Alpha 1 Gen 1 Bellows

[rollsfixer]

4.3 Alpha 1 1988 needs new U-joint bellows. I am following the repair manual procedure and I am at the place where it says to cut the core wire of the shift cable. This is apparently necessary because there is a "guide tube" over the engine end of the cable that stiffens the cable and is preventing the cable from being withdrawn to the rear. This guide tube is apparently crimped over the cable I am hesitant to cut the cable because once cut it needs replacement (I think) and I am not interested in replacing parts that are not bad. I do not know if just the core wire can be replaced.

I do not know if this shift cable is the new or old style, but looking at the aft end where the outer cable fastens to the bell housing, there is what appears to be a brass nut on the rear face of the bell housing where the cable comes through. This suggests the new style cable, but the age of the unit suggests the old. It has not been apart in this area since new.

This unit has very low operating hours but the U-Joint bellows has begun to leak water from age-related deterioration.

I would appreciate specific direction on how to proceed with the shift cable removal.

Oh yeah, my serial number is OC419200

 

[Bt Doctur]

Re: Alpha 1 Gen 1 Bellows

No need to remove the shift cable just for main bellows replacement.if you mean the shift cable boot,thats different. Usually boot and cable are the same age and both are usually replaced at the same time.must not have the real Merc manual, go here.
http://www.boatfix.com/merc/Servmanl/srvcovr.pdf

 

[rollsfixer]

Re: Alpha 1 Gen 1 Bellows

Yes, thanks, I can see that it is not necessary to remove the shift cable to get the u-joint bellows off and on. I assume you just let the bell housing hang on to the shift cable (support weight to avoid damage to the shift cable) and it would be possible to get at the u-joint bellows. I have been thinking that after 20 years it would be worth doing the shift bellows as well. This is not a job I want to do multiple times. However, maybe the shift bellows naturally has far greater life than the U-joint bellows, justifying letting it alone. It does seem like no serious damage is going to occur to the drive if the shift bellows fails, unlike the u-joint bellows which has let water destroy the gimble bearing.

I have been using the Clymer manual hard copy I bought years ago, but in the "real" manual it says the same thing almost exactly about the guide tube (referred to here as "support tube") and cutting the cable in step 6 of the part for "Component Disassembly" in this section of the manual: http://www.boatfix.com/merc/Servmanl/6/6B4R3.PDF

Anyway, as I look carefully at the support tube, I see the crimp on the end near the bitter end of the core wire, and I am going to buzz it off there with my Dremel and a diamond wheel. That will shorten the cable only about 1/2 - 3/4 of an inch, which I think I should be able to make up with cable adjustment. It will shorten the tube only 1/8 onch or so which should not make any difference.

Do you concur with that approach?

 

[ChrisCraftJohnny]

Re: Alpha 1 Gen 1 Bellows

Nope! If you must remove the cable, cut the retaning safty wire only, Then slip off the shift bellows. Use new safty wire to secure. If the shift bellow looks good, leave it be.

If it aint broke, dont fix it. Just as you said before Tie up the belhousing with a bungee or wire and leave the shift cable and the shift cable end alone. If you were shifting fine before the take-down. You should by all means shift fine after the job is done.

One tip: Place a good goop of Merc 2-4-C grease along the shift shaft where the wire comes out and also some in the pocket where the cable end lives. Also on the roller of the selector. Make a huge difference in shifting smoothness,

Johnny

 

[Bt Doctur]

Re: Alpha 1 Gen 1 Bellows

You can disregard that reference to cutting the cable core . That was for the early shift cable ,the support tube mentioned was installed on the cable and then the plastic slide was installed. the later style cables are already cut to size and do not use this support tube for the cable itself. the only "support tube" mentioned is the white plastic one on the end of the shift cable sheath.