89 OMC Cobra OD Install Help

[GLanguell]

I removed my 89 OMC Cobra to grease the u-joints. In the process I replaced the pick up screen, all the o-rings and seals I had access to. Also replaced the shift cable & both shift box cables. My question is how does the OD go back on?? I spent two frustrating hours with the OD balanced on a jack while trying to get the U-joints past the upper boot seal. Man what a pain! I have the seal pretty scarred up thinking I need to replace it before trying a repeat performance. The outter lip of the sea folded back inside and was cut up while trying to install the OD.<br /><br />Any tips or tricks getting this thing back on would be greatly appreciated! I tried using two big bar clamps but that didn't help much. I did read here that someone used a ratchet-strap to help force it in. I might give that a shot this week.<br /><br />Thanks all!<br />Geno

 

[dick]

Re: 89 OMC Cobra OD Install Help

Light oil around the bellows and on the yoke , put drive on as far as you can then use a long screw driver to turn the yoke as you push in . Be carefull not to break grease fittings or damage the bellows with the screw driver.

 

[GLanguell]

Re: 89 OMC Cobra OD Install Help

Thanks Richard. I will give that a try later this week.<br />Geno

 

[Fox River Cruiser]

Re: 89 OMC Cobra OD Install Help

Geno,<br />I just did that job last weekend. I ran into the same thing, hung up on the u-joint housing. You need two people to make that job go better. Use a screwdriver turning the u-joints while pushing the drive back on. I didnt have help, but I rigged a rope aroung the drive, and used a large screwdriver to turn & tighten like a turnikit. Not very high tech, but it worked.

 

[loadnet]

Re: 89 OMC Cobra OD Install Help

I just installed one last week as well.<br /><br />It was acting up going in plus the gimbal kept movin on me so I lifted the gimbal and put a long steel rod accross under the gimbal so it wouldn't move around any more.<br /><br />The goofy thing went right in like nothing after that..<br /><br />Just letting ya know - I had a helper with me to manage the shaft while I pushed inward on the OD at the same time.

 

[metwrench]

Re: 89 OMC Cobra OD Install Help

Ahhhhhhhh TRICKS !!!<br /><br />I have done a Ton of these, and YES you can scare that Boot seal pretty Badly trying to ram it through..<br /><br />Light Coat of oil<br />Put the OD in Gear !! Thats right ..In Gear ! as your installing turn the prop as you push. If the shaft splines are lining up then the U-joint Yoke is getting hung up on the Boot/seal. If you Rotate the prop a little which in turn rotates the Shaft SLIGHTLY it will help it " Walk In". Right before you meet the OD with the Housing shift it back to Nuetral.<br /><br />That should do it !

 

[GLanguell]

Re: 89 OMC Cobra OD Install Help

Many thanks everyone! I got that rascal in... It was my last ditch effort. Last Wednesday after class I decided it was now or never!! At 11:00 PM and my last warm evening I got started. Working outside the garage, I grabed a ratchet strap to put around the OD & the Gimbal housing. I balanced the OD on my floor jack, aligned the drive shaft with the engine flywheel. I began to muscle the OD in. Using the screwdrive thru the U-joint suggestion, I worked it back and forth. Next thing I knew the OD slipped right into place. Only 20-minutes and bruises in my crotch & belly and it was in!! YA-hoo!<br /><br />Now my only concern is if I have the newly installed shift cable installed and adjusted correctly. I have this sickening feeling that it is off.... I followed Stewart's instructions to a tee...but....<br /><br />It -popped- in to reverse and everything locked up great. But shifting into forward, nothing happens. I have a bad feeling that the bellcrank ended up on the top side of the shift rod's duck bill. I removed the shift cable at the engine and tried to shift by hand, same results. Since I've winterized the engine already I didn't want to drag out the muffs and run the engine. So my game plan is double check eveything next spring.<br /><br />Stewarts pictures are a bit fuzzy, but thats to be expected and I do not have the original shop manual as he suggests. I could only find a Clymers manual at the time. I took pictures of the shift cable in case anyone would be willing to check my work. Otherwise, I'll give it a shot next spring!<br /><br />I want to thank you ALL for your help! I am so glad there is a web site like this!! Take care, talk soon.<br />Geno

 

[Lou C]

Re: 89 OMC Cobra OD Install Help

BTW you can still get the OE OMC shop manual, it is very good, you can order one from a Johnson/Evinrude dealer, about $35 or so, good pics in it!

 

[metwrench]

Re: 89 OMC Cobra OD Install Help

Yea That shift cable adjustment is tuff, even by the book !! I followed it to a " T " and after all the proper measurements I have still had trouble. Now I use the measurement and Get it close, then Fine tune it By 2 Spins on the thread and re-install. I know you dont want to pull that lower end again, But thats what you may need to do for fine tuning. Dont chance a Little labor for Screwing up the gears for a bad adjustment. <br /><br />The Screwdriver thru the U-joint is the same as in Gear and Turning the Prop. The idea is your spinning the U-joint Yoke pass that Lip on the seal..thats where they Bind up.<br /><br />Anyway, use your Common sense to guide you which way you need to spin that Gear slector...<br /><br />Good Luck Mate

 

[seahorse5]

Re: 89 OMC Cobra OD Install Help

Older bellows had almost a press fit to get the u-joint saddle thru it. As they got older the rubber would swell and make it even more of a hassle to install the drive, especially in cold weather. Finally the factory got smart and the new bellows, part no. 3854127 (about$53), have a larger inner diameter so the drive fits effortlessly every time. The nice thing about Cobras is that the bellows are a cinch to change out.

 

[GLanguell]

Re: 89 OMC Cobra OD Install Help

Just for piece of mind, I think I will replace both bellows and double check the shift cable next spring.<br /><br />Boat is stored for the winter now.<br /><br />Thanks everyone for your help! Sure got me out of the woods! Until the spring thaw....<br />L8r,<br />Geno