Major Damage to Sterndrive Past Weekend - Need Input

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
I originally posted this in the outboard section. Just realized posted wrong, moving to I/O.



Had everyone's most dreaded nightmare... a rock below the water line. After spending hundreds of hours working on my tow vehicle and boat during the off season (got the boat for $1,100 at end of last season) to get it ready for this summer, definitely disappointed about what happened.
**
Need some input, below you will find the order of events as they unfolded this past weekend. After that you will find my major questions that I need input on.
**
Boat is a 1976 Invader Continental Tri-Hull. Everything mechanical is Mercrusier. Engine is an inline 6 cylinder 250 cu in at 165 HP (MCM 165).
According to the manuals, the stern drive is the MC-I.


Run down of the "major damage" events:
Okay, so, this past weekend I hit something in the water, pretty sure it was a large rock based off of the damage. All I know is it was below the water line, made a HUGE thud...
I immediately killed engine to survey the damage. Trimmed up the stern all of the way so I could more easily see the propeller. The trim went all the way up without any issues. Surveyed the propeller and could see significant bend in one of the blades with only minor scratches on the others.
Swam under the boat, couldn't feel any hull damage.

At this point, decide I was going to go back to the launch ramp to grab spare prop and throw it on and continue.
HOWEVER, tried to hit the button to lower the stern back into the water and it would not go down. The hydraulic system sounded like it normally would, like it was pumping fine and trying to move it, but it was not actually moving. Keep in mind, I was able to raise it up immediately after the incident, but it won't go down but it sounds normal like it?s trying to go down...
I realize most "smart" boaters would have called it quits here and looked for a tow... Anyways, since I couldn't get the trim to go back down, but had everyone move to the back of the boat to keep the prop under water... Started up the boat, put it into idle, and started moving. There were not any issues other than kicking water up, but prop was fully under the water... Did this for about 10 minutes before finally deciding to flag someone down for a tow, it was taking too long in idle.
Didn't run it anymore, got tow to the ramp, and then loaded it up with ropes.
Once out, surveyed the damage, that?s when the cursing started... Right at the front of the stern drive, on the front most part of where the propeller shaft is. There was a 2" round dent in it. Around the dent was a crack and the gear fluid/oil was dripping out. I put a cup under it and was able to collect about 5 ozs of fluid before it was fully empty.

So, full summary
1) Bent prop
2) Trim system went up, but can't get it to go back down, but sounds like its running fine
3) Dent & Crack on the front bottom part of the lower unit, all fluid leaked out





Questions:
1.0) PLEASE NOTE! Disregard the rest of question 1 below. I came home today and tested the trim system and it DID succesfully go fully down! So I think the trim system is fine. I have no idea why the trim system would not go down in the water. It also would not go down when I first took it out of the water. But after letting it sit for 2 days and trying to day, it is able to fully list it up and down. It takes normal amount of time for both up and down and seems fine. Anyone have any ideas why it would not have worked on Saturday but is working fine now?
1) Any ideas why the trim system would not lower the stern drive? It had no problems raising it, it?s fully up now, but can't get it to lower... Any ideas?
1a) I don't see any damage to the hydraulic lines or the hydraulic cylinders...
1b) If I detach the hydraulic cylinders from the stern drive, am I okay to test moving them in an out with no load?
1c) Assuming I am okay to test them with no load, if they move in and out, is this an indication that I am okay? (My thoughts here are that perhaps the gears within the lower unit are "wedged" in such a way that the drive can't lower down now that it is fully up)
2) I know I messed up and should not have driven for the 10 minutes... I realize at the VERY least I will have to replace the lower unit because of the crack...
2a) What other things will I more than likely need to replace?
2b) What is the likelihood that I will need to also replace the upper unit?
3) When rotating propeller, there is now a clicking sound coming from the stern unit. It sounds about once per rotation. Keep in mind; this is while rotating it with NO gear fluid in there from it leaking out... I am hoping this clicking is a result of the damage to the front of the lower unit or from having no fluid, but is this any indication that I will need additional repairs anywhere else?
4) If I am buying a stern drive off of Craigslist, any tips on making sure I acquire the correct one? Do I just look at serial numbers and make sure it falls within the ones in my manual and make sure it?s the same design? Any "gotchas" to watch out for?


MY PLAN:-I have already located 4 different stern drives that should work with my boat on Craigslist. 2 of them are upper and lower unit for $400 and $500 (1 in great condition and other in crappy/so-so). 2 of them are for lower unit only $400 and $400 (1 in great condition, other in so-so).
-Since it looks like I will be able to buy an upper and lower unit for the same price as a lower off of Craigslist, my thought was to lean towards upper and lower. That way if I find out there is damage to the upper unit, then I already have one available
Concerns: Since the stern drive won't lower, I am concerned that even if I replace the entire stern system, that the hydraulic system might have issues... I would hate to start the repairs only to find a lot more $ that needs to be spent.


I have also added in pictures.

Picture of propeller:


Picture of zoomed out side view of damage to lower unit:


Picture of zoomed in side view of damage to lower unit:


Picture of zoomed in view from front of lower unit of damage:
 

haulnazz15

Captain
Joined
Mar 9, 2009
Messages
3,720
Re: Major Damage to Sterndrive Past Weekend - Need Input

Partner, for an extra $200 or so, you can get a brand new complete upper/lower from SEI. I'd just go ahead and replace it all since it is more than likely OE from 1976.
 
Joined
Mar 27, 2010
Messages
3,008
Re: Major Damage to Sterndrive Past Weekend - Need Input

Gonna have to agree. You might luck out with the used drives but... They also might have seal issues, or need u-joints, definately the impeller. gonna add couple of hundred minimum to get em ready to bolt in.

The new SEI drives are aftermarket and come with 3-year warranty. You would use the SE 106, Alpha 1 equivelant with the short yoke, they're sold: short-older and long- newer. APX $1200.00 complete upper and lower ready to go.

If you can open the top cover on your upper and confirm there is no damage there they sell the halves individually as well.

Good luck,
 

skipdow

Cadet
Joined
Apr 4, 2008
Messages
26
Re: Major Damage to Sterndrive Past Weekend - Need Input

If you have insurance then they can replace the drive.... My father did the same thing a year ago.
 

Doernuth

Petty Officer 1st Class
Joined
Jul 6, 2010
Messages
332
Re: Major Damage to Sterndrive Past Weekend - Need Input

First the hydros could be bad. It sounds like they are not pulling the drive down and there wasn't enough force on the downside to pull the drive down when in the water but the weight was enough to push down out of the water.

Replacing the outdrive is not as simple as just matching serial Numbers you need to get the correct gear ratio also. These are dependent on the engine that they are attached too. Come in a couple of varieties. I have a Sea Ray from 1977 with twin 165's (same engines) with gear ratios of 1:1.65.

Second you bent too blades on the SS prop from the photo not one. Whatever you hit you hit really hard.

Pull the outdrive. Seperate the upper and lower. by running it you probably got water in the upper so take covers off and check. Prob time for a whole new unit, both parts. Check the hydros as well and make sure they are opperating to spec.

Keep us informed of the repairs.
 

Utahboatnut

Senior Chief Petty Officer
Joined
Jan 15, 2009
Messages
785
Re: Major Damage to Sterndrive Past Weekend - Need Input

Check your u joints real well too running that way for ten minutes may have done some damage to them.
 

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
Re: Major Damage to Sterndrive Past Weekend - Need Input

Partner, for an extra $200 or so, you can get a brand new complete upper/lower from SEI. I'd just go ahead and replace it all since it is more than likely OE from 1976.


Lot more than 200. I can get a upper and lower from Craigslist for 500 for great condition. Would be another 700 for brand new.

One in particular from Craigslist comes with a brand new lower body from SEI with an upper body that has been looked over and repainted for only 500.

I am fairly comfortable with Craigslist, just afraid I'll buy one that doesn't match on my boat.

I agree it makes sense to go with brand new if it was 200. But understand, I bought my boat for 1,100. I'm not looking to pay more money for a new stern drive than I paid for my boat.


PS - I do have insurance, but didn't bother with comprehensive for the sole reason of "well, if I wreck something and its my fault, and its going to cost more than 1,100, I'll scrap the boat"... I don't think any insurance company would pay for these repairs because it costs more to go the brand new route than my boat is worth.
 

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
Re: Major Damage to Sterndrive Past Weekend - Need Input

First the hydros could be bad. It sounds like they are not pulling the drive down and there wasn't enough force on the downside to pull the drive down when in the water but the weight was enough to push down out of the water.


Sorry, I think I didn't explain this well before.

I didn't have anyone stand on top of the out drive to hold it in the water. I just had people move to the back of the boat. This was because once I tilted the stern drive up, the prop was about 1" below water still. So I had all the weight move to the back of the boat to lift up the front end. It was enough to get the propeller far enough under the water... I did this because I was just concerned about the impeller and everything.



Please note, I believe the hydraulics to be good. When I tested everything last night, the hydraulics seemed to function fine. Not sure why they would not work on Saturday.


Tonight I will be removing the lower unit off of the stern to start surveying the damage, before doing that, I will have someone try to pull up on the drive while trimming down... Just to help eliminate the concerns that the hydraulic system is possibly only working out of water because of less force on it.
 

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
Re: Major Damage to Sterndrive Past Weekend - Need Input

If you can open the top cover on your upper and confirm there is no damage there they sell the halves individually as well.

Good luck,



Anyone know any website that have a walkthrough of things to look for when taking apart the stern? I was going to remove the lower unit tonight, but would like some guidance on how to tell if the upper unit is good not.

I have a manual I purchased as well as the online manuals from forums. But they don't always describe "when taking apart your stern, look for xy&z, otherwise you might have jacked it up"... But not sure if there are any websites with pictures or videos that describe what to look for.

Definitly up for only buying a lower unit if I can confirm that the upper isn't damaged. But need to make sure I know how to TELL if its damaged or not prior to purchase.
 

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
Re: Major Damage to Sterndrive Past Weekend - Need Input

Should I just leave the upper unit on the boat and remove the lower unit from the upper? That way I don't have to get new seals and o-rings?

Or is it recommended to remove the upper in order to work on the lower?
 

Kainon

Chief Petty Officer
Joined
Sep 13, 2009
Messages
608
Re: Major Damage to Sterndrive Past Weekend - Need Input

If you got water in the upper its only a matter of time before the bearings are junk, need to get the top cover off and get some WD40 on them quick.

As for the hydraulics, run them up and down a few times to get the air out, check for leaks. the drive is supposed to kick up when you hit something. cycle up/down about 5-8 times, check the oil level in the pump to..

You can use an Alpha One Gen I on there, but the gear ratio needs to match, your inline 6 uses a 1.65R.. dont by a 1.98 or 1.84 you'll have to change props, and the speed and power wont be right. Mecruiser went to newer gear ratios, I think 1.64 which is fine. May find that on rebuilt drives.
 

chomamma

Seaman Apprentice
Joined
Jun 7, 2010
Messages
36
Re: Major Damage to Sterndrive Past Weekend - Need Input

Curious. It's sort of hard to see, but if it isnt too bad maybe it can be repaired. What is it made from? Cast aluminum? Steel?
 

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
Re: Major Damage to Sterndrive Past Weekend - Need Input

As for repairing it, I have no idea what kind of metal it is.

When it happened and I fianlly saw the damage out of water, that was my first thought, that perhaps it could be welded. But I assumed that the dent would be pushing inward on the components behind it. I imagine there are gears behind it or something that I assumed that trying to repair it would not be possible.

Unless perhaps there was a way to pop the dent back out from the inside, but I assume that would be difficuilt to get to that area and would have to remove all of the gears.


Sure would love to just weld it up and call it a day, but I assumed people would cring and laugh me away from the forums for even proposing the idea...

I don't know, anyone else think something like this is worth considering?

If this is something even worth considering, I could post higher resolution photos for you to get a better view.
 

Dakota47

Senior Chief Petty Officer
Joined
May 22, 2007
Messages
722
Re: Major Damage to Sterndrive Past Weekend - Need Input

Clean it up and slap some JB WELD on it. re-fill the outdrive. and go boating. cant hurt trying.
 

chomamma

Seaman Apprentice
Joined
Jun 7, 2010
Messages
36
Re: Major Damage to Sterndrive Past Weekend - Need Input

If it isn't "dented" too bad and doesn't touch any gearing there be enough room for lubrication to go where is needs too. Maybe take it apart and have a look see. You gotta do that anyway. Not sure what you would risk by trying to repair it. You can pressure test it or watch for leaks. Doubt it would cost you any more if it did.... Sorry, but I am just a tight wad...
 
Joined
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Re: Major Damage to Sterndrive Past Weekend - Need Input

Clean it up and slap some JB WELD on it. re-fill the outdrive. and go boating. cant hurt trying.

Try it in the driveway shifting thru the gears and see what happens. If your considering the drive a loss anyways, the worse thing to happen is you'll get stranded on the water.

Have a VHF handy and membership to Safesea/Seatow, keep it close to the ramp for the day. prob won't take long for the gears to go kaput, if they r gonna. Maybe you'll get lucky.;)
 

ispaydeu

Seaman Apprentice
Joined
Apr 6, 2010
Messages
40
Re: Major Damage to Sterndrive Past Weekend - Need Input

Okay guys,

Last night, with a friend, test the hydraulics "under load" and am confident they work find both up and down.


Remove the upper unit from the boat, the the lower unit from it.

The upper unit looks great. So will plan to re-use it. There was a little bit of water, in the gimbal area, but it was all in the LOWER part of it, around where the water passes through, in the oring area. The only area that showed residue of "what gear oil" or anything was in the cavity that houses the shift cable in the housing. But it looked old, not recent.

So I am just going to clean up the upper unit, and buy the stuff needed for reattaching it (new gasket, o rings, and general purpose lubrication). While I have it off, you guys have any other "general maintance" recommendations?


For the lower unit, we took it off as well. looked everything over, the inside looks "clean as a whistle". For something that is 34 years old, I expected rust and stuff, but it looked good. There was still gear fluid clinging to areas but it was normal, not watery.

For kicks and giggles, I also pulled the impeller to get more acquainted with it. Was surprised because it looks great (never checked in on this stern before).


So, OVERALL, it appears as though I am only left with the lower unit to worry about.



Do you guys REALLY think that JB weld would be enough? Around the 2" dent, I would say there are very rigid cracks around half of the diameter of the dent. That was where it was leaking from. I would imagine that the "rigidness" of the cracks is enough for the JB Weld to get up in there and get a decent bond. But do you REALLY think that would hold up over time? Or are we talking a temporary fix that would only work for a while?
... I guess I don't have tons of experience with JB Weld, didn't realize it would be strong enough. I assume I would have to truly weld it.

On a side note, when spinning the propeller yesterday before disassembling anything, it was smooth without any issues or clicking. So that might be some indication that the dent isn't intruding into any gears.


How much work would it be for me to disassemble the lower unit enough to be able to see past the propeller shaft and see if there is clearance? I realistically don't think I would be able to see it well enough to tell if there is damage.

Let's say I do proceed with the JB Weld, I would be scared that it wouldn't be permanate (again, I am inexperienced with JB Weld), and would end up working the first time or two. Only to go out for a full day of tubing and stuff, have it start leaking, and do MORE damage than I originally did. What are your thoughts on this?

I am all game for the JB Weld, I would just hate:
1) To end up doing more damage because of gear fluid leaking and not realizing it and as a result mess up the upper unit or worse...
2) Also would suck to buy the expensive gear fluid, only to find out that its going to leak.


Someone mentioned pressure testing it. What is the best way to go about pressure testing it? I would certainly prefer to do that first before wasting the money on the gear fluid. Also, what PSI range would it need to be in?
 
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