1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

[Hope2hitWater]

I have a 90 hp Force engine from a 1991 Bayliner Capri. We just found out that water was in the leg - possibly since last year. Huge mistake on our part. We thought it had been sealed when we had a water pump fixed and "thought" it had been checked for water before winter. We launched it a few weeks ago and to make a long story short we ended up pulling the lower unit off in the parking lot of a campground. We opened screws to check the oil and water came out - no oil. We turned it upside down and water came out between the water pump housing and the gear shaft ? It appears that there is nothing cracked from freezing - the unit "looks" solid. We are hoping to fix this one. We have it off the motor, and the prop off. I have a repair manual and I'm trying to get the tools needed. I've been searching the web for tips, videos, etc and have not had much luck. Before I start or help with this HUGE undertaking. Just wondered if it will be worth the trouble and money to try? I've looked on ebay and online for used lower units and I don't know which ones will fit. I can't afford to buy a rebuilt one - the whole boat with motor was about that price. I hope to sell some stuff and work extra hours to fix it or try to buy a used one.

My motor is 1991 90hp FORCE
numbers on motor mount 906x91E serial 027861

If anyone can give me a list of lower units that may work please help.

Thanks

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Pictures of my lower unit

Hope to repair or replace

 

[Frank Acampora]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

It is not a really huge project BUT-- if you had free water inside the leg, no oil, and the lower unit is locked, then it is an almost certainty that gears and bearings are rusted. You won't know for sure until you pull the prop shaft but I would guess that the only salvageable part is the casting and water pump. Not worth time and money to repair.

At the rear you will find a threaded ring with a stainless locking ring. Bend out the tab on the lock ring and screw out the threaded ring. Now pull out the prop shaft, reverse gear and dog clutch assembly. If they are rusty, just buy a good used lower unit.

Almost anything from Chrysler 1978 through Force 1991 3 and 4 cylinder will physically fit, (with the exception of Force 70 and 75) but you will need to match the shaft length on pre-1989 lowers.

You already have a dual exhaust lower unit so if you want an exact match, 1990-1991, possibly 1989 will do it.

The only Chrysler lower unit with a 2 to 1 ratio is the 90 HP. all the rest are 1.76 to 1 so if you get an earlier unit, you may need to reduce prop pitch by 2 to compensate since your 90 has about 1.95 to 1 ratio.

Some Force 85 engines did come with 2 to 1 ratio lower units.

So: Check the condition of your existing lower and when you find rust, then look around on the auctions and craigslist for a used one.

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Was able to remove propshaft and the bearings didn't look bad. There is a minute amount rust on the gears. We have removed the waterpump and housing (which has a crack in it). Had to stop here for the night. We will have to make a tool to remove the shaft that goes vertical (don't know the correct name for it yet). Hope to salvage as much as possible and rebuild it. It looks really promising. I know I will need to replace several seals, rings, gaskets, etc. I've taken pictures of each item as removed and placed them in labeled ziplock bags for speedier reassembling. I may have questions as I go. Thanks

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

We have removed everything except the OUTER BEARING RACE (OBR) that holds the 18 pinion gear roller bearings.
We plan to replace the bearings. What is the best method of removing this OBR ? Is is hard to replace this OBR without special tools?

We have thouroughly cleaned all of the shafts, gears, etc. and plan to replace all of the bearings, seals, and waterpump.

Any tips will be greatly apprecitated.

 

[emoney]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

A tip; might save time if you post pictures of anything in question. Lots of help here at iBoats, but it makes it a LOT easier on them if they can see the part in question. Plus, with so many threads needing help, it helps to set yours apart. Good luck, you'll get it and be back on the water in no time.

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Here is the best picture that I could draw over the bearings that are in question. I used the same numbers as the schematics from several parts stores. I can't get my camera inside the housing.






Thanks

 

[jerryjerry05]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

You have the type B drive.
I believe the pinion bearing is a caged bearing that can be driven out from the top???
The shaft that holds the pinion is called the drive shaft.
No race in the pinion area(I think)
Did you get the nut off the bottom of the shaft?
Did you get the pinion gear off?
The coupler is sometimes used as a tool.
A pipe wrench on the coupler and a long wrench.
Or a big breaker bar with a 6 point socket.
Use the best socket you can get.One slip and it can get messy.
Forward gear come out??

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Yes, we have removed every shaft, gear, etc from the gear case except this one bearing race. We have the 18 bearings out that we plan to replace. Just didn't know the best way to remove the race. I'm not very versed in the terms for some of the parts. What is the coupler that you mention? I'll try to borrow a strong socket - didn't think of that - thanks

 

[emoney]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Great picture with drawing, btw. If everybody put pics like yours, labeled like you did, it would probably really help these guys. Good job!

It's times like these that we all wish we owned one of those thin "snake cameras" that let you see down/up into tight places. I've looked at them every time I'm at Harbor Freight but never pulled the trigger. Oh well, I diverge....you're almost there, keep us posted.

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Great picture with drawing, btw. If everybody put pics like yours, labeled like you did, it would probably really help these guys. Good job!

It's times like these that we all wish we owned one of those thin "snake cameras" that let you see down/up into tight places. I've looked at them every time I'm at Harbor Freight but never pulled the trigger. Oh well, I diverge....you're almost there, keep us posted.

Thanks - ---I need a SURGEON's camera

Here are some new pics that I shot from inside the gearcase showing the only two places that a driving tool can touch to drive this out.






We tried to remove this last night, but couldn't find anything that we had to work. We are trying to get something that will work. The repair manual mentions special tools P/N T11209, T8907, & T11205 or T16433. I can't find any pictures online of these tools.

Anyone have any of these willing to post a picture???
I can get access to lots of junk metal, a drill press, a metal lay, and some grinders if needed.

Thanks

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

Confused about gear ratio for my lower unit. I have no knowledge at all about any of this at all. First time working on any motor.

I've looked at the skematic diagrams on several parts stores and do believe that I do have the type B drive as mention on this thread.
My confusion comes from the parts list -
I'm copying and pasting below
FS707023 GEAR ASSY., FORWARD (1.93:1 - TYPE B & C)
816435 GEAR, REVERSE (1.93:1 - TYPE B & C & D)

I am hoping to get by without replacing any gears. I wanted to replace the bearing on the forward gear assembly, but it is not sold separately. I found one used on ebay that may work, but I don't want to get the wrong thing.

Thanks for any help.

 

[Hope2hitWater]

Re: 1991 Bayliner Capri Force 90hp lower unit locked up - repair? help please!

We have now officially removed ALL parts from the lower unit We were able to knock it out with a long "modified" chisel and hammer. Getting the new one back will present a new challenge.

So now comes the $$$$ - we have to order all of the parts and start putting this thing back together.
While we're waiting on parts, we have some rust removal and cleaning to do.

May need more help during the putting together phase. It's easier to take apart than to rebuild.