lower unit install/ gear concerns/ alpha 1

[wcsparky05]

just overhauled my impeller and ready to put it back together. but, the book said shift into fwd and turn prop ccw. it only turned cw but i heard the definite "click" the book talked about. was this a misprint? how do i know when i reassemble if i'm in the right gear? also, could the prop shaft or gearshaft turning a bit during the water pump removal damage anything? why is there no gasket betweem the lower unit and upper? Also, to refill the cooling system with water, do i just pump water through the outboard intakes? thx for the help, again!

 

[tommays]

Re: lower unit install/ gear concerns/ alpha 1

Which Alpha 1 GEN I (before 1991) or GEN II (1991 and up)

I can give you a link to the service manual to read


Tommays

 

[bgt3000]

Re: lower unit install/ gear concerns/ alpha 1

First, the gasket....there should be a small round ring (about 3/8') for the oil hole between the upper and lower unit. That's the only gasket it needs....and it HAS to be there. I keep a few on hand cause they are easy to loose.
When you put the lower unit, putting the remote in fwd and turning the prop ccw is right as long as the shift shaft is turned to the fwd position as well. if the prop won't turn ccw (or will only turn a few inches then stop) then the shift shaft is in the right position. Turning the prop also holds the shift shaft in the proper position when aligning the two halves.
Once the two halves are together, lower the outdrive, sift into the gears and make sure the prop turns in the right directions and turns free in neutral WITH THE ENGINE OFF.

Hope this helps.
PS...It took me about 10 tries to get it on right...until I learned about "putting it in fwd", so it really does work.

 

[wcsparky05]

Re: lower unit install/ gear concerns/ alpha 1

thx, bgt3000. but, the oil hole you speak of...are you talking about the small gear directly above the lower unit drain/fill that needs a 3/8 rubber washer over the 3/8 metal washer or a gasket? again, thanks for the help!

 

[bgt3000]

Re: lower unit install/ gear concerns/ alpha 1

When you take off the lower unit, there's a small hole on the right side on the top of it. it will be recessed a little bit. This is the channel that the gear oil passes through from the upper to lower unit. That's where the small o-ring goes to seal the hole when the 2 halves are put back together.
I think the 3/8" metal washer you are talking about is the one over the shift shaft (at the front of the unit). That's equally important, but not related to sealing the 2 halves.

 

[Haut Medoc]

Re: lower unit install/ gear concerns/ alpha 1

http://www.boatfix.com/merc/Servmanl/6/6covr3.pdf

 

[Don S]

Re: lower unit install/ gear concerns/ alpha 1

I think things are getting mixed up in terminology here.
The Lower Unit is the lower half of the outdrive, and is not what most people call the outdrive.
So, if you are trying to put the lower unit back on the upper unit, the process is different than putting the outdrive back on the bellhousing on the boat.
The small quad ring bgt3000 mentions goes between the lower unit and the upper gear case and has nothing to do with putting the drive back on the boat.

 

[wcsparky05]

Re: lower unit install/ gear concerns/ alpha 1

thx everybody. got it figured out and a new gasket from the impeller rebuild kit put in near the water pump housing. thx. you guys are the best!!!