How do you install a new Volvo water connection housing?

[jberenyi]

I have the AQ290 Volvo Penta outdrive and it needs the water connection housing replaced. Does anyone know if you need to drop the intermediate drive to replace it? I have never worked on this drive before so I am clueless what it will take to do this task.

 

[PiratePast40]

Re: How do you install a new Volvo water connection housing?

No reason to pull the intermediate section but it's easiest to replace after pulling the gearbox. Since that's a normal maintenance inspection item, it wouldn't be a bad idea to inspect and service the u-joints and possibly replace the bellows. Any water in the bellows and you've most likely got a bad seal in the gearbox as well. It could also be that everything is fine but you won't know until you look.

I don't recall seeing a link to the 290 but ask Don S and I'm sure he'll send you a link.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

No reason to pull the intermediate section but it's easiest to replace after pulling the gearbox. Since that's a normal maintenance inspection item, it wouldn't be a bad idea to inspect and service the u-joints and possibly replace the bellows. Any water in the bellows and you've most likely got a bad seal in the gearbox as well. It could also be that everything is fine but you won't know until you look.

I don't recall seeing a link to the 290 but ask Don S and I'm sure he'll send you a link.

Thanks for the advice. The only other thing I noticed is that the bottom of the exhaust bellows show water coming out but I believe this is acceptable. I PM'd DonS for some help so hopefully he will respond.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

I just called local Hansan Marine in SLC Utah 801-466-4731 and they have the part #854031 in stock as well as gasket #814356...thank goodness. I asked them if I have to drop anything to replace the unit and they said you can replace if you have a stubby 5mm allen. I will attempt it and report back. Would still like to hear from others though.

 

[PiratePast40]

Re: How do you install a new Volvo water connection housing?

You can try but I don't thing Don normally responds to PM's. He's usually pretty good about looking at recent posts so this might work as a flare for help .

 

[PiratePast40]

Re: How do you install a new Volvo water connection housing?

I just called local Hansan Marine in SLC Utah 801-466-4731 and they have the part #854031 in stock as well as gasket #814356...thank goodness. I asked them if I have to drop anything to replace the unit and they said you can replace if you have a stubby 5mm allen. I will attempt it and report back. Would still like to hear from others though.

I've been told that it can be done without pulling the gearbox but that it's a real bear. I'd really advise pulling the gearbox for an inspection - it's not that hard and gives you a chance to inspect the u-joints. Don't get me wrong, I'm not advocating the "fix it till it's broke" approach. I'm just saying that the water inlet pipe is a normal maintenance item and that if it's corroded to the point that you've got leaks, that indicates that other maintenance way also have been missed.

And by the way - my feelings aren't hurt by you saying that some other opinions would make you feel better. A consensus allways helps.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

I've been told that it can be done without pulling the gearbox but that it's a real bear. I'd really advise pulling the gearbox for an inspection - it's not that hard and gives you a chance to inspect the u-joints. Don't get me wrong, I'm not advocating the "fix it till it's broke" approach. I'm just saying that the water inlet pipe is a normal maintenance item and that if it's corroded to the point that you've got leaks, that indicates that other maintenance way also have been missed.

And by the way - my feelings aren't hurt by you saying that some other opinions would make you feel better. A consensus allways helps.

I'm all for checking other areas. I just didn't know how tough and complicated it is to take off the gearbox. If its not tough I will attempt it. I have a Clymer Volvo Stern Drive Shop Manual I can reference.

 

[PiratePast40]

Re: How do you install a new Volvo water connection housing?

Here's a link to a thread about removing the bellows and gearbox. It also has a link to the shop manual from Don S. Check below the thread and you'll also see similar threads on pulling the gearbox:http://forums.iboats.com/showthread.php?t=338739&highlight=volvo+290+bellows.

You'll need to order some new o-rings for the gearbox to intermediate section interface and might as well also get the new ones for the dipstick, oil fill, and drain plug. A new bellows is a good idea as well but it depends on how long ago yours was replaced. You can get all the o-rings and gaskets from the local dealer. I bought my bellows as an aftermarket item but the dealer certainly has that as well.

The job is not as hard as it initially sounds and this peice of maintenance and inspection is critical to the life of your drive. This is the only way you can service your u-joints. Believe me, you want to do this before serious problems develop.

 

[captmello]

Re: How do you install a new Volvo water connection housing?

Just wanted to agree with P.P.40 regarding pulling the gear box.

Removing and inspecting the gearbox, ujoints, bellows, etc is an annual part of maintaining your outdrive. Once you've done it the first time, is quick and easy the next.

Be sure to replace all the two orings and get some perfect seal or Permatex aviation gasket sealant, I use this on everything.

With the gear box off replacing the hose connection is a snap.

BTW, I've replaced my hose connection and gasket twice without removing the gear box and found it to be fairly easy. However my outdrive has no corrosion and is not exactly the same as yours.

why are you replacing the fitting to begin with?

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

why are you replacing the fitting to begin with?

The end broke off due to corrosion. This boat only sees lake water but it still corroded.

 

[Don S]

Re: How do you install a new Volvo water connection housing?

If the connector corroded away, you can bet the bellows will be the next thing to go. Pull the upper gear box, change the hose connection, put on a new bellows and seals on the gear box and be done with it. If the bellows leaks in a Volvo 290 style drive, you will probably get water into the flywheel cover bearings and then you have to pull the engine to fix it.
With new bellows, new gear lube, new hose connection by pulling the gear box, it's an hour and a half to 2 hour job for even a first timer.
Read this thread, http://forums.iboats.com/showthread.php?t=309095

and here is the manual. (which won't really help much for this job)
http://www.4shared.com/file/48536730/fa3b3311/280_to_DP-C_Drive_manual.html

PS: PM's about boat problems are covered in my signature line. BELOW.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

Took the gearbox off last night. That wasn't hard at all. Upon inspection I found that the bellows was slit on the bottom allowing water to enter. Further inspection showed some very slight surface rust on the universal joint assembly. So water was getting inside this area. I will proceed to inspect the universal joints and probably replace them.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

Does anyone know how to remove the universal joint assembly from the gearbox? Does it just slide out?

 

[PiratePast40]

Re: How do you install a new Volvo water connection housing?

Does anyone know how to remove the universal joint assembly from the gearbox? Does it just slide out?

If you can get the clips off of the crosses, it's best to not remove the shaft unless absolutely necessary. In order to remove the shaft, you need to disassemble the gearbox.

This is where you start to get into some tricky areas for the DIYer. Here's what happened to me: The capscrews that hold on the clamping ring were frozen and I ended up rounding out the allen head sockets in the screws. I took it to an automotive machine shop and they milled the bolts out. That screwed up the clamping ring so I was then at the point on needing a replacement. At that point, I decided to call it quits and took it to a Volvo tech. He found several other issues with the gearbox but offered me an exchange for $450. The exchange unit had new seals and he also took my lower end and measured clearances so I had the right shims between the intermediate housing and the gearbox.

I thought I could safely pull apart the gearbox by watching the shims and not disturbing anything. I wasn't comfortable with measuring rolling torque and setting the torque on the end screw. I ended up being in over my head and needed to "seek professional help" :redface:. It also turned out that there was a broken roll pin on the bearing sleeve that I had missed. Others may have had better experiences but just wanted to let you know how I ended up with trying to disassemble and put new seals in the gearbox.

Others may tell you that it's a piece of cake, and it may well be a non-issue but think twice before you decide to take apart the gearbox.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

If you can get the clips off of the crosses, it's best to not remove the shaft unless absolutely necessary. In order to remove the shaft, you need to disassemble the gearbox.
QUOTE]

Believe me...I don't want to take apart the gearbox. I just want to replace the U-Joints. So I will leave everything intact and do the R&R on the U-Joints. Thanks for sharing your experiences. Lessons learned are always much appreciated.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

Well I tried to remove the inboard u-joint and you can't unless you pull the whole assembly out of the upper gear box. Wish I knew this before the wife picked up all the parts 80 miles away! Now I'm short new O-rings! If someone has ever removed the inboard u-joint without removing it from the gearbox I would like to know what magic spell they used

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

How do I get the stupid u-joint assembly out! I tried collapsing that snap ring and it needs the jaws of life to squeeze it. Do I have to remove the snap ring in order for the case to come apart or remove the u-joint assembly? Someone please give me assistance!

 

[captmello]

Re: How do you install a new Volvo water connection housing?

Here's how I did mine last year.

Look at the link. I removed the 4 screws #36 which released the gear box.
Those are the one's that PP40 stripped out. I remember them being tough, make sure you have the correct allen wrench.
Once the ring and gear box is removed, you can remove screw #33 and washer #34. At this point the ujoint assembly can be removed. Shouldn't need any additional orings or seals.


http://www.volvopentastore.com/UPPER_GEAR_UNIT_AQ_DRIVE_UNIT_290_851340/dm/*******.639422054--**********.340677815--store_id.366--view_id.315489

I do think replacing the ujoints can be done without removing the clamping ring #35 but I haven't tried.

If I recall the book suggests replacing part #'s 33 and 34 but I'm not sure why. I didn't but I put locktight on the threads on the advise of a local mechanic.

maybe a professional will chime in with some useful hints.

Good luck. Let us know what happens.

 

[PiratePast40]

Re: How do you install a new Volvo water connection housing?

Sorry to hear that you're having problems.

Have you been able to remove the outer u-joint? The inner should be the same thing. It's either a clip or a snap ring. If a snap ring, you need a good pair of snap ring pliers. A little penetrating fluid and a few taps with a hammer should help loosen things up.

As far as opening the gearbox to remove the shaft: Just like Captmello said, you don't need to remove the large snap ring holding the outer seal unless you're replacing the seal. Just remove the 4 bolts holding the clamping ring to the housing. If you decide to go this route, you really need to be following the manual.

 

[jberenyi]

Re: How do you install a new Volvo water connection housing?

I finally separated the clamp ring and u-joint assembly. I had no idea the clamp ring was that tight! Anyhow, I'm off to work to replace all the u-joints now and I should be able to put everything together when I get home. My only question is when I put the clamp ring back on the gearbox with the three shims....it says to use a sealant No.2 by Permatex. Do you have to seal between the shims as well? Not sure about this part.

PS Thanks so much guys for helping me.