Alpha one gen 2 sterndrive will not install

[Fettb]

Ok folks, I have searched the forums and the google machine and I'm stuck good. I have just completed bellows and gimble bearing replacement on my 4.3L Merc alpha one gen 2. I went crazy on engine alignment and have that near perfect, installing the tool without resistance in all motor positions. Grease reads splines evenly all around the tool.

Now it's time to grease the drive shaft and put it in, right?

Wrong!! I'm on night two of wrestling with this beast and at the end of my rope. This drive will go in all the way except for the last 1/8" where it stops. I checked the shift cable linkage and it is in the channel where it belongs. Everything looks real swell except for that last 1/8". It hits what feels like a hard stop, but perhaps it's not metal to metal as the drive is difficult to jockey around to hear it. It seems to be the shaft or joints hitting something, but it's a mystery as to what. I also thought maybe I have a stubborn ring that simply doesn't want to compress upon install. I wiggled and jiggled the best I could but no luck getting it to slip in.

Does something engage at the very last moment (like an o-ring)? Has anyone ever encountered this? I am following the manual to a T and have read so many of your wonderful threads helping out poor fools such as myself, but there is no mention of my problem.

Thanks in advance for any advice!

 

[Fettb]

Apparently I'm out of patience.... I put two nuts on the studs and slowly tightened them down. I felt very little resistance and the drive seated fully. Obviously I'm not dealing with a hard contact here. Either I am struggling with the last ring going into the gimble bearing, or I am simply compressing the large 4" O-ring a touch. 1/8" seems like a lot of compression for that big ring so I'm guessing this is a gimble bearing oring that doesn't/didn't want to go easy.

I'll let it sit a few and hope somebody replies and says I'm good. Otherwise, I'll it apart again (the last thing in the world I want to do) and inspect the various rubber parts for signs of mis-install or shearing due to my "slightly" forced installation which I know is very frowned upon

 

[Grub54891]

I think you are fine. The O-rings have a tendency to not compress well if they have to much grease on them, "hydrolock".
Been there done that. Bolt her up, and happy boating.

 

[Fettb]

yes, I have "sufficient" grease on them... and then some!

Would I feel a vibration or hear a noise if something wasn't right down there or will it just implode? It wouldn't surprise me if the boat simply sunk the way this job has gone (and I might just be ok with that!)

 

[stang32]

your most likely fine, i hads one last week that had a burr on the shaft and the last 1/2" would not go, i then had to pry the drive off and the nice new gimbal bearing came out, stuck on the shaft. i got some emery cloth and a new bearing, sliding the bearing on & off, sanding, testing, testing, sanding, finaly got the bearing to slide all the way done the shaft, installed bearing, checked alignment and the drive slide right on that time. . your fine,

 

[harringtondav]

I also think you're OK.

Just be sure the drive is in the gear you select. In FWD, the prop will lock CCW, REV it will lock CW. You can also check by looking at the bell hsg slotted shift arm to be sure the out drive drive shift finger is engaged in the bell hsg lever's slot. This is the last connection before the out drive comes home. If not, remove the nuts, pull it back just enough to get a pair of needle nose pliers on the out drive shift finger and align it straight ahead. The console controller must be in FWD, WOT. Slip a your prop. on and hold it CCW to ensure everything is lined up. Once you were w/in 1/8" your splines were lined up. So don't pull the drive off any further than it takes to get the shift linkage engaged.

 

[Fettb]

You guys are all my favorites now! I really didn’t want to take that beast back off!!!

My shift linkage is aligned and engaged properly and the prop behaves as it should in neutral, forward, and aft after the cable adjustment was completed.

i do believe that I can finish this and put this crazy nightmare behind me tomorrow!

thanks again everyone!!!!

 

[gergAlicious]

Glad you got it!!!

I put mine on yesterday and it was challenging at first, but when the splines lines up it seemed to just pop right into place.

I was dreading the job and fully expected an experience like yours!!

 

[Fettb]

You guys are all my favorites now! I really didn’t want to take that beast back off!!!

My shift linkage is aligned and engaged properly and the prop behaves as it should in neutral, forward, and aft after the cable adjustment was completed.

i do believe that I can finish this and put this crazy nightmare behind me tomorrow!

thanks again everyone!!!!

 

[Bt Doctur]

What your most likely seeing/feeling is the large rubber ring compressing a bit , within an 1/8 inch is about right, tighten the nut and go have some fun.