Looking for a little guidance on outdrive

[RiffeShooter]

First of all I am new here so hello!:thumb: I just purchased a Bayliner Trophy 2502 with a 300 hour AQAD41A motor in it and a duo prop outdrive. I've taken it out a couple of times now and she runs excellent. I now want to do all of the "make my mind safe" maintenance such as fluid changes, filter changes, etc. The fuel and oil seem to be straight forward as I am no stranger to engines but the outdrive is a new beast to me.

First of all, I am not sure which one I have (tag on top worn out) but I do know it is either a 280, 290, or 290A, and obviously a Duo Prop, hopefully someone here can tell me. The props on it are the A6 series. Here is a couple of pics:






Second - There appears to be some small leaks and some water intrusion since the oil is milky. Is there an "easy" place where I can find the part numbers I need to order? :facepalm: Here are pics with what I think are 3 separate leaks:




Third - I think I read somewhere 2.7 quarts is the ticket. Should I go with a 75/90 synthetic gear oil like Amsoil or do these drives like something different?

Fourth - Which paint should I use on this one and where do I get it?

Finally, with regards to the props, does someone make a stainless set for this drive? All I have seen are aluminum.

Thanks again for any help, I do appreciate it!!!

Jason

 

[Bondo]

Re: Looking for a little guidance on outdrive

Ayuh,.... Welcome Aboard,... I imagine the same outdrive paint I use, in white insteada black would work just Fine for ya,...
I scuff my drive off once a year or so, 'n shoot it with rattlecan Rustoleum...

 

[Don S]

Re: Looking for a little guidance on outdrive

Parts you can find here at iboats Volvo Penta Marine Engine Parts and Accessories Online Store - Volvo Penta

The first place I would look for water leaks is the bellows. It looks old, and water gets into the ujoints, and the drive since the front seal of the drive is not designed to keep water out. The bellows is supposed to do that.

The drive is either a 290 or a 290A, Basically the same thing, just minor differences inside, nothing that changes what you can do, or seals or anything like that.

Gear lube is GL5 90W mineral gear lube for that drive.

You can use stainless props, but there aren't specific diesel props as in the aluminum props. Might check our prop forum for more info on the props.

That red shift cable is shot, it's not a Volvo part, just a basic Teleflex cable you just need to find the length of yours.

You might want to spend some time here VP Information. for tips on changing the bellows, and other drive information.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Thanks for the info gentlemen. Since the boat did not originally come with a diesel option I suspect that cable was used as a custom cable. I will try and determine what length/brand it is and get a replacement. Yes, there are a couple of gouges in it.

I will go through the links you provided Don S. and thanks in advance as I am sure I will be using the vast wealth of information you have posted here!

As far as the water intrusion in the outdrive, should I just continuously run that 90W through until I see clear? Or does this mean it needs to come apart and be cleaned? Thanks!:joyous:

 

[Don S]

Re: Looking for a little guidance on outdrive

If there are leaks, they need repaired, DO NOT keep running it like that. Drain the drive and pressure check it and find out where all it's leaking. Obviously the bellows leak won't cause oil to leak out the back cover.

That shift cable has nothing to do with diesel or gas, it's just a standard 33C cable with threaded ends Volvo Universal Type Control Cables - iboats

Here is the procedures for the Pressure and Vacuum check of the drive. You might find this service manual handy as well. 280 to DP-C Drive manual

.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Thank you! I will get the pressure test done as soon as I can and report back. I won't run it until then...

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

I am going to order the seals that you have listed on http://forums.iboats.com/mercruiser-i-o-inboard-engines-outdrives/vp-357328.html#post2360521this thread but can not find the bellows part number. Do ya'll offer a "bellows kit"? I noticed one of those but in the Sierra brand.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Second, is anything I should replace while doing the bellows such as the u-joint maybe? Or, anything else in the area that can be knocked out while doing the bellows?

 

[Don S]

Re: Looking for a little guidance on outdrive

Get the OEM bellows, they are much better than the aftermarket. The "Kit" consists of the bellows and 2 new clamps with instructions on how to position the clamps properly (Very Important). Item #60 here Upper Gear Unit: Drive Dp-A - 7745630 - Volvo Penta

No need to replace the ujoints unless they are needed. You won't know that until you get it apart.
If they are rusty, you will also need to replace the input shaft seal in the drive, and check for water intrusion into the bearings in the flywheel cover. If those bearing are rough and make noise, you really need to replace them before the take out the housing itself.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Thanks! I pulled the shift housing cover off just to take a look and there is some oil seepage in that area, what other seals should I add on to correct this? I'm assuming there should be none there based on there be no gasket or o-ring for that cover...


EDIT - Oh yea, I have not noticed any abnormal noises whatsoever coming from drive...

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Closer up pics of two potential leak spots... Between top and intermediate and intermediate and lower...





Don't know why these keep coming out sideways... Look fine when I upload. Lol

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Upper Gear Unit: Drive Dp-A - 7745630 - Volvo Penta

I feel like an idiot today. Where do I navigate to to find these exploded views? I have a hard copy of the workshop manual but it doesn't give me the part numbers but does have the exploded views. I would like to print out the part numbers and prices to stick in the book so I know what stuff is called.:lol: I can't find the intermediate or lower portions...

What time is your shipping cutoff today?

 

[Don S]

Re: Looking for a little guidance on outdrive

Volvo Penta Engine Part Catalog - Volvo Penta Here at iboats.

In the box that says Instant Search By Model # type in your engine model number.
Once you are on that page go to transmission section and find your drive, or whatever you are looking for.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Cool, thanks. Didn't hear back on anything else I should add to order so I just placed the order of the above stuff and requested overnight delivery. Thanks!

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Started taking top off to do bellows. Bellows disconnected, allen bolts out, side nuts off, shift linkage disconnected and it don't want to budge. Any pointers? Heat? Big arse hammer?:joyous:

 

[Don S]

Re: Looking for a little guidance on outdrive

Assuming you are removing the upper gear box, I just use my hand and hit the top of the upper side to side to break the sealer loose.
If your hands are tender, a mallet will work, just don't bang on it like you are trying to break it.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Yep, the upper to change the bellows. I just got back from playing 36 holes so my arms are a little tender. Lol, in any event, I just broke out the mallet and it was still really really stubborn. Had to do some careful prying eventually but finally got her free. This is what I am seeing, a little milk, some rust on the u joints but not too terrible (in my mind any way). If I should replace them I certainly will... Inside of bellows contains some oil with some moisture but no puddles of water anywhere.

 

[Don S]

Re: Looking for a little guidance on outdrive

Ahhhhh, a salt water boat. I can tell by the corrosion.
Was looking at your location (Lake Jackson, Texas) and thought you had a lake boat.
See your gentle prying took out the shift cable as well.

You need new ujoints for sure, and about a 99.9% chance you need a new front seal in the upper and the sealing washer it rides on. Which will require the front of the upper gear box being removed, disassembled, cleaned and dead parts replaced, along with getting the shimming right and the rolling torque.
You can bet money the shims will look just as good as the rest you have pictured, and that's not good.

You up to that?

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

Well if I have to... Lol, How bad is it? U joints no problem. Shimming an out drive, never done it. The cable was fubar already. I did just pull it out to replace it. It has rips like that in several places. I measured it and it is a 25 footer. Pulling that thing out was a little pita in the transom area. I actually cut the cable and pulled it from outside and then the other 21 feet from the shifter area.

1.) How bad is this shimming procedure and what tools do I need? The shims I have aren't exactly one color but they are discolored. They can probably be reused but if what you are proposing changes the angle of the dangle...

2.) U-joints, check. I'll submit an order tomorrow probably for overnight delivery.

 

[RiffeShooter]

Re: Looking for a little guidance on outdrive

And oh #$%^, I think I remember reading somewhere that you should use a string to pull the new cable through. Ok, how screwed am I?