Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

[DogCompany]

Hello,

Boat: 1996 Sea Ray 175 Five Series
Engine: Mercruiser 3.0L/LX Alpha One
Engine Serial Number: 0F794366
Transom Serial Number: 0F845055
Drive Serial Number: 0F871236

Just bought this boat. Took it out, ran great. Brought it home and found the green/turquoise puddle on the ground. Lurked on this site for a long time and diagnosed the problem. Below is a picture of a hose on the lower unit, from underneath. It is the hose that comes from the Drive (Gear) Lube Reservoir. There is a metal fitting on the fore side, can't see se aft side. The hose length is about a foot. Each end seems to go over a fitting with a plastic crimp (at first I thought it was zip ties, they are not, but similar). The leak is come from the aft side of the hose. It appears to be cracked/weathered where it bows on the bottom side. So, it seems as though either the aft fitting is lose or the hose is weathered/cracked. I want to replace the hose and the plastic "zip ties" (I know there is a proper term for those, substitute that for zip tie). I live in the Seattle area and it is boating season and all the shops are booked. My question is can I do this myself without removing the lower end? If so, which parts should I order? Seems like all I need is the hose and the two "zip ties". It seems really hard to get to though, which has me thinking the unit has to be removed to access. Your input is appreciated. Below are pics of the leak:

 

[drolds72]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

is the hose pliable enough to repair using a brass or plastic splice? Like a double ended barb? cut the hose at the leak, clean up the ends and repair. Otherwise you are going to need to remove the bellhousing- essentially all the work required to replace all the bellows...

 

[Don S]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

See if these help.

View attachment Gear lube monitor.pdf

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

is the hose pliable enough to repair using a brass or plastic splice? Like a double ended barb? cut the hose at the leak, clean up the ends and repair. Otherwise you are going to need to remove the bellhousing- essentially all the work required to replace all the bellows...

I think the clips, or zip ties, could be loose too. I'd prefer to replace the entire tube and the clips holding the ends of the tube on the fittings. Seems so simple if I could just get to it :confused-new:

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

See if these help.

View attachment 193541 View attachment 193542

For future reference, in the left manual, the replacement process is described on page 4A-46 After reading it seems the answer is I have to remove the stern drive. Sucks, all I need to do is place one 10" hose.

 

[MarkSee]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

Seems so simple if I could just get to it....

Welcome to IBOATS.

Sometimes those lube fittings/hoses necessitate removal of the drive to provide access to where you might need to get to.
Here's a link to the service manual to investigate further: page 4a-42 starts around where replacement comes in.
Boatinfo - Mercruiser Service Manual nr. 14 - 1991-Current - Sterndrives Alpha One Gen II</

Mark

edit: guess you beat me by a few seconds making my post of no use.

 

[achris]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

For future reference, in the left manual, the replacement process is described on page 4A-46 After reading it seems the answer is I have to remove the stern drive. Sucks, all I need to do is place one 10" hose.

Removing and refitting the drive will be the easiest part of the job.... Trust me, it takes just a few minutes to remove, and about the same to refit..

Videos:

Removing Alpha drive
Installing Alpha drive

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

Removing and refitting the drive will be the easiest part of the job.... Trust me, it takes just a few minutes to remove, and about the same to refit..

Videos:

Removing Alpha drive
Installing Alpha drive

OK. Haven't watched the videos, but I like the sound of it. Thanks for posting the vids. I promise to follow up and close the thread.

 

[Don S]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

Not only is pulling the drive easy, it should be done yearly for maintenance, and inspecting the bellows. The ujoint bellows should be replaced every 5 or 6 years so it doesn't deteriorate like that little hose did. If it goes bad, things really start getting expensive to fix as you also replace gimbal bearing, u-joints, drive yoke etc.

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

See if these help.

View attachment 193541 View attachment 193542

I used the serial number on my boat and it came up with a diagram that also included the hose I was looking for:

I am ordering these parts:



Will also replace u-joint bellows while I'm at it. Now to watch the videos.

 

[Don S]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

You don't have the round reservoir, besides, you should be using the drive serial number for that hose, not the engine number.

It's still the same hose and clamps, so that isn't a problem.

 

[smassey22180]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

Even with the outdrive and bell housing removed, I still had trouble getting the new hose on the transom end. The tip of fitting was twisted up against the transom housing and there was no room to slide the hose on. I had to go inside the boat and loosen the fitting so it would pivot.

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

You don't have the round reservoir, besides, you should be using the drive serial number for that hose, not the engine number.

It's still the same hose and clamps, so that isn't a problem.

Oddly enough, I do have the square reservoir...maybe a retrofit from a previous owner. Thanks for the tip on using the drive serial number. Parts ordered, waiting for delivery. One question, except for the spedometer and 6 bolts, is there anything else that needs to be reomved? I watched both videos and I didn't see anything. Isn't this Gear Lube Monitor Hose I'm replacing connected?

 

[achris]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

.. Isn't this Gear Lube Monitor Hose I'm replacing connected?

The gear lube monitor are 'push together to open' fittings, and requires no intervention on your part...

Once you get the drive off and have a look at it you'll understand....

 

[Don S]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

Oddly enough, I do have the square reservoir...maybe a retrofit from a previous owner.

The square one is the one it should have from the factory. the 91 and 92 Gen II drives are the only ones that would have used the round ones as it would be an option not OEM, and they didn't go through the gimbal housing.

There are no video's for changing that hose.

 

[achris]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

I think (from memory) the square monitor was a factory option on the 3 litre (gen IIs), standard on all other engines. I'm also pretty certain at some point later it became standard on the 3 litre too, but can't remember when.

Chris........

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

I successfully removed the lower unit. Followed the videos perfectly. However, I can't access the Gear Lube Monitor Hose, see picture. What else do I need to remove to access the hose? Any video suggestions are most welcome Thanks for your help. The part should be here next week:

 

[achris]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

You may have to remove the hinge pins and pull the bell-housing back slightly. To access the hinge pines, turn the steering about half way in one direction to expose one of the trim senders. Remove the 2 screws holding the sender on, then remove the big steel hinge pin. Turn the steering the other way (being careful not to trap the loose trim sender) and remove the other sender and hinge pin.... Be careful, as there are milar washers on the inside of the gimbal ring, next to the bell-housing... They have a habit of falling out very silently and you don't even know they're gone... Not good when you come to re-assemble...

Chris.......

 

[DogCompany]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

Is a hinge pin removal tool required or can I use an existing tool? After watching a few videos and looking how tight these spaces are to access, I'm starting to doubt this procedure. It was reccomended to me by a friend that I don't need the reservoir, just clamp it off. Doesn't sound like a good idea to me even if it does work because water might leak into the gear lube system. Thoughts?

 

[MarkSee]

Re: Mercruiser 3.0L/LX Alpha One - Gear Lube Hose Leak

a 1/2" allen key works instead of the hinge tool...

Keep the reservoir

Mark