Alpha one gen 2 drive oil leak

[jackd1023]

I have a alpha one gen 2 that is leaking drive oil into u joint bellow, It pressure tests good, any ideas? Getting frustrated

 

[tpenfield]

My idea is that it may not actually pressure test good. I would review and perhaps re-do the pressure test. . . . not really any other way that I know of to get gear oil in the bellows except for a leaky seal of other outdrive issue that would show up in a pressure test.

 

[achris]

Only path for (gear) oil into the bellows is through the front seal and/or the seal carrier 'O' ring. Either way, the front of the drive has to come off and be stripped to replace them. And since you'll have the box mostly apart, do all the seals and 'O' rings...

Chris........

 

[Rick Stephens]

Only path for (gear) oil into the bellows is through the front seal and/or the seal carrier 'O' ring. Either way, the front of the drive has to come off and be stripped to replace them. And since you'll have the box mostly apart, do all the seals and 'O' rings...

Chris........

I second that. Only reason to pressure test is to find a leak, you already know you have one and where it is coming from.

Only other factor is if the 'oil' in the bellows is actually a bit of water mixed with u-joint and gimbal bearing grease and not gear oil. I have mistaken that slurry for gear oil for a few seconds, a quick smell will usually resolve that as grease and water don't have the stink of gear oil.

 

[Bt Doctur]

called a "rotating leak" that will pass a pressure test. If you do have gear oil in the bellow, replace the seal and inspect the yoke

 

[jackd1023]

I second that. Only reason to pressure test is to find a leak, you already know you have one and where it is coming from.

Only other factor is if the 'oil' in the bellows is actually a bit of water mixed with u-joint and gimbal bearing grease and not gear oil. I have mistaken that slurry for gear oil for a few seconds, a quick smell will usually resolve that as grease and water don't have the stink of gear oil.

100% drive oil, its blue.

Anyone have a quick manual to handle the reseal? I picked up the seal kit today

 

[achris]

100% drive oil, its blue.

Anyone have a quick manual to handle the reseal? I picked up the seal kit today

Here's the quick manual.
Drain oil.
Spilt drive.
Remove front cover nut.
Remove yoke and bearing pack (don't lose the shims).
Remove top cover screws and top cover.
Remove upper drive shaft and driven gear.
Replace lower seals.
Disassemble yoke and bearing pack.
Replace seal and o ring.
Reassemble and set rolling torque.
Drop upper drive shaft and driven gear back in.
Refit shims to front of housing and refit yoke and bearing pack. Hand tighten front cover.
Fit new o ring to top cover and fit top cover. Torque screws to 20ft-lb.
Torque front cover to 200ft-lb.
Check for slight clearance between drive and driven gears.
Refit top housing to lower housing.
Pressure test (@3psi and 15psi), making sure to rotate shafts while under both pressures.
Fill with oil, refit drive to boat.

Chris. ...

 

[Bt Doctur]

http://www.boatfix.com/merc/Servmanl/14/14a3.pdf

 

[jackd1023]

Here's the quick manual.
Drain oil.
Spilt drive.
Remove front cover nut.
Remove yoke and bearing pack (don't lose the shims).
Remove top cover screws and top cover.
Remove upper drive shaft and driven gear.
Replace lower seals.
Disassemble yoke and bearing pack.
Replace seal and o ring.
Reassemble and set rolling torque.
Drop upper drive shaft and driven gear back in.
Refit shims to front of housing and refit yoke and bearing pack. Hand tighten front cover.
Fit new o ring to top cover and fit top cover. Torque screws to 20ft-lb.
Torque front cover to 200ft-lb.
Check for slight clearance between drive and driven gears.
Refit top housing to lower housing.
Pressure test (@3psi and 15psi), making sure to rotate shafts while under both pressures.
Fill with oil, refit drive to boat.

Chris. ...

thank you!!! I truly appreciate your time and knowledge Chris!!!

 

[jackd1023]

http://www.boatfix.com/merc/Servmanl/14/14a3.pdf

thank you sir!! printing now