replacing bellows on Alpha one Gen2

[dlogvine]

Man, this is such a pain in the neck! I was going to replace the gear lube monitor hose in the bell housing, but since it required complete gimbal removal, I decided to replace the bellows and the bearing as well. Took me almost 6 hours and still Im not finished. I struggled mightily with installing exhaust bellow on the bell housing, the tool that I purchased did not fit because of the shift lever being right in the middle of the hole. Finally I managed to pull it on and tighten the sucker. Then I pulled the second bellow on and of course I was not able to insert the ring. When I tried to push it in with the installation tool, the bellow was sliding off the bell housing. So I gave up for now and looking for an advice on how to finish installation of the bellow. Thank you. Will continue tomorrow. Seloc manual really sucks!

 

[dlogvine]

U joint bellows

 

[dlogvine]

Also, a gear shift lever, it has a lock screw that looks to release it, but when I tried to remove this screw, it appeared to be of a very soft aluminum and I did not want to break it, so I stopped. This lever was getting in the way when I tried to use the bellows pulling tool. But now im curious if this is actually a screw (bolt) or a rivet type insert? Will make a picture tomorrow morning if necessary.

 

[tpenfield]

You really need the Mercruiser Service Manual to do outdrive work. the generic manuals just won't cut it.

It is a bit hard to tell, but it does not look like you have the u-joint bellows inserted all the way into the bell housing. that might be why you cannot get the retaining ring to install.

 

[Rick Stephens]

+1 to Mercruiser manual. Anything else is worthless

you must remove shift shaft. It may have the screw locktighted in which is removed after a little application of heat. The screw is steel but can be damaged. Correct size screwdriver is essential.

I ended up up using carb cleaner as a lubricant to insert the retainer. Merc manual and many forum members recommend Powertune, which is a merc product. Usually you can press on with your fingers and maybe a small piece of wood when the bellow is in place and lubricated.

 

[Scott Danforth]

achris has videos that follow the factory manual process. link in the stickies

you can view factory manuals online. link in the stickies.

here it is if you need. Boatinfo - boat brochures and manuals for boats and marine engines!

 

[Bt Doctur]

 

[Scott Danforth]

when I worked at the heat exhanger company, we had P80 lube for assembling rubber parts. worked great. https://p80lubricants.com/what-are-p-80-lubricants/

ky jelly also works for getting the retaining ring to seat..... however the counter people at walmart look at you funny when you walk out with a tube of ky and 6 quarts of gear lube and 2 rolls of scott paper towels

 

[Bt Doctur]

I`ve been using rubbing alcohol , works good

 

[JASinIL2006]

I used Powertune and was able to slide the retaining ring on with my fingers, easily. That installation tool looks like a pain!

 

[dlogvine]

For exhaust bellows, i managed to use the expander tool without removing shift shaft. Cant say it was easy, but it was workable. I was just affraid to damage the holding bolt. So i disconnected the hands of the expansion tool and inserted them one by one into the exhaust bellows hole. Had to turn them 180 degrees. Once they were positioned right, i reconnected the pieces with the bolt and was able to use the tool. Of course, to remove it i had to take it apart again and did it 4-5 times until bellows were in place. Next time Ill be better educated. Ill have to repeat the same procedure for my older 1993 larsen boat too.
one other question, the only rubber boot that i did not replace was the shifting gear boot. I was concerned that i had to go all the way to the shifters inside of the boat and disconnect the shifting cables, thread them out and then have a great time trying to adjust them back following seloc instructions. Also i was not sure what socket or wrench should i use to disconnect the shifting gear cable from the bell housing. The nut appears to be deep in the bell housing and reaching it looked quite a difficult task. Thank you

 

[harringtondav]

+1 to Mercruiser manual. Anything else is worthless

you must remove shift shaft. It may have the screw locktighted in which is removed after a little application of heat. The screw is steel but can be damaged. Correct size screwdriver is essential.
.

Yes and yes. I ground one of my hammer operated impact driver bits to fit that screw. On reassembly I use the blue Loctite removable thread sealer. It still puts up a fight, but not nearly as bad as the green bearing locker. A narrow blade screwdriver with a crescent wrench on the shaft flats will work, but you have to keep the screwdriver pushed in tight, or you will strip the slot. Then it's time for your angle grinder and new shift linkage parts.

Tying the bell hsg down helps when pulling both bellows onto/into place. The manual doesn't call for it, but bellows adhesive applied in the driveshaft bellows bore and on the bead will keep a stubborn bellows in place. But the bead must be fully seated in the groove, or you will get nowhere with the driver

I usually have my 2-4-c grease gun to lube the shift arm seal, pivots, etc. so I lube the retaining ring w/this. The ring must be square and centered on the bellows, else you'll pound and get no where. Lined up it will tap right in.

 

[dlogvine]

achris has videos that follow the factory manual process. link in the stickies

you can view factory manuals online. link in the stickies.

here it is if you need. Boatinfo - boat brochures and manuals for boats and marine engines!

Hi Scott, thank you very much, much better service guide than Seloc. Muchos graciaz!!!

 

[Scott Danforth]

dlogvine ....the stickies have the answers to 90% of the questions asked.

 

[dlogvine]

Scott, what are stickies?

 

[poconojoe]

The stickies are the threads highlighted in yellow. They describe common procedures. They are at the top of each subject section. For instance, if you go to "forums" and pick a section such as where you posted this thread..."Mercury Mercruiser Sterndrives and Engines", there are stickies at the top.

 

[harringtondav]

Scott Danforth Same question. I know what stickies are, but don't know where to find them. (?)

 

[Scott Danforth]

At the top of every forum are pertinant stickies. In the hull and restoration forum are stickies on hull restoration, in the Mercruiser and Volvo forums are stickies on I/O Motors

 

[dlogvine]

thank you, learned something new Also I managed to snap the insert sleeve ring into the U-joint bellows! YEAH!!!
Now since the gimbal is assembled , all the bellows and hoses in the bell housing are replaced, how do I check if I did not goof anywhere, before taking the boat on the lake and risking flooding the boat if I screwed up anywhere. Thank you.

 

[Rick Stephens]

thank you, learned something new Also I managed to snap the insert sleeve ring into the U-joint bellows! YEAH!!!
Now since the gimbal is assembled , all the bellows and hoses in the bell housing are replaced, how do I check if I did not goof anywhere, before taking the boat on the lake and risking flooding the boat if I screwed up anywhere. Thank you.

Great!

Knowing you got it perfect is the trick. Only way I know is to back it in and look before you drive it off the trailer. I don't do that when I drop my boat in the lake any longer unless I just worked on it, but before I leave the dock area I let it idle in forward heading out while I pop the doghouse and look at everything. Water or oil leaks, gas leaks!, loose parts, broken belt, etc. Every last trip - even though I ran it on the muffs before leaving home.