Mercuriser alpha 1 gen 2 Out drive will not slide in the last 1"

[tazzerblue5]

Ok, so now I'm installing the out drive, mercrusier alpha 1 gen 2. I have the shifter lined up, shift linkage lined up. checked and checked again. I looked at the old drive and if it only has 1inch to go its already in the coupler. What's the Trick? called the dealer and he said to hit with mallet, tried that no go. Turned motor over, tried again. Nope. So I decided to take bake off that took a lot of prying then it popped off. And after greasing everything again and checking it over I tried to install again only to cut the gasket!!! Sh....!!! Now have to get another one. I ripped that **** off. I'm ready to sell all these ffffing toys!

 

[13ZowieHowie]

I understand your pain...had the same problem. It finally went in when I put my shoulder to it, rocking it back and forth. Patience my friend, patience...

 

[kenny nunez]

This may sound stupid but is the shafts the same length ? If you know how to remove the forward section of the drive shaft on the old drive you can use it to square up the gimbal bearing and use it for an alinment tool. Did the old drive come off easy? If not then you have an alinment problem. If you have someone who welds have them weld a piece pipe to the old shaft so that you can push and pull it to re-Aline the shaft coupler by using the adjustment in front of the engine. To help installing the drive balance it on a floor jack .

 

[Rick Stephens]

Last inch is either too much grease under one of the o-rings preventing it from passing into the gimbal bearing, or the shifter is not lined up. Make sure shift lever is in forward. Make sure outdrive is in Forward. Put a bungee on the prop holding it CCW. It will go in.

Best of luck to you.

 

[Bt Doctur]

or you put the wrong O ring where the bearing goes. Putting the one for the middle of the shaft where the bearing goes will prevent the drive from going in

So I decided to take bake off that took a lot of prying then it popped off.

There is no need to pry, kick, 6 x6 bump or front bumper to installing a drive. It either slides on to within a 1/8 inch or there is something wrong

 

[tazzerblue5]

I had the boat to the dealer to install the gimble bearing and aline the bearing, 500.00 labor for that and new bellows install. Can I pull two of the middle studs and install longer ones to pull on? I've jacked up the boat to help make it a straight shot. wiggled and pushed, even tried a ratchet strap but stopped thinking I had an issue. Is it possible the large black rubber o-ring is the wrong size? When I looked in there it didn't look like it was quit up to that yet..
It's not quite up to the shifter, needs to go a 1/4 inch yet.

 

[Bt Doctur]

STOP and review what your doing.
The large rubber ring is glued in place in the housing. Control box in full forward, shift rod in forward (in a straight line)
Start drive into housing, turn prop SLIGHTLY counterclockwise to align splines, push on,

The mounting kit comes with 4 O rings 2 small for under the bearing, 1 med for the middle of the inputshaft, 1 larger for the water inlet

 

[stang32]

have you checked the alignment again? why di dthe shop do all the work and not hang the drive? its a 15 minute job?
if the alignment is off slightly, it will make going in the last inch very difficult. you need to check the alignment. put the shaft in, if it is snug, whack the shaft on the sides, not on the head. whack it with a rfubber mallet to ensure the gimbal bearing is in line properly

 

[achris]

... its a 15 minute job?.....

Man, you're taking your time.... :lol::lol::lol:

 

[tazzerblue5]

Well I didn't send the outdrive along because I didn't have the new impeller installed. And I THOUGHT it would be an easy job.... Guess AGAIN... I assume all Alpha 1 gen 2 drives are the same?? But I can check the shaft length now..

 

[achris]

Yes, all gen II shafts are the same length. In fact, all shafts have been the same length since 1983. ( I have no idea why he said that. :facepalm Have a look at the video I did of a drive install... might see something in it you missed. Click the 'My Videos' link at the bottom of this post.

Chris.

 

[tazzerblue5]

Thanks, I had already watched a couple. But can always learn more...

 

[stang32]

you need to get your hands on an alignment tool, if no one you know has one, buy one on ebay or amazon, the cheaper ones are 30 biucks. money well spent.

 

[stang32]

or, take the boat and drive to the place that did all the work and tell them they didnt align it properly so now the drive will not go on.

 

[stang32]

Man, you're taking your time.... :lol::lol::lol:

well , ya gotta make it look goods, ya cant suck down more than 2 beers in 5 minutes while installing the drive

 

[JoLin]

After confirming alignment, sometimes it just takes a long time to line up the input shaft splines until it slides in. Turn the prop shaft just a touch at a time until it finally slides in. I've had it take up to a dozen tries. I've only had a drive slide in on the first try ONCE. I was so surprised, I thought something was wrong.

That bellhousing gasket is a pain. The top surface is only about 1/8" wide and it's easy to break. After once breaking TWO of them trying to get a drive on, I got in the habit of putting a dab of gasket sealer on the top surface and the top 2 stud holes to hold it in place while I slide the drives on.

Once you've got the drive on to within about 1/2" of being seated, you're golden. You can use a rubber mallet, or use a couple of nuts to draw it in evenly. Just be careful. It should take virtually no torque on the nuts to seat the drive.

My .02

 

[Bt Doctur]

Once you've got the drive on to within about 1/2" of being seated, you're golden. You can use a rubber mallet, or use a couple of nuts to draw it in evenly. Just be careful. It should take virtually no torque on the nuts to seat the drive.

More like an 1/8 inch if everything is correct, no need to use the nuts to "draw" it together

 

[fsamie1]

I am assuming you are putting the same drive you pulled out easily. If you have one inch to go, most probably shifter alignment is not good. Look underneath to make sure alignment is good. In my case, line up on the drive moves and I have to turn the prop and line it up correctly. have been doing it or 29 years, what a stupid design, to remove outdrive and grease the u-joint. I heard new ones have sealed bearing?

 

[tazzerblue5]

I had the dealer install the gimble bearing read my other post!! Why? Because I didn't have the tool to align it! I Have have attached a photo of the two shafts, same length, and diameter. but the one I'm trying to install does not have the center O-ring. Why? Is this a problem?

 

[Bt Doctur]

If you believe the alignment of the gimbal bearing is correct the drive should just slide right on.If you have a second shaft available tie a small piece of rope on it where a U joint goes and drive the shaft all the way in until bottomed out.
IF everything is correct by you aligning the bearing to the coupler the shaft should pull out with a slight tug on the string.
Should you need a lot more pull to remove it alignment is still not correct