Rebuild or replace Alpha 1 lower

[freak007]

I pulled my drive due to no longer having the ability to move under my own power...

here is what I have found...


I when I drained the rest of the gear oil there was a ton of metal shavings in the last bit of oil...

No key to keep water pump impeller anchored to drive shaft

The gear case has been damaged before (evidence of welding), as well as a broken cavitation plate (covered with a hydrofoil/stabilizer)

Unit will only go into reverse (shift shaft will only rotate ~90* CCW),

The splines in the drive shaft housing that the drive shaft mates with turn with the engine

The shift shaft coupler in the drive shaft housing moves with the controls...


It seems to me that the water pump was replaced and not properly installed, when it became loaded down the water pump quit causing the drive shaft to break Looks to me like when the water pump quit, everything overheated real nicely... I wasn't able to check the propeller shaft side play, but it has enough that I can feel it (quite likely more than .003"). The "Rubber Centrifugal Slinger" at the base of the water pump drive is also badly cracked...

I only have about 3 hours of run time on the boat since I got it, 1 hour of which was when it was hooked up to a garden hose, 20 - 30 minutes test drive before changing the prop, and the remainder (trying) to tube behind it...

At any rate unless someone can convince me that what happened was just a fluke (or something I caused), I think I am going to have to choke slam the previous owner...


http://i258.photobucket.com/albums/hh258/freak007/IMG_0730.jpg

http://i258.photobucket.com/albums/hh258/freak007/IMG_0733.jpg

http://i258.photobucket.com/albums/hh258/freak007/STA70068.jpg

http://i258.photobucket.com/albums/hh258/freak007/STA70074.jpg

http://i258.photobucket.com/albums/hh258/freak007/STA70075.jpg

http://i258.photobucket.com/albums/hh258/freak007/STA70066.jpg


final questions:

Looking at the "special" tools and the time involved in further disassembly/rebuild I think it is probably in my best interest to just get a new/used/rebuilt gear case... any other thoughts? Or do you think it would be more economical to have someone rebuild it for me (keep in mind the case might have more undisclosed damage)


I believe I have a "R" type drive (preload pin on driveshaft)... if that is true can I install a Alpha lower (without preload pin)?

I will also be doing the bellows and the gimbal bearing (different thread), is there anything else I should look at?

 

[TilliamWe]

Re: Rebuild or replace Alpha 1 lower

At the prices Sterndrive Engineering charges (They are the $1195 or $1295 drive you see advertised on here) I can't see why anyone would have a drive repaired. I will guess that the $1195 drive they sell as an Alpha replacement will bolt right up. That way you have an ALL NEW drive, top and bottom, no guessing and a 3 year warranty. Sell you drive for parts, tear it down yourself for a project, whatever, but do it when you aren't boating with your new drive installed. This one was easy.

 

[Pbear]

Re: Rebuild or replace Alpha 1 lower

At the prices Sterndrive Engineering charges (They are the $1195 or $1295 drive you see advertised on here) I can't see why anyone would have a drive repaired. I will guess that the $1195 drive they sell as an Alpha replacement will bolt right up. That way you have an ALL NEW drive, top and bottom, no guessing and a 3 year warranty. Sell you drive for parts, tear it down yourself for a project, whatever, but do it when you aren't boating with your new drive installed. This one was easy.

I'd have to agree - rebuild and you lose your summer of boating waiting for it. and $1200 is pretty good for a new unit.

 

[Don S]

Re: Rebuild or replace Alpha 1 lower

You also can't rebuild a drive without the special tools for setting gear heights and setting shimming. And all those special tools cost more than a new SEI outdrive. Yea, I know people say they do rebuilds without them, but they also don't tell you how long they last either.
Kind of limits the options doesn't it.

 

[Limited-Time]

Re: Rebuild or replace Alpha 1 lower

As Bondo stated in your other post ..........take a look at the SEI drives....

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

I did look at the SE drives... but because my "other post was starting to branch off into several different directions I started 2 threads... each dedicated to their own issues...

I was going to order the lower from SE... but because I am having trouble getting on plane (even with the "right" prop) I decided to take a closer look at the upper as well... I counted the teeth 4 times... 17/19 every time... I had initially ruled out the drive ratio because the serial number on the drive unit matched what the plate on the engine said I was supposed to have and it was stamped "1.98R"... guess I should not assume anything... looks like a whole new drive unit is in the works... Now the only thing left to figure out is the whole gimbal bearing thing...

I hope for my sake that I never see the old owner again... "water ready" my @$$!!

 

[Don S]

Re: Rebuild or replace Alpha 1 lower

Trust me, it's not unheard of for people to put wrong gears in a drive, just because the gears are handy and cheap. Probably came off ebay for 20 bucks and installed by someone that didn't know how to shim them either.
Suck it up, put the new SEI on it and go boating. After a few days of actually using the boat you won't even remember the cost of the drive ............... well, maybe a little bit.

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

LOL... I will remember if for no other reason than my wife will not let me forget... the worst part is I will have another $1500 into a $1700 boat... For $3200 I could have gotten a much nicer boat... ohh well... you live and learn... sometimes the hard way...

 

[Bondo]

Re: Rebuild or replace Alpha 1 lower

ohh well... you live and learn... sometimes the hard way...

Ayuh,....

Ya found the Right place for that,......

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

so me being the cheap b@$t@rd I am... I started looking around for used outdrives... I found a used, low hour, fresh water complete drive for $800... Not sure if that is a fair price or not... If I can avoid having a small fortune into this thing I would like to... but I am a big fan of only doing something once


Also are all shift cables the same? The conduit was broken off at the bellhousing so I need a new one... Where is a good place to get them as well as the trim position/limit switches (position switch was broken by inproper installation)

 

[Don S]

Re: Rebuild or replace Alpha 1 lower

I would get an OEM lower shift cable (if that is the one you are referring to) the inner cable is now covered with a teflon coating and really moves smooth and cuts down on friction and wear. And only costs about 10 bucks more that the cheap aftermarket cables (that I truly hate using)

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

yup, I need the lower... is there a good place to buy OEM parts without getting raked over the coals... I hate going to the stealership...

Also are there different length cables... or are they all the same?

Any advise on a used outdrive?

 

[Don S]

Re: Rebuild or replace Alpha 1 lower

Here's one place for OEM parts, rather it's cheapest or not I don't know. Item #10
http://www.crowleymarine.com/mercury_parts/2686/60.cfm

Also are there different length cables... or are they all the same?

Any advise on a used outdrive?

1. all the same
2. never buy used outdrives. they are usually used up not just used.

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

THANKS!!! that part number was what I needed to start searching... does this OEM tool/parts list look right for my "project"? Prices look fair? Shipping would be $15-30 depending on carrier/time

MER-865436A02 ...... ASSY-SHIFT CABLE SS Replaces 19543A10 ... $53.53
MER-91-32325T ...... PULL TOOL-BRG ........................................ $28.33
MER-91-37323 ........ DRIVER ROD ............................................ $10.15
MER-91-30366T 1 ... INSTALLER TOOL ...................................... $24.40
MER-91-45497A 1 ... EXPANDER ASSY ....................................... $45.76

Is THIS the right alignment tool?

Add to that the complete SEI out drive, as well as a "install kit", "transom seal kit", and a anode set and trim limit/position sensor set... Grand total of $1560 +



Also, which trim sensor kit would be right for a 1984 model:

MER-805320A 1 Power Trim Sender $69.81
Includes trim limit switch also. Fits MC-I, R, MR, Alpha One, Gen II, Bravo drives.

OR

MER-805320A03 SENDER KIT ALPHA/BRV $71.77
Fits MC-I, R, MR, Alpha One, Gen II, Bravo drives.


Thanks for all your help!!

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

anybody??

 

[freak007]

Re: Rebuild or replace Alpha 1 lower

OK, I think I got this thing all figured out... maybe...

just in case anyone else was wondering, both of the above part numbers are the "right" parts... the difference is the "A03" is the updated style... I don't see why the manufacturer would change something unless it would be to improve it... So I will be ordering the updated style...

As I said in my gimbal thread, I think I found a way around the "special" tools...


I am trying to finalize my shopping list so I can order everything tomorrow... right now it is looking like:


SE106 complete out drive

80-5320A 03 Single Station Sender Kit
86-5436A 02 Shift Cable Assembly
30-803098T 1 Transom Seal Kit (w/ Exh. Tube)
11-52707Q 1 Propeller Nut Kit

26-88416 Gimbal Housing Oil Seal (unless it is included in the transom seal kit)


I also want to order a new anode because there is not much room for the prop and the previous owner painted it ... the tab that is on there now has "31640" cast into the underside, my google search has made me believe that this is a Mercruiser zinc tab. This tab clears my 15 1/4 x 21 prop fine, but is close on my 14 1/4 x 17 ... anyway I want to go to a "822777" to gain more prop clearance, but I do not know for sure what material (or the PN suffix) would be best for my application... I am in the Midwest, so it will never see salt water... however we do have a lot of Iron is some of the lakes I run in... My understanding is that Magnesium (822777A 2?) is probably the best material for me... can someone help me out?

Also do the anodes on the lower gimbal bolts need to be the same material as the trim tab? How do I tell what ones are on there now? How do I change them out (I could not find anything about them in manual #6)


Is there anything else I am missing?