gearcase lube won't pump past valve assembly

[bigAl52]

I replaced the bellows and water and oil hoses. Also replaced the oil valve assembly that sticks out from the bell housing and pushes into the outdrive. Once everything was reinstalled I tried to refill the gearcase with lube. Everything went fine with oil starting to come out the vent screw hole. Once I put screw in and started to pump the oil again the pressure built up until the tube popped off the lube bottle and I had a real mess. It seems there is a blockage at the oil valve assembly point. The mechanic at the local dealer told me to just top up the gear lube in the container on the engine and that it would work it's way down. Not sure if that makes sense. I don't want to be on the water and have the oil heat up and expand as there is no where for it to go. Should I bite the bullet and pull the outdrive and check the valve? If so what am I looking for? Also, if I do should I be gluing the large rubber ring that goes between the drive and the bell housing? I didn't do that, and didn't see that mentioned in the manual, although I might have missed it. Thanks.

 

[dubs283]

Based on your post, questions and issues it would seem you are working on an alpha gen 2? If so, yes the mechanic is correct. Fill the drive to the upper vent hole, install the plug with a new gasket ensuring the old one was completely removed, then do the same at the lower fill/drain plug. You only need to top off the monitor on the motor, often times after the first few runs the drive will "burp" and the monitor level will drop slightly. Just top of the monitor and don't forget to check it periodically. After all it is a monitor.

The large quad ring in the bell housing just needs a dab or two of bellows adhesive to hold it in place while you install the drive, too much adhesive can actually inhibit the sealing of the quad ring and cause a leak

 

[bigAl52]

Based on your post, questions and issues it would seem you are working on an alpha gen 2? If so, yes the mechanic is correct. Fill the drive to the upper vent hole, install the plug with a new gasket ensuring the old one was completely removed, then do the same at the lower fill/drain plug. You only need to top off the monitor on the motor, often times after the first few runs the drive will "burp" and the monitor level will drop slightly. Just top of the monitor and don't forget to check it periodically. After all it is a monitor.

The large quad ring in the bell housing just needs a dab or two of bellows adhesive to hold it in place while you install the drive, too much adhesive can actually inhibit the sealing of the quad ring and cause a leak

Thank you for your response. Yes it is a gen 2. I will pull the drive to be sure ring is in proper position. Hope to get on water for the long weekend.

 

[QBhoy]

Hi. As eluded to above. You only pump it in until it comes out the vent hole. Then close everything up tight. Then you top up the reservoir bottle from the engine bay. First few runs out…it will drop in level to take up the void space between that and the vent level. Just top it up again until it settles.

 

[poconojoe]

Hi. As eluded to above. You only pump it in until it comes out the vent hole. Then close everything up tight. Then you top up the reservoir bottle from the engine bay. First few runs out…it will drop in level to take up the void space between that and the vent level. Just top it up again until it settles.

This is why I always keep a bottle of drive lube in the boat.

 

[QBhoy]

This is why I always keep a bottle of drive lube in the boat.

Likewise. I always have one for the top up required after the first couple of outings, after servicing.