Mercruiser Outdrive Gear Lube Running Out of water intake

[timmeraw]

Hi,

I just purchased a 17' boat that has a Mercruiser 120/140 and the outdrive was off because the owner had heard a clunk last run out last fall in the water(tried it again at home in driveway and it didn't happen) but he pulled outdrive off and winterized it. Got a great deal on it and he said it might only be a shift cable adjustment as he had a new one installed right before.

So today I reinstalled the outdrive and lower unit and filled lower unit with gear lube until it was coming out the vent hole.

Was getting hose ready to fire it up(getting hose and muffs ready etc) and I noticed gear lube was leaking out of the water intake vents and small hole in front of foot. Figured I would need to pull lower off again anyways and drain so I hooked up the hose to see how it was running and shifting. Fired it up and ran nicely and checked forward and reverse which worked perfectly(and it was pumping water).

I only had it running for like 3-4 mins but did notice a clanking sound it the upper outdrive casing which I assumed was the u-joint probably lacking oil by now.

Question.... What would cause the gear lube to run out the intake? I am hoping that perhaps I didn't line up an oil tube correctly when installing the lower( I'm and outboard guy) ..... but I fear it might be a seal issue.

FYI... After re-assembling I opened the drain plug and only a small amount of old black gear lube came out with no hint of water whatsoever.

Advise and ideas are dearly welcomed.

Thanks,
Tim

 

[Bondo]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Question.... What would cause the gear lube to run out the intake? I am hoping that perhaps I didn't line up an oil tube correctly when installing the lower( I'm and outboard guy) ..... but I fear it might be a seal issue.

Ayuh,... It Could be any of the seals in that area,...
But,...
My 1st guess is ya didn't put the little quad-ring on the oil galley when you put the lower back on...

Ya probably oughta grab a gasket set, 'n pull the upper off the gimbel, 'n look around for yer rattlin'....
The u-joints need greasin' anyways...

You'll have to get the quad-ring seperately, as it's not in that gasket set...

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

I had a gasket set and used the main for the outdrive and the O-rings on the water hole and drive shaft but had several others I didn't know what they were for.(yea it sounds like I suspected ...I missed the quad-ring on the oil galley. Not sure what you mean by the quad-ring...please explain? I'll investigate also online and in my service manual. I do remember the guy I bought it from mentioning something about the oil connection.

So if that is it ... I assume drain the gear lube completely....pull the lower ..... place the quad-ring and fill with maybe standard Penzoil cheaper 90-w as a flush and if good drain and fill with Mercruiser gear lube. Does that sound like a plan?

 

[Bondo]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

I had a gasket set and used the main for the outdrive and the O-rings on the water hole and drive shaft but had several others I didn't know what they were for.(yea it sounds like I suspected ...I missed the quad-ring on the oil galley. Not sure what you mean by the quad-ring...please explain? I'll investigate also online and in my service manual. I do remember the guy I bought it from mentioning something about the oil connection.

So if that is it ... I assume drain the gear lube completely....pull the lower ..... place the quad-ring and fill with maybe standard Penzoil cheaper 90-w as a flush and if good drain and fill with Mercruiser gear lube. Does that sound like a plan?

Ayuh,... The lower has to come down an inch to put the little squared o-ring in...

I run Mobil 1, 75W-90...
You can run whichever oil you'd like...

Drain it if ya want, the spilage from insertin' the 0-ring should be minimal...

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Ok ..... Is this quad ring a square ring in the lower? Is it over the drive shaft or shift shaft?

 

[Bondo]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Ok ..... I think I know what you mean...it is the squared ring that fits inside the bell housing? I did have an issue fitting it in as I put it on the outdrive side. Should it be seated inside first? Probably should have left the original in there as it looked good and was seated well. So now I have to remove the outdrive again??? Not lookking forward to that much.

Nope,... Not at the upper to bell connection,...

Between the upper, 'n Lower units....
Starboardside, mid-way I believe...

1/4" diameter, not 3"s....

editted the side which has the quad-ring...

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

ok that is good news. I'll pull the lower off and have a look. Much better than having to pull the upper off. Thanks.

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

ok just pulled the lower off ( its 34 degrees outside and alternating fluffy snow flakes and real cold rain) . Is the quad ring under a washer on the lower drive shaft? I also see that there appears to be a matching hole on the starboard side of the lower and upper out drive that I assume is the gear lube passage. Is that right? Are they only mated flush when the lower is bolted up?

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

You nailed it Bond-O. I pulled the lower in the snow and noticed 2 little o-rings left over in the coffee can I got with nuts and washers etc from the guy I bought it from. I assumed they were extra washers for the upper and lower gear lube screws but after looking now they are indeed smaller and meant for the oil passage(quad-rings).

Now two questions:
a) Should I completely drain and replace the gear lube fearing water getting into the housings after having the hose/muffs on?
b} should I be worried about the clacking I heard in the upper when running for a few mins or was it maybe due to lack of lube after it leaked out the foot? The U-joints seemed to be lubed pretty good but I did notice at least one grease fitting that I should have probably greased I guess. Should I pull it off again and do so?

Thanks so much for your patience and help with us "Stern-Drive Virgins".

 

[paultjohnson]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Nope,... Not at the upper to bell connection,...

Between the upper, 'n Lower units....
Portside, mid-way I believe...

1/4" diameter, not 3"s....

starboard...............

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Yes Right Side( Starboard) but what about ??

Now two questions:
a) Should I completely drain and replace the gear lube fearing water getting into the housings after having the hose/muffs on?
b} should I be worried about the clacking I heard in the upper when running for a few mins or was it maybe due to lack of lube after it leaked out the foot? The U-joints seemed to be lubed pretty good but I did notice at least one grease fitting that I should have probably greased I guess. Should I pull it off again and do so?

 

[Bondo]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Yes Right Side( Starboard) but what about ??

Now two questions:
a) Should I completely drain and replace the gear lube fearing water getting into the housings after having the hose/muffs on?
b} should I be worried about the clacking I heard in the upper when running for a few mins or was it maybe due to lack of lube after it leaked out the foot? The U-joints seemed to be lubed pretty good but I did notice at least one grease fitting that I should have probably greased I guess. Should I pull it off again and do so?

Ayuh,... Let a teaspoon of oil out, if there's no water, there ain't no water...
Oil floats, 'n water sinks...

Yes, you shoulda greased the u-joints....
Whether you do is up to you...

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Thanks Bond-o. I have two of those little square o-rings. Is there only one that goes in the lower?

 

[Bondo]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Thanks Bond-o. I have two of those little square o-rings. Is there only one that goes in the lower?

Ayuh,... Only 1 quad-ring on the 1 oil port...

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Well that didn't work. I drained all the lube out(milky)....dropped lower and installed the o-ring...seemed to fit in perfectly and was a little raised so should have formed seal. Bolted back together and filled with new lube. Within a couple of minutes the lube started leaking out the small water port in front of the intake screen on port side.

What next? Shall I go to dealer and get an outdrive gasket kit...pull outdrive and grease the u-joints well etc and also get a new o-ring for the oil port? Will Mercruiser TC4 multipurpose grease work for the u-joints?

 

[HT32BSX115]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

If that didn't work, and there was enough water in the drive, it could have froze and cracked something.

You might consider pressure/vacuum checking the drive (to find where the leak is) before you waste any money resealing it.....

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

No there was no water in it originally and no freezing.(the water was just from yesterday when I didnt have the o-ring in). I drained the little bit of oil that was in it after it was drained/removed and stored for the winter and it was very little and just black with no water it it. But good thought .....

 

[HT32BSX115]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

No there was no water in it originally and no freezing.(the water was just from yesterday when I didnt have the o-ring in). I drained the little bit of oil that was in it after it was drained/removed and stored for the winter and it was very little and just black with no water it it. But good thought .....

Yeah I reread your original posts. It appears that the water is probably from the missing "quad" ring

I would grease those U-joints too(ANY GREASE IS better...........) Also inspect them and the gimbal bearing and check the alignment while your in there!!

 

[Don S]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

Question.... What would cause the gear lube to run out the intake?

One question.

Where is the only place that gear lube is close enough to water, yet is still connected to the water intakes.

HINT: The quad ring can't leak oil out of the water intakes.

 

[timmeraw]

Re: Mercruiser Outdrive Gear Lube Running Out of water intake

ok Don thanks for the question. How about a suggested answer to my problem? It would be greatly appreciated as I would like to solve the issue and stop throwing away all this gear lube while I flounder. It did not have water in the lower when I got it recently (just a small amount of dark lube) so I'd have to assume that there is no water/freezing issue. Out drive was off and mostly drained. Owner said he heard a clunk or something on last outing last fall and took it off to diagnose but just stored for winter. When I did have it all back together I shifted it in and out of FNR and heard no clunk but hear what appears to be a clacking in the outdrive head but it is so fast I am not sure if it isn't just the exhaust I am hearing.....again lots of outboard experience but no I/O.