2002 Alpha One Outdrive Leak Question

[krazymatt73]

I own a 2002 Bayliner Capri 175, 3.0L 4 Cyl. Alpha One Inboard boat. Last year I was noticing that it would lose about half of the gear lube in the resevoir every full day out on the lake. A while back I talked to a marine mechanic and he told me it sounded like the "top end" and was unlikely the "yolk." He said that if it was just the top end, it would be about a $250 repair and if it was more involved it could be up to $600-$800.
I would really like to try and repair this myself. By the "top end" he was referring to just the top seals I'm assuming?
I am pretty mechanically inclined. I have experience removing and replacing engines, transmissions, rear ends on cars etc... How difficult would the task be of re-sealing my drive to get rid of this leak? I would appreciate any info. Thanks

 

[Don S]

Re: 2002 Alpha One Outdrive Leak Question

First thing you need to do is remove the outdrive from the boat and see if there is any gear lube in the ujoint bellows. If there is, then the input shaft seal is leaking. If there isn't any gear lube in the belows, then drain all the gear lube out of the drive, and pressure test the drive to about 15 psi and spray it with soapy water. The bubbles will tell you where the leak is at. I would bet it's around the shift, but you may have to move it (like when shifting) to see it actully leak.

 

[krazymatt73]

Re: 2002 Alpha One Outdrive Leak Question

Oh, and I forgot to mention that when it is in storage in my garage there is no sign of leakage when sitting on the garage floor. It only loses half a resevoir when being run througout the course of the day at a lake.

 

[krazymatt73]

Re: 2002 Alpha One Outdrive Leak Question

Thanks. It sounds like i have to get the marine mechanic to do the job. I have no method of pressure testing it, and I don't know where the bellows is.

 

[krazymatt73]

Re: 2002 Alpha One Outdrive Leak Question

Okay, I get it. I did a search for an outdrive pressure tester. So you just put air in it and the leak will be detected on the outside of the drive right?

To remove the outdrive from the boat, it's just 4 bolts and the u-joint and the trim arms right? Thanks.

 

[Don S]

Re: 2002 Alpha One Outdrive Leak Question

Here is a link to the OEM service manual for your drive.

http://www.boatfix.com/merc/Servmanl/14/14notice.pdf

 

[Fishermark]

Re: 2002 Alpha One Outdrive Leak Question

Okay, I get it. I did a search for an outdrive pressure tester. So you just put air in it and the leak will be detected on the outside of the drive right?

To remove the outdrive from the boat, it's just 4 bolts and the u-joint and the trim arms right? Thanks.

It's SIX nuts and the trim rams. AND make sure the drive is in forward gear before trying to remove it.

 

[krazymatt73]

Re: 2002 Alpha One Outdrive Leak Question

Thanks guys! On that manual pdf file it is only the table of contents? I know I think I have a sterndrive installation and assembly manual that came with the boat. I will look into it.

So if I get to the point of the pressure test;--I'll be using the soapy water spray on the outside of the outdrive right??

Thanks. Sorry for dumb questions.

 

[soler]

Re: 2002 Alpha One Outdrive Leak Question

Thanks guys! On that manual pdf file it is only the table of contents?

Go to the table of contents and click on a letter in red outline. They are links.

SOLER

 

[krazymatt73]

Re: 2002 Alpha One Outdrive Leak Question

Thanks. I got it to work.

I must admit the exploded view of the drive shaft assembly alone looks pretty darn intimidating. I mean 30 little parts in a special order with 4 different types of lube required in certain areas??!!! This looks much worse than building a small block chevy engine from the crankshaft up.

Do many of you folks on here do your own tear down and rebuild of stern drives???