Testing Resealed Alpha 1 Gen 2

[Jgranger01]

I just put everything back together on my outdrive and installed it back on the boat. I changed the seals but didnt mess with any of the gears or shims and everything seemed to go back together just as it should. I ran it on muffs and slightly put it into forward and reverse and it smoothly went through the gears. Whenever i would go in forward with a little higher rpm there was a weird clunky noise not super loud but went away at higher rpms. Is it normal for the outdrive to make a little noise when operating on muffs instead of in the water. I have the drive down while testing. Any input would be appreciated im just trying to be as confident as i can before i water test.

 

[Rick Stephens]

Once in gear should not hear anything but a soft whir, at most. No clunking.

 

[Jgranger01]

Once in gear should not hear anything but a soft whir, at most. No clunking.

Any idea what can be the culprit of the clunky sound in gear. I’ve read in other forums that once in the water that the clunk will go away because of there being load on the assembly.

 

[Rick Stephens]

Clunking or clattering says something is loose. If was me, I'd split the cases again and check the upper for something wrong in the gear fit. I had one of the Gen 2 uppers that I resealed. Takes the rolling torque to reassemble. After running for a few minutes that fit was loose and rattling. I pulled apart and re-torqued and no issues afterwards. I would have hated to keep running it. The gear teeth and bearing would of been thrashed. I figure at only 5 inch pounds I didn't get the bearings pulled tight the first time.

 

[Jgranger01]

Clunking or clattering says something is loose. If was me, I'd split the cases again and check the upper for something wrong in the gear fit. I had one of the Gen 2 uppers that I resealed. Takes the rolling torque to reassemble. After running for a few minutes that fit was loose and rattling. I pulled apart and re-torqued and no issues afterwards. I would have hated to keep running it. The gear teeth and bearing would of been thrashed. I figure at only 5 inch pounds I didn't get the bearings pulled tight the first time.

Thanks for troubleshooting with me rick. This is gonna sound stupid but i had a misfire and the clunking noise was just the engine. I corrected the firing order and now its running perfect. I ended up buying that expensive torque wrench and torqueing that bearing the right way and as of now seems to be operating as it should. Thanks for all the advice from you and chris alongthe way for this resealing project you both are awesome.