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  1. #1
    Petty Officer 3rd Class
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    Default rotten wire in outdrive

    bought a 1985 doral 164 with a 140HP mercruiser 3.0L and outdrive ....

    engine block is cracked from not being drained for winter ....
    I already have the replacement engine on hand .....

    when i pulled the engine out , i noticed that there is two double wires coming out of the outdrive .one goes to the trim pump (split in two )
    the other one is totally rotten ......

    are those wires exclusively for the trim pump ?

    if so ,do I have to remove the whole outdrive to fix those ?

    and then, where can I download my outdrive service manual ?

    thanks a lot for your advices ...;-)
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  2. #2
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    Default Re: rotten wire in outdrive

    included is a pic of the wires the rotten one already cut but it wont weld at all ,too damaged .



    <a href="http://s292.photobucket.com/albums/mm16/bigdan911/?action=view&current=P1160274.jpg" target="_blank"><img src="http://i292.photobucket.com/albums/mm16/bigdan911/P1160274.jpg" border="0" alt="fils outdrive">
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  3. #3
    Lieutenant Commander paultjohnson's Avatar
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    Default Re: rotten wire in outdrive

    Most likely its for the trim limit switch The other one would be for the trim sending unit - to the dash gauge

  4. #4
    Lieutenant Commander paultjohnson's Avatar
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    Default Re: rotten wire in outdrive

    And yeah outdrive and bellhousing gotta come off At that point you should change ujoint and shift cable bellows, and water hose, check gimble bearing and u joints

  5. #5
    Rear Admiral Fishermark's Avatar
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    Default Re: rotten wire in outdrive

    Most people forget trying to replace the trim limit switch and the sender. A lot of work for very little gain.

    Having said that, you do need to pull the outdrive if you haven't already to check the various parts as mentioned above. You will also need to check your engine alignment when you reinstall your new engine.

  6. #6
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    Default Re: rotten wire in outdrive

    second attempt on pic
    Attached Images Attached Images
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  7. #7
    Rear Admiral Fishermark's Avatar
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    Default Re: rotten wire in outdrive

    Here's the pic you tried to post. (If you copy the "IMG CODE" link from photobucket, then all you have to do is paste it here):



  8. #8
    Rear Admiral Fishermark's Avatar
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    Default Re: rotten wire in outdrive

    Looks like we were posting at the same time.

  9. #9
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    Default Re: rotten wire in outdrive

    the previous owner says that he had the outdrive rebuilt 3 years ago for over $1200.00 ....funny that they dint change this wire



    because if those wires are only for the limit switch ....ill take great care of not going too far

    but in any case , where can I download the outdrive manual ?
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  10. #10
    Rear Admiral Fishermark's Avatar
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    Default Re: rotten wire in outdrive

    The wires are not actually in the outdrive - they are part of the transom assembly.

    I'm not sure of the manuals are still available in the stickey at the top of the page or not... I think they were removed. But you may take a quick look at see.

  11. #11
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    Default Re: rotten wire in outdrive

    thing is , know nothing about boats ......

    just dont want to break something when stripping

    Id like to fix those two wires ,but if I have to tear down the whole thing to bare parts just for a gauge reading , i doubt it is worth it !

    the good wires go to the pump control
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  12. #12
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    Default Re: rotten wire in outdrive

    fishermark , you think I woulndt have to remove whole outdrive to fix the wires ?
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  13. #13
    Lieutenant Commander paultjohnson's Avatar
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    Default Re: rotten wire in outdrive

    If your trim limit switch still functions you could just splice wire to the broken ones inside the boat. Take your trim limit switch off Its the one on the port side of the drive that covers the hinge pin. See if its rusted to sh!&. and get yourself a meter and run a test thru the cut off wires from inside the boat and see if you have continuity. You may be able to jury rig it if the switch is still functional. On the starboard side is the sending unit that sends a signal to a dash gauge to indicate the position of your drive Do you even have a trim indicater on you dash ? If not dont even wory about the starboard switch. I dont think there is a way around removing the drive and bellhousing to run the wires thru the transom . If you follow the wires from the switchs on the outdrive up to the transom you will see they disappear into never never land above the u joint bellows. There are i believe 2 screws that have to be acessed to remove the gromet that holds the wires from the aft end of the transom. As I said before then you should do [or at least inspect] the whole works Bellows, water hose, check gimble bearing alingment u joints etc

  14. #14
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    Default Re: rotten wire in outdrive

    correct me if i`m wrong ...looks like the "rear end "
    is in two parts : transom & outdrive ....

    can I remove the outdrive as a whole unit and check the wires at the transom ?

    there seems to be four bolts holding the outdrive to the transom
    is this right?
    thanks again !
    Dan
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  15. #15
    Seaman mariner1900's Avatar
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    Default Re: rotten wire in outdrive

    PM me your email address and I will send your the manual.

  16. #16
    Rear Admiral Howard Sterndrive's Avatar
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    Default Re: rotten wire in outdrive

    not all Mercruiser powered boats have a trim gauge.

    On my boat, those wires are just hanging there.
    Baba-buoy.

  17. #17
    Seaman antsmands's Avatar
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    Default Re: rotten wire in outdrive

    Quote Originally Posted by Fishermark View Post
    Here's the pic you tried to post. (If you copy the "IMG CODE" link from photobucket, then all you have to do is paste it here):


    Looks like the tilt /trim limiter wires. Mine are rotten an I gotta replace them also. Do it while the drive is off!
    1986 Sea Sprite Mark V- Merc 140 I/O

  18. #18
    Rear Admiral Fishermark's Avatar
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    Default Re: rotten wire in outdrive

    Quote Originally Posted by bigdan1 View Post
    can I remove the outdrive as a whole unit and check the wires at the transom ?
    It sounds like you pulled your engine without pulling the drive - correct? That is possible to do, and it is even possible to put the engine back in without removing the drive. But it is a real bad idea.

    The outdrive is easy to remove and you need to learn how to do it as it needs to come off periodically for maintenance.

    You will need to put it in forward gear and then remove the SIX nuts holding it on (not four). You will also need to remove the trim rams where they connect.

    Here is a site that I haven't recommended in awhile, but since the manuals are not available... they have some good general info: General Mercruiser info

  19. #19
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    Default Re: rotten wire in outdrive

    Do you have mercathode system???
    home is where we drop anchor

  20. #20
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    Default Re: rotten wire in outdrive

    Quote Originally Posted by Fishermark View Post
    It sounds like you pulled your engine without pulling the drive - correct? That is possible to do, and it is even possible to put the engine back in without removing the drive. But it is a real bad idea.

    The outdrive is easy to remove and you need to learn how to do it as it needs to come off periodically for maintenance.

    You will need to put it in forward gear and then remove the SIX nuts holding it on (not four). You will also need to remove the trim rams where they connect.

    Here is a site that I haven't recommended in awhile, but since the manuals are not available... they have some good general info: General Mercruiser info
    when i bought the boat , the engine was already removed ,

    I just removed the outdrive by putting it in forward gear , not that hard really , just had to take my time and do visual all the time ..... now it` siting on my bench ....
    still no access to those wires ....cant even move them to see wich side they go ...I have two sensors (one on each side )

    the gimbal bearing seems ok .....I push on it from outside and turn around no rubbing or hard spot at all real smooth ..... lots of grease in that area !

    ID rather have the gauge workingin dash then the limiting switch .....wich is the gauge on the right or on the left (pilot view) ?

    thanks againto all of you !
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  21. #21
    Rear Admiral Fishermark's Avatar
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    Default Re: rotten wire in outdrive

    Quote Originally Posted by bigdan1 View Post
    ID rather have the gauge workingin dash then the limiting switch .....wich is the gauge on the right or on the left (pilot view) ?
    Forget left - right - pilot view, etc. Get used to saying port and starboard. Makes things much easier!

    I believe the switch and sender come packaged together. Forget trying to splice the wires. If you really want it to work, it is best to simply replace the two complete switch / sender assemblies. Instructions here.

  22. #22
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    Default Re: rotten wire in outdrive

    The trim sender puck on the starboard side is probably a dummy one, there s nothing in there altho it looks like.
    If you want to have a trim gauge to work with the mercruiser trim sender it must be suited for the mercruiser sender ohm range of 10-167 ohm.
    Look around some for the sender/limmit switch package as prices may differ, I got me a new set for $70.
    Good luck!

  23. #23
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    Default Re: rotten wire in outdrive

    1) both sides have wires .....

    2) the engine is in
    installed the rubber coupling while lowering the engine ....

    the bowels are both in perfect shape cleaned them up and treated them with silicone lube ....
    the gasket between the outdrive and transom part is cracked, ill get a new one ...

    now ,to rent a dummy shaft to align the engine correctly whith the gimbal bearing ...there is a boat mecanic just out of my village ....

    is the hole surrounded by a rubber "0" ring the exhaust output ? kind of small if so....
    PROPERFORMANCE engine mods at honest prices. 1985 DORAL 164 mercruiser 140HP ,
    protouring 84 cutlass, 86 CJ jeep lots of mods , hemi magnum awd .....just cant keep anything stock !

  24. #24
    Commander NHGuy's Avatar
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    Default Re: rotten wire in outdrive

    No the O ringed hole is where water gets fed into the boat, the bottom hole at the center is the exhaust.
    You might as well get yourself an alignment tool of your own, it's necessary for the future, costs about $28 plus shipping on e-bay. You will need a drive to bellhousing gasket too, they come in kits with extra o rings and etc. Maybe check your u-joints and impeller first, there are many kits available that combine some of the parts. You can get them from E-bay or mercstuff.com, or boatfix.com, or iboats.com or your local Mercruiser dealer.
    Good luck and have fun. Remember it's not work, it's a hobby that ends up with zipping across the water.
    1989 Baja Sunsport 196, Mercruiser 5.7, Alpha 1
    Moultonborough Neck, Lake Winnipesaukee, NH

  25. #25
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    Default Re: rotten wire in outdrive

    Quote Originally Posted by bigdan1 View Post
    1) both sides have wires .........
    Yup.. even the dummy has wires, but there is no sender in the puck!!

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