Yellow "gunk" in engine compartment... smells like gear oil

[SotRH]

1986 Harris Kayot 22' Deck Boat
Chevy 350 Mercruiser
260HP
Alpha 1 Outdrive

Hello Everyone!
I just put my boat back in the water (been out since early Nov 2012). When I took it out for the first run, I kept thinking I was smelling gear oil. The odor kept getting stronger, so at my first chance I stopped, shut the engine off, and started checking fluid levels, lines, connections, everything I could think of. I noticed that my bilge pump was on but was sucking air. I checked the manual switch, it was off. I crawled under the engine to check the float switch, it was jammed up with yellow gunk (description below) causing the bilge pump to run. The "gunk" was dripping from above (the bilge pump is under the engine near the transom). I opened the engine compartment wider to find a that this "gunk" was splattered all over the transom behind the engine.

The Gunk: I manage a Oil Change business for a living. Sometimes when our bulk tanks get low, air gets in the lines and this brand new oil comes out of the pump completely aerated, looking like a greasy, yellow whipped cream. This stuff looks exactly the same; however, it does not smell at all like motor oil. Although it looks nothing like it, it smells exactly like that the gear oil that I put in the outdrive.

I checked the oil level, the p/s, the hydraulic flluid... p/s was 1/4qt low. I pulled the boat back out of the water and checked the outdrive... still full, no water.

The following was done between Nov (when I pulled it out of the water) and when I put it back in:
- changed oil and oil filter
- changed lower unit oil
- replaced bilge blower
- winterized with antifreeze (flushed back with water before putting in lake)

Any ideas what this is or where it might be coming from?

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Pull the drive and check your bellows for that same yellow gunk.
When you changed the gear lube, did you use the Merc Hi-Performance gear lube (It's green or bluish green) or something else yellow in color?

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

When you changed the gear lube, did you use the Merc Hi-Performance gear lube (It's green or bluish green) or something else yellow in color?

I used all Merc products: oil, lube, filters ... The gear lube was blue.

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Pull the drive anyway. With the water and some rust, the color could change.

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Don S - Thank you for your prompt responses! You are always very helpful.

Okay. I will plan to do that tomorrow, after work (church night tonight).

I welcome any instruction, advise, tips, etc., as this will be my first time removing an outdrive.

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

First you put the shifter in forward

After putting the shifter in forward, with the drive down, remove the trim cylinders from the back of the drive.
Remove 6 nuts holding the drive to the bellhousing, then pull the drive off.

Here's a .pdf file condensed from the manual on how to remove it.

View attachment A1 R&R.pdf


Here is some other stuff on the job from the sticky at the top of this forum.

http://forums.iboats.com/mercruiser...cellaneous-mercruiser-information-329915.html

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil



So, the seal where the shaft goes into the drive appears to be shot. In one picture, you can see me holding a chunk of it that fell out next to another spot where it appears to be bowing out. The liquid you see in the bellows feels and smells like mostly gear oil, but there is some water in it.

There are a couple of spots where chunks are missing from the large thin gasket between the drive and bellhousing. I'm assuming that is how water got in, since the bellows, after thorough inspection, seem to be undamaged and still very flexible (service records from the previous owner show that they were replaced a little over two years ago). Someone used what appears to be some sort of blue sealant that is just crumbling everywhere.

So, from what I see, and based on my limited understanding: new gasket between drive and bellhousing and new seal at top of drive?

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

The gasket has nothing to do with water in the bellows, that big rubber ring, and the bellows itself is what keeps water out of the bellows.

Check the gear lube in the drive, it's probably milky too.

You also need to get all that blue sillycone cleaned off of everything. The gasket goes on dry, and the rubber ringes are glued into place on the bellhousing with bellows adhesive. I would replace the bellows as well, or you could be doing this all again.
You need new ujoints, gimbal bearing, and probably the ujoint yoke going into the drive. The input yoke gets rusty and destroys the input shaft seal in the drive.

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

I checked the fluid in the drive, and it still looks very clean; however, it's only been run for about a 20 minute ride since the fluid was changed.

I have the exploded parts view and list pulled up on another page. I'll start trying to find all the parts you listed. I somehow knew I couldn't get out for as cheap as I'd hoped , but I'd much rather do it right the first time. Thanks!

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

PLEASE HELP! MY HEAD IS ABOUT TO EXPLODE!

I don't know if I'm making things too complicated or what, but I'm struggling to find the right parts.

For example: I think I've found the correct bellows (18-2751) because it is an Alpha 1 and a 1986....but, it says fits s/n 3469428 & up... the only serial number I can find on this thing reads A504733.

Then when I look at gimbal bearings, I get a list of models A1, B1, then a bunch of 3 digit numbers???? I don't know whether I need 18-2101 or 18-2100. It looks like I need 18-2101, based on the cc, but not sure.

Here is what I have so far:
yolk assembly 18-2125
u joint 18-2104 (X2)
gimbal bearing 18-2101 ?
bellows 18-2751?
still looking for input shaft seal

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

From this page, I have circled the parts you need. Mercruiser Sterndrive I/I-R/MR/Alpha One Drive Shaft Housing Components Exploded View - iboats



The gimbal bearing and bellows numbers are correct

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

YOU ARE THE MAN! THANKS SO MUCH!

Just curious, why am I changing the gimbal bearing?

Not challenging you... just don't know and trying to learn.

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Because it's rusty inside where the bearings are. Rusty bearings are no longer bearings.

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Makes sense, gotcha.

Is 18-2820-9 the correct outdrive gasket?

The bellows job looks tough, and from what I've read on here, it's no picnic.

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Makes sense, gotcha.

Is 18-2820-9 the correct outdrive gasket?

The bellows job looks tough, and from what I've read on here, it's no picnic.

No, you don't buy just the gasket, get the gasket kit. Outdrive Gasket Set for Mercruiser - Sierra 18-2619-1 - iboats

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Okay, the parts are ordered and should be here sometime the middle of next week. Now I'm looking for some instructions on how to remove/replace the yolk and seals as well as the bellows job. I keep trying the boatinfo manuals and all I'm getting is an electronic book full of blank pages.

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

See if this one works better. Click Here

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Don S. - That one worked for me perfectly. Thank you!

Update: My parts arrived earlier this week and I've installed/replaced ALMOST everything. I am now starting to see the light at the end of this project :happy:. I've also installed a new sea pump, as many of you on here have recommended I do since the I got the boat last year. Now, with the outdrive off, it just seemed like a good time to do it. All I lack is installing the ujoint bellows (I've been waiting on the special tool to remove the hinge pins on the gimbal ring). ...

... This brings me to my next question. When I got the tool in, I inserted it just to make sure it fit and found that they were very loose (I removed the one on the starboard side with two fingers, which might explain why I couldn't seem to keep my trim sender in adjustment). On a youtube instructional video I watched, I remember the man having a great deal of trouble breaking these bolts/pins loose and had to apply heat because he said that red locktite is used when installed properly. Is this correct, that I should use red locktite when reinstalling? What is the torque specs for these bolts?

 

[Don S]

Re: Yellow "gunk" in engine compartment... smells like gear oil

Don S. - That one worked for me perfectly. Thank you!

... This brings me to my next question. When I got the tool in, I inserted it just to make sure it fit and found that they were very loose (I removed the one on the starboard side with two fingers, which might explain why I couldn't seem to keep my trim sender in adjustment). On a youtube instructional video I watched, I remember the man having a great deal of trouble breaking these bolts/pins loose and had to apply heat because he said that red locktite is used when installed properly. Is this correct, that I should use red locktite when reinstalling? What is the torque specs for these bolts?

You have the manual now, use it !!!!!!! Section 4A and 4B explains it all.

 

[SotRH]

Re: Yellow "gunk" in engine compartment... smells like gear oil

You have the manual now, use it !!!!!!!

:laugh: As has been the case since the day I started using this site, I can always count on Don S for a swift kick in the butt when I get out of line. I really did look in the manual first... CLEARLY not good enough... so sorry!

Oh yeah, and THANK YOU again for all your help.. you're a life saver!