Re: Replace PDS bearings with flywheel cover installed?
I'll try to describe the process as well as I can. It's been 6 years since I did the job.
I'll skip to the drive shaft removal assuming you've removed the upper gear box from the outdrive and the motor is removed, or at least slid out of the way. I will preface this by saying that if I were to do this again, I would remove the motor with the F/C attached as recommended by Don S. However, my boat is a 20' bowrider and engine pulling is about a 20 min job. I can understand if someone is working on a boat that is harder to remove the engine, the job could be much easier/quicker if you could just move the engine toward the bow, if only a foot or so while leaving the F/C attached to the transom shield.
Basically, the driveshaft can come out either way, forward or aft. But I would take it out the rear. With the upper gear box removed, you can see the PDS (primary drive shaft) sticking through the grease seal. Pull out the seal, you'll be replacing it. Behind the seal will be the first snap ring which keeps the seal from sliding in too far.
The snap rings can be a real PITA. I've seen it recommended that you buy a long needle nose pliers and grind the tips to resemble a snap ring pliers. I didn't see this until later but would have done it. I used a snap ring pliers and they just were to small. But I found that loud swearing helped a lot and I finally got them out.
Anyway, Once the first snap ring is removed you'll be able to see the aft set of bearings. there is another snap ring that holds the bearing at that point. There is also a smaller snap ring that goes around the PDS at that same depth. The smaller snap ring can be left there until after the shaft has been removed, but you still need to remove the larger ring around the outside race of the bearing. Once these two larger snap rings have been removed, you can move to the inside of the boat. At this point you should be able to pound the PDS out the back of the F/C. It should come out with the rear bearing and the smaller snap ring still attached. K2 - this is where the "Dead Blow" hammer comes into play. I don't know what a dead blow hammer is, bit I think I used a 3 pounder on a block of wood.
Inside the boat with the motor out of the way, there is another rubber seal. remove the rubber seal, and again there is a larger snap ring holding the front bearing in place. With the PDS out of the way it I should be easier to remove the snap ring. Once the snap ring is out, you can pound the bearing out the front of the housing from the rear, outside the boat using something long enough to go through the F/C and the right size to hit the bearing. I may have used a piece of 2x2 lumber...Keep in mind you don't have to worry about damaging the bearings at this point since they are going in the garbage.
So now you should have everything out. you just need to remove the small snap ring from the PDS and remove the rear bearing from the PDS. I think I used some PVC pipe to drive the bearing off. I'm in the home remodeling business so I've got those type of things kicking around the shop.
Clean up all the grease from the F/C and your ready for installation. Install is pretty much the opposite. You'll just need to be creative when it comes to installing the bearings so you don't damage them. start by installing the front bearing into the F/C followed by the front snap ring. Next install the rear bearing onto the PDS. I think I actually supported the bearing on something and drove the PDS into the bearing. And install the small snap ring. Now install the PDS in from the back of the boat. Again, you'll need something that will put the pressure on the outside race of the bearing to avoid damage. then install the larger snap ring that sits against the rear bearing, and the snap ring that holds the aft seal. Once you get to this point, I would pump grease in through the zerk on top of the F/C until is start oozing through the bearings. Once the seals are installed you don't want to overgrease as it can cause the seals to pop out. I've also heard of people recommending gluing in the front seal to try to avoid this, but I didn't. Once you've got it greased, install the seals the way described in this link
http://forums.iboats.com/attachment.php?attachmentid=124018&d=1322930991
well that was a lot of typing and I may have missed something. Feel free to correct me or ask any questions if something seems "off".
