1989 Mercruiser, Outdrive Problems

[ChrisK_]

Hi guys. Hoping someone could help me out.

Just purchased a used 1989 Baja Islander 190 with a 3.0 Mercruiser. I believe this is the Alpha One, from what I've read.

The third time taking the boat out I was cruising back to the landing at not quite full throttle when the boat slipped out of foward gear and the engine started to rev up. I immediately shifted to neutral and shut off the engine.

I started it back up and the boat wouldn't move, neither foward nor reverse. I feel no resistance and hear no sounds from the outdrive while trying to shift. The engine started just fine and only revved up when I moved the shifter foward or backward. I managed to get a tow back to shore and trailered the boat.

I started the boat up this afternoon, on the trailer with muffs. The problem is the same. The motor kills when I give it more than a slight amount of gas, when in foward gear.

With the shifter in foward, the prop spins clockwise with clicking. With the shifter in reverse, it spins counterclockwise with clicking. In neutral, it spins freely. I assume this means that the lower unit is engaging in gear, correctly.

The day before the problem occurred, I experienced a little bit of noise while shifting into gears.

I am assuming this is an issue with the drive system. Any ideas of what I should look for?

I do have experience with pulling the lower unit on my old 85 stringer 400, so I'm not afraid to pull the lower unit as needed. Just want to get back on the water as soon as possible.

Thanks ahead for the help.

 

[xltier]

Re: 1989 Mercruiser, Outdrive Problems

you say first that it started reving up and wouldnt go.then you said on the trailer that you couldnt rev it at all.it would kill the motor.sounds like its shift the gears good.if it is killing the motor try diconnecting the shift interupt switch.if its reving up on the water in gear then its possible a spun coupler.hth

 

[Eric 3.7LX Alpha 1]

Re: 1989 Mercruiser, Outdrive Problems

Sounds like a spun prop hub or coupler. Did you smell a burning rubber smell when it happened?

Can you see the back of the engine where the yoke(round shaft) from the outdrive passes thru the transom and attaches to the engine? That shaft is attached to the coupler which is attached to the flywheel of the engine. While the engine is running that yoke should also be turning no matter what gear the drive is in. F, N,or R.

 

[ChrisK_]

Re: 1989 Mercruiser, Outdrive Problems

Thanks for the replies.

I started the boat up again today. I took the prop off and the prop shaft does not spin when in gear. I believe this would eliminate a spun prop hub.

The yoke is turning when the motor is running. I did not smell rubber when the problem started, and I still don't when it is running on the trailer. I'm hoping this means that the coupler is good, as I don't look foward to removing the engine.

The temp gauge does appear to going up, even with the muffs on. I assume this means the water pump isn't running?

To clarify, the engine would rev when I gave it gas on the water when the problem started. On the trailer, it will only rev to a low rpm and shut off when I give it more gas. I didn't check what that rpm was.

Perhaps I should pull the outdrive and take a look at the driveshaft. I'm suspecting the problem is in the U-Joint assembly.

Any thoughts before I go into this step? With the outdrive removed, any other good maintenance I should do while I'm in there?

Thanks again,
Chris

 

[chaparall villain 2]

Re: 1989 Mercruiser, Outdrive Problems

is the prop you have one that has a rubber center hub if it is pull it out of the prop and check to see if it is spun .... should be square ... also check your shift cable wen you shift it into forward try to turn prop shaft it should lock in one direction and rotate the other direction

 

[NHGuy]

Re: 1989 Mercruiser, Outdrive Problems

If the prop shaft doesn't spin while in gear check that it truly IS in gear by putting the shift in forward, pushing the shift cable into the housing back by the engine, and then check to see if the prop refuses to turn backward. The prop not going backward is the true sign of the gears being engaged in forward.
If that test shows forward you may need to replace and properly adjust the lower shift cable. This is what you should hope is wrong, it's the cheapest and most typically neglected thing that could cause your problem.

 

[SuperNova]

Re: 1989 Mercruiser, Outdrive Problems

You probably took the teeth off the upper gearset. Look at the top of the outdrive....see the cap with the four (probably twelve point) bolts and the lifting eye? Take those bolts out and pop the cap off the top gearset is immediately below that cap.... look for damaged teeth etc. You can have somebody crank the motor over by hand slowly and see if the input gear is turning or not as well as the output gear and driveshaft.

 

[ChrisK_]

Re: 1989 Mercruiser, Outdrive Problems

SuperNova was right on. Opened up the cap and there was metal everywhere. Both the vertical and horizontal gears were completely stripped, though it appear that everything else in there was intact.

This looks like a simple fix, but I realize that can be decieving with gears as it relates to alignment, shimming, special tools, etc.

I'm comfortable working on it, but is this a better job for a Merc tech or as easy at it looks?

 

[Bt Doctur]

Re: 1989 Mercruiser, Outdrive Problems

Was the outdrive oil changed or outdrive serviced prior to use?

 

[ChrisK_]

Re: 1989 Mercruiser, Outdrive Problems

The previous owner said he had lubed up the drive in June. He either lied, missed filling the upper, or theres a fast leak somewhere.

I had just bought the boat a couple days prior and was going to go through it after the weekend trip. I shouldn't have trusted that everything was okay and checked the fluids beforehand instead of waiting.

 

[NHGuy]

Re: 1989 Mercruiser, Outdrive Problems

I've always heard the gearsets are beyond most backyarders. There are some special tools needed. Also the upper outdrive shares the same gear oil as the lower gearcase so there is a concern for shrapnel getting in the lower drive. The Mercruiser manual gives a play by play on how to do it, but it looks like a pain to me. Maybe there is a gear builder nearby if you live near big water. Here is one DIY site's take on it. http://www.sterndrives.com/rebuild_alphaone_upper.html They seem to infer that you need skill, tools, time and patience.
Where do you live, are there any donor boats around? If the boat's a real runner it's probably worth an SEI (clone alpha) drive, they cost $1195 on sale at i-boats in the parts area. Normally $1395. New Mercruiser Alpha's are big $. Sorry to hear what happened, real bummer.

 

[NHGuy]

Re: 1989 Mercruiser, Outdrive Problems

If you can't srping for an alpha 1 manual, also look at Mercstuff.com's page they have been a help for me.

 

[SuperNova]

Re: 1989 Mercruiser, Outdrive Problems

SuperNova was right on. Opened up the cap and there was metal everywhere. Both the vertical and horizontal gears were completely stripped, though it appear that everything else in there was intact.

This looks like a simple fix, but I realize that can be decieving with gears as it relates to alignment, shimming, special tools, etc.

I'm comfortable working on it, but is this a better job for a Merc tech or as easy at it looks?

Any good tech with a reasonable amount of skill using basic shop tools and a working knowledge of gear mesh pattterns as well as backlash feel can do the job. If you feel you are qualified and have access to a shop hydraulic press then I say go for it. Buy good gears and bearings for the upper and use the same shims that are in there now. Double check your pattern and backlash after you assemble it and if they are good then run it. If they aren't good, then I would suggest taking it to someone who can set up the gearset if you're not comfortable with it. With current machining practices and equipment, the variance is in the housing, not the gears like it used to be. If you are only changing the gears, then the shims that are already in there will most likely be the ones you want to use. I know a bunch here may argue, but my advice is offered from a point of actual experience from a professional auto mechanic for over 20 years (set up a LOT of gearsets) and a shadetree boat mechanic for even longer. What's the worst that can happen? You ruin another set of gears....so what.

BUT...if you don't have a little bit better than basic knowledge of mechanics...then don't even try it.....there are a lot of things to easily and completely screw up in ignorance of basic assembly and disassembly techniques.

 

[Bt Doctur]

Re: 1989 Mercruiser, Outdrive Problems

"Any good tech with a reasonable amount of skill using basic shop tools and a working knowledge of gear mesh pattterns as well as backlash feel can do the job."

The very first drive I ever did was done with no manual, no shim tools, basic engine building tools and lots of common sense. Did a lot of repairs, (street/strip) on rear ends. Outdrive is the basic principle ring and pinion. Although assembling with machinists dye ,spinning it, taking it apart, reading the "foot print"(heel and toe) ,adjusting the shim packs, re-assembling , re-reading ,etc is time consuming. The proper tools do make it a lot easier.

 

[Eric 3.7LX Alpha 1]

Re: 1989 Mercruiser, Outdrive Problems

The 3.0 had a 1.98 ratio. You can search ebay for a upper alpha one upper half with that ratio but as you know buyer beware. The gearing is in the upper set that was toasted in yours.

They are definately on there for all prices, but as mentioned above some of that metal more than likely has gotten into the lower unit. Maybe you can score a whole drive, good luck with it.

 

[SuperNova]

Re: 1989 Mercruiser, Outdrive Problems

Outdrive is the basic principle ring and pinion. Although assembling with machinists dye ,spinning it, taking it apart, reading the "foot print"(heel and toe) ,adjusting the shim packs, re-assembling , re-reading ,etc is time consuming. The proper tools do make it a lot easier.

I agree whole-heartedly...nothing like having the proper tools and the time to do the job dead-nuts correct.

 

[ChrisK_]

Re: 1989 Mercruiser, Outdrive Problems

I'd like to thank everybody for their help on this.

I pulled the outdrive and drained the lower unit yesterday. The oil was milky with pieces of metal, and perhaps less than a 2/3 cup in total volume.

I assume the lower unit has some issues too, so I went ahead and ordered a new SEI outdrive. Its time to get back on the water.

I've just got too much going on to spend the time rebuilding another outdrive, after dealing with my old OMC earlier in the summer.

My hope is that I can pull the old outdrive apart and sell in parts. If the lower unit is still good, I'll sell for a few hundred on ebay. If not, I would have had to replace it anyway and the new unit is the way to go.

Yet again, thanks to everyone. Hopefully my next post will be about when I start refinishing the paint on the new boat at the end of the season (Seriously Baja, who thought pink and maroon stripes looked good?).

-Chris

 

[tswiczko]

Re: 1989 Mercruiser, Outdrive Problems

Now that you have the drive replaced you could rebuild the old one as a spare time project and have a spare when you are done.