Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

[donskrin]

I bought a 98 Crownline 210 CCR several months ago with 102 hours on it. It has a 5.0 Merc with the Alpha Gen II outdrive. The boat, engine, and outdrive all appear to be in very good shape except the bellows have 'cracks' in them - I suppose due to their age and lack of use. There does not seem to be any leaking going on with the exception of approximately 1 drop of raw water per 2 seconds at idle and approximately 1 drop per second at speed coming out of the shift cable where it attaches to the engine. This leak was happening when I purchased the boat so I asked the previous owner (through the broker) to provide me a new shift cable, bellow, and gasket - which he did.<br /><br />Based on this I plan to remove the sterndrive and replace the bellows and shift cable.<br />I took the advice of many on this board and bought the Mercury OEM service manuals and the instructions don't seem that intimidating with the exception of several special tools identifed as needed, to include...<br /><br />shift shaft slide stabilizer tool to reinstall the sterndrive unit<br /><br />shift cable removal and installation tool (91-12037)<br /><br />bellows expander tool (91-45497A1).<br /><br />My question: Is this a job that the average mechanically inclined person can accomplish and if so are these and any other special tools required. If not, does approximately $500 (including me providing the shift cable, bellow, and gasket) sound reasonable to have this done? This is an estimate that I have received. This assumes nothing else is wrong that needs to be fixed such as a new gimble bearing, etc. (the $500 estimate does include installing a new impeller)<br /><br />Thanks in advance for your help/opinions!<br /><br />Don

 

[tommays]

Re: Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

http://www.iboats.com/cgi-bin/ubb/ultimatebb.cgi?ubb=get_topic;f=24;t=010458#000000 <br /><br />did it myself you need all the glues ,perfect seal ,aliment tool ect<br /><br />it will be a test of you patience as everthing is packed tight<br /><br />the leaking means you will find other problems<br /><br />if you pull the drive you find what else you need real quick<br /><br /><br />tommays

 

[jeff13601]

Re: Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

I have been told it is a five or six hour job. If you are going to have it done you should probably have all of the bellows changed and the gimble bearing if needed.

 

[Don S]

Re: Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

Since you have the manual and looked at the process and it doesn't sound to intimidating to you, then you can probably do it. But it will be a PITA and it is time consuming. Especially on your first time.<br />Just take your time and get it all right and follow the manual.<br />When you remove the drive, make sure there is no water or signs of water in the bellows. Water will get into the gimbal bearing and ujoints and causes them to rust and become rough and fail.<br />One special tool you failed to mention is the alignment bar. Your engine alignment should be checked yearly (everytime the drive is removed). An out of alignment condition will cause the engine coupler to fail (Requires engine pull).<br />The cause of your water leak on the shift cable is probably the shift shaft bushings in the bellhousing. If you don't replace it, you will have water coming into your new shift cable.<br />(See page 4B-37 of your manual for the bushings)

 

[rodbolt]

Re: Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

check the upper shift shaft busings. they usually leak from the exhast cavity. the stabilizer tool is a teat on a boar hog. if your changing the exhaust bellows the expander tool is worth its weight in gold. on a genII you must have the sleeve driver tool to properly seat the expander ring on the ujoint bellows. the shaft alignment tool is nessasary to check alighnment. the cable removal tool is cheap and worth it. if all your after is the cable and bellows assy its easy. I reccomend doing at least the cable and ujoint bellows and its easy to replace the exhaust bellows while your there.

 

[donskrin]

Re: Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

Thanks all for the responses! <br /><br />Don S, rodbolt: If it is the shift shaft bushings leaking would I be taking a large risk in going out a couple of times on the boat before doing this work? Also, would this necessarily mean the gimble bearing or u-joint has been exposed to water?<br /><br />Thanks,<br /><br />Don

 

[rodbolt]

Re: Changing bellows and shift cable...98 Merc 5.0 w/ Alpha Gen II

hello<br /> if the upper shift shaft seal leaks it will allow water into the shift slide pocket. with water in the pocket it allows water to intrude the caable and outer cable jacket support wires and causes a cable failure. its not an instant failure. it takes some time and as the cable gets stiffer it will start triggering the interupt switch on gear engaugenent. if the seal in the gimbal bell housing (large square oring) is in place and in good shape no water should be able to intrude the drive bellows area from the shift slide area. you have to carefully study all the sealing areas of the transom assy and understand how each and every one works and why. there are 5 main areas in the transom assy that have to get along, trim hose manifold, shift,drive,water intake and exhaust. there is a lot going on at the same time in a small space. break it down to a subsystem level and study how it works. all the hoses and parts are submerged and need to be sealed. if not bad things can and do happen.