Outdrive help!!!

[DanOnTheBoat]

1999 MerCruiser Alpha One Gen II

So had gear oil leaking. The driveshaft bellows was full of gear oil and pressure testing showed leakage from the driveshaft housing seal area.

I removed the driveshaft housing/carrier assembly and have a few questions:

1. Is it normal for there to be only ONE sealing ring installed between the carrier and upper housing? I saw a bunch of videos and they always have a thin and thick metal ring...

2. What's the proper method for removing and replacing the yoke/driveshaft oil seal in the carrier housing?

3. How is the drive gear nut torqued correctly and how is bearing preload set during reassembly?

4. When I removed my driveshaft housing assembly, the bearing cup/race remained inside the upper housing (see photo). Most videos I've watched show the entire assembly coming out together. Is it normal for the bearing race to remain in the housing on some Alpha Gen II drives, or should it have come out with the carrier assembly?

Photos attached.

 

[Chris1956]

A service manual will answer those questions accurately. Also, check the sealing area on the yoke for a groove worn by the seal. If the groove exists, usually replacement of the yoke is warranted.

 

[Candy Gramformongo]

... or a Speedi-Sleeve.

 

[Scott06]

A service manual will answer those questions accurately. Also, check the sealing area on the yoke for a groove worn by the seal. If the groove exists, usually replacement of the yoke is warranted.

X2 get manual #14 it has all the detail for changes to the bearing stack etc

1999 MerCruiser Alpha One Gen II

So had gear oil leaking. The driveshaft bellows was full of gear oil and pressure testing showed leakage from the driveshaft housing seal area.

I removed the driveshaft housing/carrier assembly and have a few questions:

1. Is it normal for there to be only ONE sealing ring installed between the carrier and upper housing? I saw a bunch of videos and they always have a thin and thick metal ring...

2. What's the proper method for removing and replacing the yoke/driveshaft oil seal in the carrier housing?

3. How is the drive gear nut torqued correctly and how is bearing preload set during reassembly?

4. When I removed my driveshaft housing assembly, the bearing cup/race remained inside the upper housing (see photo). Most videos I've watched show the entire assembly coming out together. Is it normal for the bearing race to remain in the housing on some Alpha Gen II drives, or should it have come out with the carrier assembly?

Photos attached.

I think the later ones require setting rolling torque I did mine with a low range inch lbs. Aagin get manual 14 if you have reasonable mechanical ability this will guide you 100%.


Not seeing where the bearing race stayed in the housing vs coming out the driveshaft and bearings look like mine did when I took it out.

Be aware that if you replace the bearings you have to check the gears position with merc specific tooling. If reusing the bearings keep track of the shims and go back in exactly how they were

given the age and one seal failure you should just re seal the whole drive. At the very least check your shift shaft seal. that was really the only one on my drive that was aged/stiff and dry. I caught a fishing line on the prop shaft and saw this when taking the boat out at end of season- and just went through the whole thing over the winter.

I got my manuals and tools used of ebay for reasonable pricing. I think a lot of folks buy the tools sell the boat later and dont need them