Discovered twisted prop shaft Volvo SX drive, DIY or take it in?

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craze1cars

Lieutenant Commander
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Dec 26, 2004
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1999 Volvo SX part number 3868891 serial # 4112050296

While attempting to replace my prop today on a new-to-me boat that I know no history of...I discovered twisted splines on the prop shaft. New prop will not slide on far enough to reach the thrust washer, and I'm measuring about 1/16" of runout at the tip of the shaft. Not good...

Boat HAS been running well, no strange noises, and surprisingly no noticable vibration. Therefore I do not believe there is any deep damage to any gears/bearings, etc.

I have never done this before.

In reading service manual provided to me by Don S...
Looks like prop shaft removal/replacement is pretty straightforward, but it specifies 2 special tools needed: a Spanner tool 3855877 and a Thread Puller 884789.

QUESTIONS:

1. Do I need to buy both of these tools or is there a "shortcut" method that would allow me to use "normal" mechanics tools that someone can share with me to avoid a tool investment? Can either of these tools be easily fabricated?

2. What parts specifically do I need to purchase besides the prop shaft itself? I presume I will also need some O-rings or seals in addition to the shaft?

3. How many labor hours does this typically involve? If special tools are too expensive or hard to come buy, I may be out money ahead to just have this repair done by local marina. Would anyone be willing to hazard an educated guestimate of fair cost if I take it in?

EDIT. Local marina just quoted me $603.75 for the shaft, $50-ish for seals/fluids, and $600-ish for labor. $1,300 job. Are they in the ballpark or should I be shopping around?

Might be worth my investment to buy the tools...I have all winter to get -er done.

Thanks!
 
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robert graham

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Apr 16, 2009
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6,908
Re: Discovered twisted prop shaft Volvo SX drive, DIY or take it in?

better buy a book on this procedure because there are critical clearances set with shims in these gear boxes. Plus you'd have to buy the special tools. You could pay the pro to do it or look for another foot, either used or rebuilt, put it on and keep the old one for parts or try to sell it to someone who repairs them. Maybe the folks who deal and rebuild the Volvo Drives could sell you a rebuilt one and take your old one as a "core". Maybe google up Volvo Drives? Good Luck!
 
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craze1cars

Lieutenant Commander
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Messages
1,822
Re: Discovered twisted prop shaft Volvo SX drive, DIY or take it in?

Thank you. The more I look around and read the service manual, the more I think I just want to pay someone to have this done.

I've priced a few drives...pretty high. I think fixing this one is probably most economical for me.

I have now talked to 3 local marinas, and prices are dropping. They ALL say it is a $600 prop shaft from Volvo, but labor prices are coming down out of the stratosphere...

Got $1,019 quote parts/labor from one, including everything, and the 3rd one quoted me "parts/labor/fluids just under $900." A little better than my $1,300 initial quote.

PLUS...that last "under $900" guy said he'd be more than willing to install MY parts if I can get the shaft for less jing. It's a reputable Volvo dealership I've worked with before on my other Mercruiser, and I was pretty surprised when he didn't balk at all on my suggesting I bring my own part....he was very willing. Which brings me back to Ebay, where it appears I can buy the shaft brand new for $350 instead of $600. If that is the correct part, I can get this shaft replaced for about $650 parts and labor included...not bad IMO.

Is someone able to please confirm for me that the correct prop shaft part number for my drive is indeed 3857675? I believe it is.

Thank you so much for all the help I always get on this site.
 
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