bellows and bell housing replacement

[mike456]

The moment approaches. I'm going to replace my 1992 Mercruiser Alpha I Gen II, shift cable, water hose, all bellows, and bell housing (my old one has a large hole in it) this weekend. I've got all the old parts off and cleaned and painted the transom plate. I have a Selco manual and the Mercruiser on-line one (that Don S provided). I have read the manual and prior postings extensivly. Think I'm ready to go but would appreciate any further advice or hints for a first timmer. My plan is to run the shift cable into transom first, connect the water hose from inside boat, connect drive bellows, connect exaust bellows, connect shift cable bellows, do hindge pins, finish shift cable ends connections. I do not have a gear case oil resivior. I have the tool for the shift cable. I do not have the exhaust bellows expander. Can I connect exhaust bellows to bell housing first then push it onto the the transom plate? I know it will be tight to get at. Any other expert advice on the whole process is much appreciated. THANNKS!! This forum is the BEST!!

 

[tommays]

Re: bellows and bell housing replacement

1. be carefull about hose clamp position as NOT doing them buy the book they WILL poke holes in your new parts<br /><br />2.Be carefull NOT to kink the water hose ,It has a natural curve in it that will follow the path easery<br /><br />3. Your really gonna want that exaust belows tool <br /><br /><br />tommays

 

[Bondo]

Re: bellows and bell housing replacement

I do not have the exhaust bellows expander. <br /> 3. Your really gonna want that exaust belows tool

I'd just Switch over to the newer Exhaust Tube.........<br /><br />Much Easier,.... Much Simpler......

 

[mike456]

Re: bellows and bell housing replacement

I've read about the Exhaust Tube. I guess I'll go with that if its not too expensive. Thanks for the advice you guys!

 

[natwales]

Re: bellows and bell housing replacement

I just re-sealed my transom a few weeks ago on an alpha 1. I did the shift cable, shift shaft, u joint bellows, exhaust bellows, water hose - just about anything that would ever need to be replaced was. I had never done this before and It took me two long days. <br /><br />Here are a a few tips that I came away with.<br /><br />- when putting on the U-Joint bellows, remove the stainless steel wire in the bellows so it will be easier manage. Once the bellows are glued in place, feed the stainless wire back into it's track.<br /><br />- bring a propane heat and a very long breaker bar for those hinge pins. Took me several hours to free up. It needed lots of heat and torque.<br /><br />- use the exhaust tube and not the exhaust bellows if it's an option. It'll be much easier to put on and will save you needing the bellows expander tool. You also will not have to remove your shift shaft.<br /><br />-buy all the special tools you will need. Get them on ebay and re-list them when you are done.<br /><br />- bring a portable hot water pot to boil the ends of the hoses to make it easier to get over the nipple.<br /><br />- Don't force any bolts that won't come out easily. I managed to sheer off the bolt for the trim sender and it was a real hassle. Use lots of heat and penetrating oil and go slow.<br /><br />- I found that a socket wrech with and extention and a swivel head was essential.<br /><br />- Pay carful attention to the order in which you do things and always think a few steps ahead. This makes it much easier to get at hose clamps, etc. One mistake I made was that I did my shift shaft before my exhaust bellows and the whole thing had to be removed.<br /><br />- One those hingepins- when you try to free up the port side, the whole bellhosing assembly will want to pull up as you try loosen the bolt. If it's possible leave the outdrive on for this step so you can put a foot on it for leverage. I already had mine off and had to use some line to hold the bellhousing down.