overheating and bellows just replaced....

[sptjet90Reflexx]

I just had my bellows replaced. All of them. New water hose and everything.. Had a Mercruiser mechanic do it outside of shop at my place and he seamed to do a great job.

Well I have had the boat out on the water probably 4 times since he did the job. Less than 2 months ago. While I was out today the boat started losing power and slowly dropped rpm down to 2k and wouldn't go above. Luckily I was right next to the dock and limped back. When I got back the temp gauge shot up so I shut her down and trailered her home.

Once home I hooked up the muffs and cranked her up. She started fine and sounded normal. Noticed it was VERY loud, and jumped off to check the bellows. The exhaust bellow looks like it had blown right off the out-drive side but was still very snug on the bellow housing side. Also noticed that seamed to be A LOT of water pouring near and none coming out of the exhaust reliefs. The dang water hose had come off the out-drive side also.. clamp still on and everything. WTF is going on.

Pulled the out-drive off the boat and find this.. (see attached)



Full of water.. :facepalm: :facepalm:

 

[Bt Doctur]

Re: overheating and bellows just replaced....

Dont see the large rubber ring that should have been glued in the housing. That much oil loss could have melted the upper gears.
pull the top cap off the drive and inspect the gears.I suspect the`ll look similiar to this. Once like this the water pump dosent turn and you get hot quick.

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

So you think that is gear lube and not water?

And are you referring to the rubber ring that goes around the housing the ujoint shaft is on? It is there I just have it sitting at the end so I wouldn't lose it.

 

[Bt Doctur]

Re: overheating and bellows just replaced....

its gear lube mixed with some water, have you checked the upper gears?

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

So as you can see in the pictures 2 of the bolt heads snapped off. WONDERFULL! YAY BOATS.. not sure how the heck im going to get those out.. maybe grind down 2 sides flat and put some vice grips on it.

Gears look good though.

 

[Bt Doctur]

Re: overheating and bellows just replaced....

I made a jig for that very thing,let me see who has it. uses atleast 2 bolts to locate it properly and lock it in place, then drill out the remaining 2 bolts

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

interesting.. let me know shipping costs.

on the other hand gears look good ya? so just gotta figure out how im going to re-connect the bellows...

 

[ktbarrentine]

Re: overheating and bellows just replaced....

On the lighter side.... Each one of those accordian things is called a bellows (yes, even just one)(like a fireplace bellows). "Bellow" is the sound you made when you pulled your drive and found the surprise inside! :blue:

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

... I don't like these kind of surprises..

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

are those gears supposed to be submerged in oil?

 

[ktbarrentine]

Re: overheating and bellows just replaced....

are those gears supposed to be submerged in oil?

When static, the gear oil is at the level of the bottom of the vent port (i.e. when you fill from the bottom, you fill until oil comes out of that opening). When operating, it gets pretty turbulent in there and oil is splashed everywhere, keeping the gears and bearing lubricated.

Did you drain your oil before pulling the cover, or are those pics of the "as found" condition of the drive with existing oil in it?

Sounds like the water hose coming loose was the cause of the temperature excursion, but still need to nail down the initial issue with the power loss to 2k rpm, and the issue with the bellows leak.

How does the drained outdrive oil look (water, metal filings, color, smell, etc.)? I'd say pull the drive apart to check the vertical shaft, and pressure test each half independently to look for any other issues. (Probably good to do a prelim pressure test of the assembled drive, after you get the top cover bolts fixed and the cover reinstalled, before taking anything else apart). And do a fine-tooth comb inspection of the drive bellows. In the first few pics, it looks like the large drive O-ring (between the drive and bell housing) is on the drive, but cant be sure because of the lighting. I would have expected it to have stayed in the bell housing if it was properly glued there to start with. I am really suspecting a leak from that area, but am looking forward to hear back from you on what else you find.
KB

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

Yes those pictures were the moment I pulled the drive, no it does not appear the huge O ring was glued into the bellows housing as you say it should have been.

All of the bellows are brand new straight from the Mercruiser dealer. They better not be damaged..

How can water get into the ujoint bellows? even if that large oring was not sealed right should the outdrive gasket not seal it up?

 

[ktbarrentine]

Re: overheating and bellows just replaced....

I dont trust that outdrive gasket very much at all (if you have any leakage at all in your shift shaft bushing, that gasket doesnt help there).... The primary seal for the drive-to-bell housing joint (to keep water out of the bellows at that point) is that large O-ring. Another way water gets in is if the bellows is not installed correctly.

 

[djmakko]

Re: overheating and bellows just replaced....

did you change the impeller when did bellows and pressure tested?

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

never pressure tested, but I did do the entire sea impeller replacement. Housing/gaskets/impeller whole kit.

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

anyone get me a picture of where that huge rubber gasket is suppose to be installed?

 

[Bt Doctur]

Re: overheating and bellows just replaced....

2A-15 this link http://www.boatfix.com/merc/Servmanl/6/6A2R3.PDF

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

BT Doc any news on that jig?

 

[jackd1023]

Re: overheating and bellows just replaced....

Going to chime in on bolt removal..... Casing is cast aluminum, bolt is steel, weld a steel nut onto the broken bolt, it will not stick to the case. and wrench it off.

 

[sptjet90Reflexx]

Re: overheating and bellows just replaced....

YESSSSSSSSSS another reason why I love having a welder.. just didn't think about trying it