches.

People on here have said they have done it without the tool. I tried... after quite a long time and many 4 letter words, I quit and bought the exhaust boot and did it the easy way.
 

jtmarten

Master Chief Petty Officer
Joined
Aug 2, 2004
Messages
825
Re: Mercruiser Alpha bellow replacement question

+1 for the exhaust tube instead. For a single drive it'll cost less than the bellows tool.

To make the bellows install easier you can either clamp it, fully stretched out, to a piece of PVC tubing for a day or so, or soak it in a bucket of very hot water to soften it and make it easier to stretch.
 

FreeBeeTony

Captain
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May 15, 2002
Messages
3,991
Re: Mercruiser Alpha bellow replacement question

I would ditch the exhaust bellows and install the exhaust tube instead......
 

cr2k

Captain
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Mar 19, 2009
Messages
3,730
Re: Mercruiser Alpha bellow replacement question

Let's see, 3 bellows X 2 ends each -1 end of the exhaust = 83.34% done. Not counting the end of the shift cable bellows not clamped.
 

jtmarten

Master Chief Petty Officer
Joined
Aug 2, 2004
Messages
825
Re: Mercruiser Alpha bellow replacement question

Let's see, 3 bellows X 2 ends each -1 end of the exhaust = 83.34% done. Not counting the end of the shift cable bellows not clamped.

Nice recap, but what was the point?
 

ken_23434

Petty Officer 1st Class
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Jul 28, 2008
Messages
313
Re: Mercruiser Alpha bellow replacement question

If I remember correctly, the bellows tool runs about $40 or $50.

The exhaust tube only hooks up on the transom end. It's not a bellows, but a rigid tube made of rubber. When the drive is down fully, the tube slips over the end that's part of the gimbal ring.

Some say the tube is louder than the bellows, most say they cannot hear the difference.

I never tried the stretching the bellows on a piece of PVC for a few days to stretch it out, though. Might try that the next time.
 

GalaxyBR

Cadet
Joined
Sep 11, 2009
Messages
8
Re: Mercruiser Alpha bellow replacement question

yeah i just did the bellows in my Galaxy did my old Galaxy and got it to work no problem may have gotten lucky. Used the tube on my new boat and i like it a little louder than through foot makes my 4.3 v6 sound like a V8. and they are easy
 

chrisg00

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Joined
Mar 27, 2010
Messages
13
Re: Mercruiser Alpha bellow replacement question

YES, many, many, many 4 letter words have been said over the past 2 hours of trying to get that boot on and now trying to get it to stay. I thought of ditching the boot for the new style but I am too determined to use it. I pushed the drive in as far as I could and used a wide, thick pry bar to pull the ribs out, onto the exhaust flange (on the drive end). A little grease around the flange helped to get it on but now it keeps sliding off when i tighten the clamp. Maybe it needs to be pushed on a little more, will try again this morning.
Thanks for the help.
 

badognobisc

Cadet
Joined
Jun 17, 2009
Messages
22
Re: Mercruiser Alpha bellow replacement question

there is bellows adhesive according to the install manual. You apply and then let it sit for 10 minutes then install and it does stay on there.
 

kljr99

Recruit
Joined
Jun 26, 2010
Messages
3
Re: Mercruiser Alpha bellow replacement question

i tried to post this in the what works and why of the exhaust tube vs. bellows but it was closed. The question is why the tube. In my aftermarket service book it says. If the bellows gets soft or you have a 350 mag or 4bbl
than the tube should be used because the bellows can blow up and press on the drive shaft bellows. the driveshaft bellows will hit the spinning u joints and then you have water in your gimble bearing not the best place for it.
just a thought. it also says it will reduce back pressure some.
 

RichRab

Petty Officer 1st Class
Joined
Jun 10, 2010
Messages
249
Re: Mercruiser Alpha bellow replacement question

On my alpha1 gen 2 I used Merc bellows glue and I think that helped slide the transom end slide on easier. Then I pushed a sprinkler head first and then the fat end of a baseball bat in the other end for a few days each and put vise grips on the end to stretch the bellows as far as possible with a bungee cord. When my son's buddy and I (the smaller and stronger the hands the better)put it on I used a hair dryer to soften the rubber and after my fingers got glued together we worked through it and hopefully it is on to stay. We used a wide flat bar to push the lip on. The bat worked easier because it is tapered and I could force it in. We did it with the drive down as far as possible-about 1/3 down I think. There are little clips (grounding clips?) that I guess are important to be be on there. Good Luck
 

Simoniz

Petty Officer 1st Class
Joined
Dec 30, 2007
Messages
242
Re: Mercruiser Alpha bellow replacement question

YES, many, many, many 4 letter words have been said over the past 2 hours of trying to get that boot on and now trying to get it to stay. I thought of ditching the boot for the new style but I am too determined to use it. I pushed the drive in as far as I could and used a wide, thick pry bar to pull the ribs out, onto the exhaust flange (on the drive end). A little grease around the flange helped to get it on but now it keeps sliding off when i tighten the clamp. Maybe it needs to be pushed on a little more, will try again this morning.
Thanks for the help.

Thats the problem with the exhaust bellows, if you use lubricant, it goes on easier but then the thing will slip off again. I used acetone which lubricates the rubber while you fit the bellows, then dries out and wont provide a lubricant to allow it to slip off again.

Youreally need a tool though to expand the bellows and pull it onto the stub in the bellhousing. I made one from a couple of bits of flat steel about 18 inches long, drilled and pivoted with a bolt in the middle like scissors. I found a decent washer which fitted snugly inside the folds of the bellows, sawed it in half then welded one half to each end of the steel arms. Worked a treat to expand the bellows and then pull them home over the stub.

Note any tool you make up has to be able to pass through the exhaust stub on the bellhousing. Sounds pretty obvious now but it didn't occur to ne while I was making the tool and it was only pure luck that it was small enough to pass through.
 

Simoniz

Petty Officer 1st Class
Joined
Dec 30, 2007
Messages
242
Re: Mercruiser Alpha bellow replacement question

There are little clips (grounding clips?) that I guess are important to be be on there. Good Luck

Yes the clips on the bellows allow the hose clip to be electrically connected to the rest of the drive thus preventing corrosion from occuring.
 

tacconelli6

Seaman Apprentice
Joined
Aug 2, 2008
Messages
32
Re: Mercruiser Alpha bellow replacement question

My bellows tool from sierra cost $23.50. seems worth the money to me.
 

Simoniz

Petty Officer 1st Class
Joined
Dec 30, 2007
Messages
242
Re: Mercruiser Alpha bellow replacement question

My bellows tool from sierra cost $23.50. seems worth the money to me.

I agree.

Trouble is, in Europe we cant get them for anything like that price and buying one in the States pretty much doubles it due to postage.

Same reason I had a machine shop make up an alignment bar for me.
 
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