Bellows replacement mercuiser alpha 1

Jamz3333

Seaman
Joined
Oct 12, 2010
Messages
72
I'm going to be replacing the bellows on my mercuiser alpha 1, and was wondering if there is an instruction manual that I could get. Not sure about how to remove the shift cable to replace the bellow. Any help is greatly appreciated.
 

poconojoe

Lieutenant Commander
Joined
Sep 10, 2010
Messages
1,966
Google boatinfo for all manuals.
You should click "adults only" at the top of the mercruiser I/O repair section. LOTS of reading and links there that will help you.
 

Jamz3333

Seaman
Joined
Oct 12, 2010
Messages
72
I wasn't able to find anything on the shift cable removal. Maybe I was in the wrong spot.
 

poconojoe

Lieutenant Commander
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When I did mine (alpha1 gen2), the shift cable instructions were covered in the bellows replacement instructions.
What alpha do you have?
 
Joined
Feb 19, 2015
Messages
74
Do a search on YouTube for changing bellows and changing shift cable. I just did this on my alpha gen+, the videos were great help.
 

Jamz3333

Seaman
Joined
Oct 12, 2010
Messages
72
I have a alpha 1 gen 1. I'll try to look it up. Does anyone know if the shift cable runs up to the shifter or does it go to the motor first?
 

NHGuy

Captain
Joined
May 21, 2009
Messages
3,631
There are 2 cables that meet at the shift plate. The lower cable is the one that's normally changed, if any. It runs between the shift plate on the starboard exh manifold and the transom.
Once the cable is disconnected at the top and bottom slide it in and out through it's range. It has to be perfectly smooth and slide nicely. Any restrictions or kinks will cause you fits well beyond what it costs.

You basically put the shift in forward,remove the drive, cut the shift cable bellows and remove the lower shift cable. Then remove the sensors on the pivot ends of the bell housing, remove the pivot bolts on either side of the bellhousing, cut the 2 drive and exhaust bellows. Now it's apart. Get your cell phone or camera and note the position and direction of all the clamps. It only goes together well one way.
Buy good parts, you don't need to save $10 and have it cause a poor seal or short bellows life.
When you put it back together you need the right bellows cement and you'll need a long thin straight blade driver for the bellows clamp that's straight in from the little round hole on the outer side of the transom plate. I also get good use from my 1/4" drive flexible spring extension, to run in some of the clamps.
To adjust the cable there are steps that need to be done in sequence. Best way is to watch achris's video.
 
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poconojoe

Lieutenant Commander
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Sep 10, 2010
Messages
1,966
NHguy has good advice!
+1 on watching YouTube videos by chris. They are a must.
+1 on getting a 1/4" flexible extension for your 1/4" drive ratchet.
+1 on the use OEM parts. I've heard problems with other brands.
The mercruiser manual is a definite must! It gives step by step instructions.
 

poconojoe

Lieutenant Commander
Joined
Sep 10, 2010
Messages
1,966
I went to boating and for your alpha1 I think you need mercruiser manual #6 and it does explain the shift cable replacement in the bellows section page 91.
 
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