Alpha 1 Trim Sender and Limit Switch Replacement Help

[mceagle]

Greetings! So while fighting a high RPM overheat issue I discovered a U-joint bellow leak. Stupic or lucky, I just dont know. I decided to do the whole transom seal / repair process including shift cable. During disassembly, I noticed that the trim limit and tilt sender wires were toast so decided to replace those as well. My outdrive is of the 1984 variety and has the wire cover with the two bolts. The upper bolt is impossible to get to using swivel sockets, etc. I read somewhere that Merc used to have a special wrench available but no luck finding one. Any help, suggestions ideas are very much welcome. Thanks!!!

 

[wellcraft-classic210]

Are you referring to the 10-32 phillipshead screws that hold the trim sensor / switch on? If so- Is the steering turned for optimal access?

 

[alldodge]

Greetings! So while fighting a high RPM overheat issue I discovered a U-joint bellow leak. Stupic or lucky, I just dont know. I decided to do the whole transom seal / repair process including shift cable. During disassembly, I noticed that the trim limit and tilt sender wires were toast so decided to replace those as well. My outdrive is of the 1984 variety and has the wire cover with the two bolts. The upper bolt is impossible to get to using swivel sockets, etc. I read somewhere that Merc used to have a special wrench available but no luck finding one. Any help, suggestions ideas are very much welcome. Thanks!!!

In most cases the folks that remove the bolts either remove the gimbal ring entirely which will help, but everyone either gets the Merc special tool or they find a wrench, heat it up, then bend it to make it work. There was another poster hear which upon reassembly he used stainless Allen head cap bolts. Using those, he could use a ball driver if needed next time. If achris or Bondo doesn't come in one this one later, PM them and ask, they have done a lot of them

 

[Bondo]

In most cases the folks that remove the bolts either remove the gimbal ring entirely which will help, but everyone either gets the Merc special tool or they find a wrench, heat it up, then bend it to make it work. There was another poster hear which upon reassembly he used stainless Allen head cap bolts. Using those, he could use a ball driver if needed next time. If achris or Bondo doesn't come in one this one later, PM them and ask, they have done a lot of them

Sorry, Not Me,.... I find those 2 switches/ sender Unnecessary in life,....

I cut the wires, 'n toss 'em,....
My current Alpha has billet aluminum caps where those used to be,....

 

[mceagle]

In most cases the folks that remove the bolts either remove the gimbal ring entirely which will help, but everyone either gets the Merc special tool or they find a wrench, heat it up, then bend it to make it work. There was another poster hear which upon reassembly he used stainless Allen head cap bolts. Using those, he could use a ball driver if needed next time. If achris or Bondo doesn't come in one this one later, PM them and ask, they have done a lot of them

Thanks, Dodge. Perhaps Bondo has the right idea, but I'm not surrendering yet. Man, I have never heated a wrench to bend to a usable shape. Maybe a vice and some leverage may do the trick. Do you have any idea about where I could buy, borrow or rent the merc tool? Appreciate the help.

 

[mceagle]

Sorry, Not Me,.... I find those 2 switches/ sender Unnecessary in life,.... I cut the wires, 'n toss 'em,.... My current Alpha has billet aluminum caps where those used to be,....

You don't know how close I am to following your lead. Where to buy the billets? Man, this one has me stumped

 

[NHGuy]

Just snip off the wires and leave the old sensors there. It will look better than with none, and protect the stuff underneath from corrosion. If you need to bend a wrench get some heat going and a cheap wrench. I bet you could bend a parts store wrench with some mapp gas.

 

[wellcraft-classic210]

Are you talking about the trim sensor swithch screws or the hinge pins? If its a Merc hinge pin tool amazon sell then for about $10.00 -- http://forums.iboats.com/forum/engi...trim-sender-and-limit-switch-replacement-help

 

[mceagle]

Hello, Wellcraft Classic - Thanks for your posts. The bolt that's giving me fits is one of the two that holds the plate in place, above the gimbal bearing and to the right of where to water hose connects at the transom. The plate holds the trim sender / sensor wires (they have molded in grommets) where they enter the transom. A complete PIA to get to! Headind to Harbor Freight after work to get a set of offset box wenches that I will attempt to bend to the right shape. If no-joy, ill probably proceed with the "Bondo Method" outlined above.