1991 Mercruiser 3.0L, Alpha 1 Gen 2 Outdrive

[Roadblock007]

The boat is a 1991 Bayliner Capri Bowrider with a 3.0L Mercruiser and an Alpha 1, Gen 2 outdrive. I purchased it late spring this year and had carb rebuilt, new alternator belt, new thermostat. Had plugs, oil, fuel filter, distributor cap, rotor, and wires changed as well as outdrive oil/lube changed. I did this all before my first day on the water because I wanted a good shop to give it a once over to make sure nothing was wrong with it. It ran great for me during the summer. In my driveway recently it has developed a leak at the seam on the top of the lower unit. Very slow and green so it is the lower unit oil. I am starting to plan my fall/winter maintenance and would like to know if I have missed anything on my list.

Because of the leak I will be looking at changing my shift shaft seal and lower drive shaft seal under the water pump cover. I will also be inspecting my shift shaft housing. I will be changing the impeller with the kit so it will include the gaskets. I am wondering if I should also be pulling the whole unit off and doing the bellows and inspecting the gimbal bearing.

I have extensive mechanical knowledge, tools and ability but so far just with cars. This is my first shot at boat mechanicals.

Thanks.
RB

 

[Rick Stephens]

Every year you should pull the drive, drain it, inspect everything including u-joints, gimbal and bellows, check alignment. That is standard maintenance. In your case, pressure testing is in your future. Do not just go to replacing seals without then pressure testing before refilling the drive with lube.

 

[Roadblock007]

Every year you should pull the drive, drain it, inspect everything including u-joints, gimbal and bellows, check alignment. That is standard maintenance. In your case, pressure testing is in your future. Do not just go to replacing seals without then pressure testing before refilling the drive with lube.

Thank you. I was thinking about replacing the seals not just because of the leak, but because I don't know if they've ever been done and I am a big believer in PM.

 

[Scott Danforth]

Thank you. I was thinking about replacing the seals not just because of the leak, but because I don't know if they've ever been done and I am a big believer in PM.

Than if you follow the PM schedule, you pull the drive every year for the service that Rick mentions. Part of the PM is a pressure test

 

[JoLin]

Thank you. I was thinking about replacing the seals not just because of the leak, but because I don't know if they've ever been done and I am a big believer in PM.

An annual pressure test wll tell you what you need to know. My drives are the same vintage as yours. In the last 3 seasons, pressure testing revealed that I needed to replace 1 shift shaft seal and one lower drive shaft seal. In the second case I was replacing the water pumps on both drives, so I replaced both seal assemblies at the same time. You should always replace the washers on the vent and drain screws.

I wouldn't talk you out of replacing the shift shaft and drive shaft seals, unless they look new when you eyeball them. They're cheap and easy to swap out.

My .02

 

[Roadblock007]

This is great information. Thanks guys.

 

[Roadblock007]

Than if you follow the PM schedule, you pull the drive every year for the service that Rick mentions. Part of the PM is a pressure test

Scott, could you please post or give me a link to the PM schedule? I'd like to see anything else that I am missing.

Thanks.

 

[achris]

Scott, could you please post or give me a link to the PM schedule? I'd like to see anything else that I am missing.

Thanks.

Best thing to do is get the FACTORY (Mercury) service manuals for your ENGINE and DRIVE... They have all the required maintenance and repair procedures. You should also find a maintenance schedule in your owner's handbook (you know, the one everyone throws away... )...

Chris........

 

[Roadblock007]

Thank you Achris. That is very helpful. I will have a lot more questions as I get going on it I'm sure. Thanks!

RB