Bellows replacement

[BigBoatinOkie]

I set out to replace the lower shift cable on my '86 alpha 1. When I removed the drive from the bell housing, I found a little water in the u-joint bellows. It wasn't a lot of water and the bearing seemed fine, so I'm guessing that I just need to replace the bellows. Am I right? If so, please tell me what I need to do the job and maybe where is a good place to get it. Seems like every job requires a special tool, is that true in this case?. Thanks for the help.

 

[ken_23434]

Re: Bellows replacement

There is a special tool needed for the exhaust bellows. I gave up on mine (did not have the tool, did not want to wait for ordering one) so I used an exhaust tube instead.

No special tool needed for the u-joint bellows, specifically. However, to get the bellhousing off (I think that's the correct name) you need a special socket that will fit the 2 pivot pins (under trim sender and limit switch). I think it was $35 at the local boat dealer for that. I have heard of other just using a 1/2" square drive bit to do it. I was afraid of stripping out that bolt. Not worth it for $35 in my opinion.

Other than the bellows, you will need the oudrive gaskets (which I assume you already have since you pulled off the out drive) and some bellows adhesive.

I think that was all I needed.

For about another $40 you can replace that gimbal bearing "just in case". Now would be the time.

 

[jam1ej20]

Re: Bellows replacement

1/2 inch stock hex key or a 1/2 inch allen socket will work for the hinge pins. That's what I used on mine, but it's a fresh water boat and hasn't seen any salt water. If they were corroded, I could see the hex key posing a stripping problem. The drive shaft bellows sleeve can be installed and the old one removed without the suggested tools, however, the tools certainly make the job easier. If there was water in there, I'd go ahead and replace the gimbal bearing and be sure to inspect the u-joints and drive shaft carefully for rust and wear. Lastly, you need an alignment tool to check alignment anytime the outdrive is off.

As far as gimbal bearing replacement, you can rent a slide hammer from autozone to remove the old one. I would suggest the driver to install the new one. Other guys have suggested everything from pvc to wood blocks to drive it in but you'll save yourself a lot of time by just getting the bearing driver.

 

[BigBoatinOkie]

Re: Bellows replacement

Okay so:
bellows
gimbal bearing
1/2 allen wrench for hinge pins
engine alignment tool
bearing driver

Does that sound like everything?

Pardon me for being ignorant, but how is the engine alignment tool used? Are there adjustments that can be made if something is out of alignment? Sorry, just trying to learn.

 

[jam1ej20]

Re: Bellows replacement

A 1/2" allen wrench will be tough if you're talking about the bent stock style. You'd be better off with a socket style and a 1/2" drive breaker bar or ratchet.

The alignment tool slides through the gimbal bearing and into the engine coupler. If it slides in and out easily, you're in alignment. If it is tight or won't slide in freely, you need to raise or lower your front motor mounts. The procedure is covered in the merc service manuals. The manual is truly your friend for these procedures.

You might as well replace the exhaust bellows and shift cable bellows while you've got it all apart, as they are probably due replacement also. Most people will also recommend replacement of the shift cable itself. Apparently they tend to have a life expectancy of about 5-6 years.

I know this seems like a lot, but you'll be glad you're all fresh back there after you see what a job it can be to take all this apart. You won't want to be doing this again before the season is over because the shift cable bellows is leaking too when you could have EASILY replaced it when you did the drive bellows.

Best of luck!

 

[ken_23434]

Re: Bellows replacement

To get the 1/2" allen socket you will probably spend about $15. I would still look at the real thing for an additional $20. Once you add up all your parts, you are talking about $150 to $200. I would not want to be chiseling out a pin cause I tried to go cheap on the one tool.

It's always recommended to check the engine alignment each time you pull off the outdrive. Pulling off the outdrive IN NO WAY can change the engines alignment, though. The alignment check itself is really easy. All you do is slide a metal rod into a hole. If it goes easily, then the alignment is good. If not, then you need to adjust the engine until it does.

So, you will find yourself in 1 of 2 scenarios.

#` You order the alignment tool, wait for it to arrive and then check your alignment. It slips right in, and you think "I just wasted money and time with this check".

#2 The other scenario is you do not do the alignment check, but you engine happens to have shifted or sagged a little over the years. Within a few times of taking the boat out to the lake, your new gimbal bearing gets fried or you burn up the engine coupler cause the alignment was off. In that case you think "If I had only spent the $$$ to get that tool."

While you have everything taken apart and are doing the work, it just makes sense to do the alignment check. However, the engine is in the exact same alignment it was prior to you taking the drive off. So, there might be a little comfort in knowing that it will be as good (or as bad) as it was before.

Your decision.

I got a kit with all 3 bellows, the water hose, gimbal bearing and a gasket set from a local boat shop for $150. There is a guy on Ebay that has the kit for about $100 that has been mentioned on the forum a few times. I would get the kit with an exhaust tube, save yourself the hassle and the extra money needed for another special tool.

That's my 2 cents...

 

[BAYLINER185]

Re: Bellows replacement

ive done the exhause bellows with out any special tools. I just used my bare hands and I gotta tell you it wasnt easy. I did the job and im happy with the bellows.

A lot of people are now using the exhaust tube in fact the shop i bought the bellows from said they will problably never order another bellows and only have been using the tube. I like the bellows idea, the tube seems a little cheese to me but it can save alot of work. I like my boat to run real quiet I just dont know how quiet the tube is personally.

 

[BigBoatinOkie]

Re: Bellows replacement

As I said in my first post, I was in the process of replacing the shift cable anyway, so I already have the parts necessary for that job including the cable bellows and some o-rings and gaskets. I have allen wrenches and allen sockets, so I'll give those a shot, and if they don't look like they are going to work I'll quit before I tear something up. I will be investing in an engine alignment tool. If that exhaust tube is easier to install and is safe to use, I'll try that I guess. I'm sick of buying tools. I've got way more money in tools than parts so far.

I do have a question about gimbal bearings. One bearing I've seen includes the housing and tolerance ring and the other is just the center without outer alignment ring and tolerance ring. Apparantly the tolarance ring and housing are reusable.

Thanks

 

[jam1ej20]

Re: Bellows replacement

While the outer ring is technically "re-usable," it's highly suggested that you replace the whole set-up. You really don't save that much money and you'd be putting a new center bearing in a used and worn housing. It'll cause your bearing to fail that much faster. Also, there is always the issue of lining up the grease holes to ensure proper lubrication.

 

[ken_23434]

Re: Bellows replacement

The exhaust tube is standard on some engines (larger ones). So, I would not have any concerns about "issues" it might cause.

Honestly, I do not notice any difference in noise from my engine since swapping to the exhaust tube. I know it isn't true, but my boat actually seems quieter now. It must be due to some other reason, though.

When your drive is trimmed down, the exhaust tube slips over the same spot the rear of the exhaust bellows gets attached. So, it is almost doing the exact same job as the bellows.