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You have an EZ lube axle that someone put a Bearing Buddy on. Typically you can't put Bearing Buddys on those since the Zerk would hit the backside of the Bearing Buddy piston.

Not getting power to the relay or is the relay not getting energized?

The buzzer or horn isn't always installed. My 98 Volvo didn't have one. It's up to the boat manufacturer who installed the engine/drive

I had no issues finding parts/numbers on http://www.volvopentastore.com/ If you find a part that is discontinued, you would have an issue finding that part no matter what website you used. Out of curiosity, what parts are you finding discontinued?

Thankfully, you didn't go and split the drive.

Since your boat was made during the Volvo OMC joint venture years, you can also look at OMC. However, you will still have the issue of discontinued parts. What is your model number. Within the model number is a 2 letter code that designates what "model year" it is.

Its normal for one to be hotter than the other especially at idle. Was it so hot you couldn't leave your hand on it?

Remove the 1" hose going to the thermostat that comes from the raw water pump. Start the engine and see how much water comes out when you have your engine running at 1000RPM. At what temp is it getting up to and what does it go down to? Did you you replace the impeller with an OEM Volvo...

Stick a cell phone down there and take some pictures looking up. It will help you find the bolts

Pretty hard for these to lose prime since the water level is above the pump. You are testing this in the water I assume? You have an air leak somewhere.

Out of curiosity, is this the Ford or GM engine?

And make them disk brakes and they have very little maintenance.

Electric over hydraulic with discs for me. I hate drum brakes whether they are hydraulic or electric.

If you put the drive in a tub and started it, you fried the impeller. Hopefully, it isn't the one you have in there now.

Another thing...are you sure you have the two hoses going to the pump in the proper orientation which means the inlet is the inlet hose and the outlet is the outlet hose and they aren't swapped?

Yes.

There is no way I would do that. If the drive is sitting in the water and idling the part could be completely cracked and it would never overheat.

I looked back at one of your posts and see you have done this. Have you tested your thermostat yet?

Personally, what I would do is, put the boat in the water, start the engine and pull the hose going to the thermostat and see if you are getting any water out of it. There is no way I would be dissembling your stern drive. You can buy alignment bars on ebay. Its the same alignmnet bar used for...

If your boat is overheating just sitting in the water, nothing that is broken on your drive would cause you an issue since everything is under water. When you are on plane, the water is forced up the drive so still unlikley that a crack in anything would be a problem either.