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  1. Rick Stephens

    Alpha One Gen 1 Shift Shaft Seal

    Merc changed that bushing to one that the seals are no longer contained inside but in a larger part of the bushing. Looks like the picture. You should switch to that setup, it is not expensive. I think the part number is 23-805041A2
  2. Rick Stephens

    4.3 TKS Repeat oil pressure switch failures

    achris's modified schematic.
  3. Rick Stephens

    5.7L Vortec vs Pre-Vortec Height Dimension?

    It is easy to find Vortec drawings.... but any assumption as to which intake and which carburetor is dependent on what you choose, they have several models, 2 BBL, 4BBL, and EFI. You can find dimensional drawings of everything except pre-vortec here.
  4. Rick Stephens

    5.7L Vortec vs Pre-Vortec Height Dimension?

    Only difference possible would be dependent on what intake manifold and carburetor. Otherwise the motors are the same.
  5. Rick Stephens

    Strange noise Mercrusier

    Don't forget pressure testing the drive. Looks like an input shaft seal is leaking.
  6. Rick Stephens

    Mercruiser Alpha 1 Gen 1 Project

    Seal just keeps grease from creeping into bilge.
  7. Rick Stephens

    Gear lube leak

    Possibilities... 1) the oil seal under the water pump got mangled. 2) You dropped the lower without taking off the upper and in reassembly the bottom seals on the upper got thrashed by a not straight in lift of the lower. 3) the quad ring on the oil passageway is crooked.
  8. Rick Stephens

    Strange noise Mercrusier

    Everything is a gooey mess inside and a corrosion mess outside. The gimbal bearing is rusted to the drive shaft. There's gear oil all over. Needs a lot of maintenance. Your photo taking is excellent though.
  9. Rick Stephens

    Need to tweak shift cable for reverse

    For me the obvious elephant in the room is the need to replace the lower shift cable...
  10. Rick Stephens

    Hard to get into neutral after reverse

    The gear teeth on a mercruiser are back cut. They have to be unloaded to disengage. Any owner of a mercruiser Alpha 1 drive should read this page on how the shift interrupt works.
  11. Rick Stephens

    Engine cut out while slowing down....

    I keep hearing different philosophies from folks about what equals zero lash. Zero must be vertical play in the rods. No twisty turn type feel. I was taught early on to turn a rod, took years of having to redo valve adjustments to learn that feeling up and down is the key.
  12. Rick Stephens

    Engine cut out while slowing down....

    Unless you have the rockers run down too far it sounds like heads were the least of the problem.
  13. Rick Stephens

    Delco Voyager EST.... New ??

    I believe the shift interrupt with Thunderbolt ign grounds the module, not the coil.
  14. Rick Stephens

    Alpha One Gen II outdrive won't fit in gimbal ring

    Bondo, many early Gen2 did not have an oil port - mine does not.
  15. Rick Stephens

    Alpha One Gen II outdrive won't fit in gimbal ring

    You are absolutely correct that the Gen2 is a different width, you cannot install a Gen2 drive on a Alpha1 gimbal. Your fix is sell the Alpha 1 parts he handed you and buy off fleabay or wherever, the Gen2 gimbal parts. Or, install the older outdrive in its place. as it will fit.
  16. Rick Stephens

    Delco Voyager EST.... New ??

    yup.
  17. Rick Stephens

    Mercruiser Alpha 1 Gen 1 Project

    If it has rubber parts, I buy OEM. E v e r y t i m e.
  18. Rick Stephens

    Delco Voyager EST.... New ??

    EST system is a bit different.
  19. Rick Stephens

    Delco Voyager EST.... New ??

    Is very simple. Power to ignition, fuel pump and electric choke is the purple wire coming from the ignition switch.
  20. Rick Stephens

    New boat owner with dumb questions

    You can get the manuals here. I use #14 for a '92 Gen 2. Might be a newer one but that one will do for everything but the motor. I never used the motor manual.... for me, a small block chevy is a small block chevy. Been working on em longer than Mercruiser been using em in boats.
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