Volvo aq125 rattling and noise when turning (hole in upper bellow)

[CodyT]

'83 Bayliner with aq125a with 270 drive

This problem just started while out on the boat the other day. It was running like a champ for the last few weeks (just bought it) and then it started rattling and grinding when turning the wheel. If I turn the wheel fully to either side it will even kill the motor. I took it out of the water and saw that the upper bellow has a hole in it. Haven't pulled the drive apart yet to see how the u-joint looks.

I have a decent amount of skill and wanted to see what I would be getting myself into by tearing into it. I have read a couple other posts where the problem went all the way to the bearings at the flywheel requiring the motor to be pulled... Don't think I could do that with my tools or knowledge. Could it be possible that it may just be the u-joint or parts accessible without pulling the motor? Or will I be able to tell if the intermediate bearings will need to be changed without pulling the motor? I'm looking at the parts on volvopentastore.com and trying to figure out everything I may need... Bearings, Bellow kit, seals, washers and anything else.

http://www.volvopentastore.com/Uppe...*****.519047022--store_id.366--view_id.325849

Any recommendations? Or can someone that has done this give me a list of all the parts that I may run into that should be replaced?

Thanks for the help! Cody

 

[Don S]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Torn bellows means water in the ujoints, probably in the flywheel cover bearings too, water in the drive, etc. What exactly it's going to take in the way of parts won't be known until you take it apart and inspect things and find out what all is wrong.
From your discription, I would expect you need the flywheel cover bearings for sure, maybe even worse depending on why it kills the engine when you turn it hard over.
Start by removing the upper gear box and inspecting some things.
Here is a link to a Lot of Volvo information you should read on how to remove the upper gear box etc.
http://forums.iboats.com/showthread.php?p=2360521#post2360521

 

[PiratePast40]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

The pictures below show what can happen if you let it go too far

 

[CodyT]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Thanks for the help! I'll keep you posted when I get into it. It's raining here this weekend so I may not be able to get to it yet like I had hoped.

 

[CodyT]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Do I need to disassemble the entire upper gear housing before getting to the u-joints, or will the bearing box just lift out without taking it apart? When reading the outdrive service manual, it shows to open it up and take it apart to remove it. Just want to make sure before I increase the amount of work to get to the parts that may be causing the problem! Thanks for the help! Cody

 

[captmello]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

the bearing box/ujoint assembly is held in the upper by a clamp ring with four allen head bolts. they can be tough ones to remove.

Part number 37

http://www.volvopentastore.com/Upper-Gear-Unit-Aq-Drive-Unit-270-270t/dm/*******.631032321--**********.743290845--store_id.366--view_id.317448

 

[CodyT]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Well this hurts! Everything's tore up inside the bellow. U-joints broke and took some other things with them it looks like. How do I get the joint fork off the main gear? It looks like I need to replace the u-joints, seals and bearings but I'm wondering if the flywheel cover needs to be replaced. The bellow was connected to it nice and tight when I took it off but I'll show the pictures of it to see what you guys think... So what else does it look like I'm going to need? The drive shaft feels nice and tight inside the housing but should I just pull the motor anyways while I'm at it to replace the bearings inside the flywheel cover? I guess this looks pretty close to worse case scenario huh? Well thanks for all the help! Time to get parts and get to fixing it! Cody

 

[rucaradio]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Here's how it is from one Volvo AQ owner to another...

1. Notice something is "odd" with the steering.

2. Notice hole in the drive bellows.

3. Thinking its a relatively easy repair, you go on iBoats and find out its not.

4. Say bad words.

5. Contemplate selling boat (or cutting it into pieces).

6. Pull the leg and motor.

7. Change pilot bering at flywheel, change intermediate bearing, change u-joints.

8. Reinstall motor and drive.

9. Install new bellows.

..and finally, perhaps most importantly..

10. Check bellows OFTEN and change RELIGIOUSLY every 2 years!!

 

[PiratePast40]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

IMO, the condition of the flywheel damper is now suspect as well. I'd wait to hear from the pros but there is a tremendous amount of potential for damage. Would suspect that you'll have aluminum shavings from the flywheel cover in the PDS bearings and that the forward bearing in the flywheel has probably been exposed to water.

The clamping ring on the gearbox has also been beat up pretty bad.

The amount of damage gives an indication of the tremedous amount of rotational energy released.

We all have different comfort levels but I'd be really uncomfortable not knowing the condition of all the driveline components at this point. If you pull the engine to inspect everything, it'll give you an opportunity to further inspect the transom and make decisions before spending much more money.

Certainly not a good senario. Welcome to the world of old #%*&@ boats

 

[captmello]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Here's how it is from one Volvo AQ owner to another...

1. Notice something is "odd" with the steering.

2. Notice hole in the drive bellows.

3. Thinking its a relatively easy repair, you go on iBoats and find out its not.

4. Say bad words.

5. Contemplate selling boat (or cutting it into pieces).

6. Pull the leg and motor.

7. Change pilot bering at flywheel, change intermediate bearing, change u-joints.

8. Reinstall motor and drive.

9. Install new bellows.

..and finally, perhaps most importantly..

10. Check bellows OFTEN and change RELIGIOUSLY every 2 years!!

Hmmmm... this sounds like the first two weeks after I bought my boat.

No matter how much we encourage others to check over the boat before taking out on the water...

Cody T, If you like this boat and would like to keep it for a while, you may as well pull the engine and do the intermediate bearings like you mentioned above. The chances of them lasting for any period of time is slim. We've all done them. however, you may want to check ebay for a replacement flywheel cover. That one you've got has lost a lot of metal and I'm not sure the bellows will even seal properly anymore.

 

[CodyT]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

I need some more direction here... When ya'll are saying the ujoints, do you mean the entire assembly? As in the steering yoke, intermediate section, joint fork, and the 2 cross pieces?

Or is it just the universal joint seal kit as in this kit-

http://bpi.ebasicpower.com/mm5/merc...wer&Product_Code=GLM87720&Category_Code=VOL1C

In the bulletin on u-joints from volvopenta store, it says that all the parts need to be replaced because a new assembly has been made.

http://www.iboats.com/volvo_penta/P...*=159981832&**********=988754835&store_id=366

So far it looks like these are the parts needed. Can anyone verify or add or subtract from these? Thanks a lot! Cody

69 ? ? Bellows kit 876294
universal joint seal kit from above site
19 ? O-ring 925256
7 O-ring 925259
34 O-ring 125017
37 ? Rubber ring 804190
70 Sealing ring 946242
71 Ball bearing 11013
74 Sealing ring 958860
37 ? Rubber ring 804190???


The bearings inside the flywheel cover are not shown in the picture... Anyone know those parts? Are they the same bearings and sealing ring that are on the outside of the cover? Thanks

 

[captmello]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

you can buy the new ujoint assembly from Volvo but its over $400.

http://www.marinepartsexpress.com:8080/mpeCart/details.faces?productId=3860231&Go.x=14&Go.y=13&Go=Go

I would just replace the ujoint crosses with these.

http://www.iboats.com/U-Joint-Sierra/dm/*******.323497206--**********.466462998--view_id.187696

Looks like you've got the right parts. When I did mine, Don S told me I could reuse the Two large seals, #37, if they weren't totally flat and that he was usually able to reuse them. So I would hold off on those.

http://www.volvopentastore.com/Connecting-Components/dm/*******.323497206--**********.466462998--store_id.366--view_id.325843

from this link, I would also replace...

#53 with this part, these are commonly corroded and cause overheating issues. It's not a thermo housing like Iboats says.
Looks like one though. It comes with the gasket.

http://www.iboats.com/Thermostat-Housing-Sierra/dm/*******.323497206--**********.466462998--view_id.173338

As for the other orings, you need the two between the upper and intermediate housings, and get yourself a half dozen of the drain plug and dipstick orings (same part)

The bearing you have listed is the bearing in the flywheel cover. Some flywheel covers has two bearings, some have one. The cover that comes up for your aq125A shows the single bearing style. IF that is what you have, there is also a bearing in the flywheel/crankshaft.

#28 in this link

http://www.volvopentastore.com/Crankshaft-And-Related-Parts-Aq125a/dm/*******.323497206--**********.466462998--store_id.366--view_id.325907

I'm not sure why this bearing is necessary however, since the drive shaft in the flywheel cover spins with the crankshaft.

My setup had the double bearing in the cover so I haven't worked with the bearing in the crankshaft.

I hope this helps, Keep up updated on your progress and we can all commiserate together.

Good luck!!

 

[CodyT]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Ok so got the motor pulled yesterday and took the flywheel cover off today.

Pretty sweet motor lift huh? For anyone who is looking for a hillbilly way to lift a motor, this is it! A big tree! Couple of questions... Does the bearing in the flywheel/crankshaft need to be replaced? (in 3rd picture)


number 28 -- http://www.volvopentastore.com/Cran...*****.466462998--store_id.366--view_id.325907

If so does the flywheel need to come off to get to it or do you just pull the lock ring out?

Then once I get everything replaced inside the flywheel cover, how much grease do I put in the bell housing, on the bearings, and on the ujoints?

Anyone know if these bolts can be found at a hardware store? Marina wants $7 each!

number 38 -- http://www.volvopentastore.com/Conn...*****.747012092--store_id.366--view_id.325843

And the last question - While I have the motor out I'm going to replace the oil pan gasket... From the pictures, what other gaskets/seals should I replace just for good measure while I have the access?

Hopefully the boat will be ready for the water this coming weekend! Thanks Cody

 

[captmello]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Cody,

Glad to see you're hard at it. I'm afraid I'm not familiar with the single bearing flywheel cover and crankshaft pilot bearing setup. Nor can I answer your question regarding the replacement bolts except to say, if you can match them up in Stainless steel at the hardware store...

But I'm sure someone else knows, don s...

It looks like you rented the same hoist I did.

[/IMG]

FWIW, if you find your not getting a response to your other questions, don't be afraid to start a new thread with a specific question about that aspect of the project.

 

[CodyT]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

So it runs great! Sorry it took so long to post this but I kind of forgot! Thanks so much for the help guys, I couldn't have done it without this forum that's for sure! Replaced intermediate bearing, all seals, drive bellow, oil pan gasket, impeller cross-piece and seal and I think that's it. $500 or so with tools and parts and somewhere around 30 hours of my time. Well worth the savings!!!

 

[PiratePast40]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

So it runs great! Sorry it took so long to post this but I kind of forgot! Thanks so much for the help guys, I couldn't have done it without this forum that's for sure! Replaced intermediate bearing, all seals, drive bellow, oil pan gasket, impeller cross-piece and seal and I think that's it. $500 or so with tools and parts and somewhere around 30 hours of my time. Well worth the savings!!!

AWESOME - Way to go!!!

 

[captmello]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Glad to here you got it done!!

 

[Tommywalton]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Wow! After reading all that I'm so glad I got help from you guys. I also got suspisious when I saw a hole in my bellows and started looking. Fortunately for me my u joints were only loose. But now my OCD is wearing me thin because I didn't check bearings 2 weeks ago when my engine was swinging from a chain!!!

 

[captmello]

Re: Volvo aq125 rattling and noise when turning (hole in upper bellow)

Wow! After reading all that I'm so glad I got help from you guys. I also got suspisious when I saw a hole in my bellows and started looking. Fortunately for me my u joints were only loose. But now my OCD is wearing me thin because I didn't check bearings 2 weeks ago when my engine was swinging from a chain!!!

Well, you can still check the bearings for play with only the upper gear box removed. No use obsessing over it now. Again, having your own thread may have helped us alert you to the bearings...Anyway, glad you're learning. Those bearings typically won't leave you stranded on the water. They usually start growling at you to let you know they're ready to go.