(moving this conversation to new topic to help others find in the future)
Engine: Volvo Penta 8.1 Gi-F (2004-2005)
Transom: SX-MHP
Drive: DP-SM 1.78 (M22)
This is my first time replacing a U-Joint, so any suggestions / corrections / tips would be VERY much appreciated. Below is the information that I have found so far and where the results of the project will be posted in order to help others.
It is very important that our boats function reliably and none of us want to dig into the pinion gear assembly to redo this project, so let's document how to "do it right the first time".
Researching various forums and YouTube videos led to the following info and questions.
Here are the installation instructions:
Volvo Penta Universal Joint Kit - Installation Instructions (3860842)
... and the exploded parts diagram:
DP-SM Outdrive - U-Joint and Bearing Carrier
The U-Joint Kit comes with the pinion gear retainer screw (#4 on parts diagram) and crush sleeve (#5).
The existing pinion carrier oil seal (#8) looks fine on my drive. No leakage. Just need to replace the U-Joint.
I will measure the running torque before disassembly to establish a base-line. The general wisdom appears to be to carefully clamp the pinion gear housing (#10) in a vice and use a precision torque gauge (I will be using a 0-30 in.lb. dial wrench) to turn the pinion gear retaining screw (#4) which is either a PTX-500 torx (old) or 11 mm 12-point socket (new). Note that the torque required to start the motion may be higher than to keep it going. We want the torque value to keep it going. The proper specs are between 9 - 14 in.lb.
Wondering if I can just replace the U-Joint by:
1. Remove the pinion gear retainer screw.
2. Pull out the U-Joint (one video suggested hammering using a wooden dowel. best method? is it tight?).
3. Put in the new U-Joint.
4. Replace the pinion gear retainer screw, tightening it very carefully to achieve the base-line running torque.
Q1) How important is it to press out the bearings from the pinion bearing carrier and install a new crush sleeve?
The instructions call for four Volvo special tools to remove and then reinstall the bearings after replacing the crush sleeve. Haven't been able to locate these specific tools in stock at one place yet and they are a bit pricey. There probably is a good way to do this work without the Volvo tools that are well known to a Volvo Jedi. Humble Padwan would love to learn the ways of the Jedi. :^)
Q2) If the crush sleeve should be replaced, then what is the best method to do so (i.e. correct tools to use to remove the bearings and how to best use them)?
Thanks in advance for any words of wisdom as I head out into uncharted waters.
- Brad
Engine: Volvo Penta 8.1 Gi-F (2004-2005)
Transom: SX-MHP
Drive: DP-SM 1.78 (M22)
This is my first time replacing a U-Joint, so any suggestions / corrections / tips would be VERY much appreciated. Below is the information that I have found so far and where the results of the project will be posted in order to help others.
It is very important that our boats function reliably and none of us want to dig into the pinion gear assembly to redo this project, so let's document how to "do it right the first time".
Researching various forums and YouTube videos led to the following info and questions.
Here are the installation instructions:
Volvo Penta Universal Joint Kit - Installation Instructions (3860842)
... and the exploded parts diagram:
DP-SM Outdrive - U-Joint and Bearing Carrier
The U-Joint Kit comes with the pinion gear retainer screw (#4 on parts diagram) and crush sleeve (#5).
The existing pinion carrier oil seal (#8) looks fine on my drive. No leakage. Just need to replace the U-Joint.
I will measure the running torque before disassembly to establish a base-line. The general wisdom appears to be to carefully clamp the pinion gear housing (#10) in a vice and use a precision torque gauge (I will be using a 0-30 in.lb. dial wrench) to turn the pinion gear retaining screw (#4) which is either a PTX-500 torx (old) or 11 mm 12-point socket (new). Note that the torque required to start the motion may be higher than to keep it going. We want the torque value to keep it going. The proper specs are between 9 - 14 in.lb.
Wondering if I can just replace the U-Joint by:
1. Remove the pinion gear retainer screw.
2. Pull out the U-Joint (one video suggested hammering using a wooden dowel. best method? is it tight?).
3. Put in the new U-Joint.
4. Replace the pinion gear retainer screw, tightening it very carefully to achieve the base-line running torque.
Q1) How important is it to press out the bearings from the pinion bearing carrier and install a new crush sleeve?
The instructions call for four Volvo special tools to remove and then reinstall the bearings after replacing the crush sleeve. Haven't been able to locate these specific tools in stock at one place yet and they are a bit pricey. There probably is a good way to do this work without the Volvo tools that are well known to a Volvo Jedi. Humble Padwan would love to learn the ways of the Jedi. :^)
Q2) If the crush sleeve should be replaced, then what is the best method to do so (i.e. correct tools to use to remove the bearings and how to best use them)?
Thanks in advance for any words of wisdom as I head out into uncharted waters.
- Brad