Repair questions from a new boater

[Wmoore]

Greetings,

I just purchased a used (1979 model) Skipjack 25 with a Volvo Penta 255B V-8 engine coupled to a Volvo Penta 280 outdrive. I am the third owner, the first owner having kept the boat in a salt water marina for the first 27 1/2 years, the second owner kept it trailered in the high desert and used it only twice. The original owner passed along both service manuals for the engine and the outdrive and they were heavily annotated in pencil, evidence that the original owner had striven to take care of his boat. Several photocopies of assorted Volvo service bulletins were nestled within each manual and I consider myself very fortunate to have them

This is my first boat and after taking it on a shakedown cruise in San Diego Bay my son and I changed the oil, and spark plugs in the engine (which is in great condition) and the oil in the lower unit of the outdrive. When we drained the oil we were dismayed (but not too surprized) to discover that water had leaked into the lower unit and emulsified the oil - it looked like thin chocolate milk. Upon further examination we discovered the bellows covering the U-joint had split in several places, exposing the diifferential to salt water.

We are now in the process of disassembling the lower and middle units to perform a detailed examination and intend to replace any/all parts that need replacing. I'm going to buy new O-rings for the outdrive oil filler-dipstick and the drain plug and I need advice on what could be causing the water leak.

The exhaust bellows is a candidate for replacment and we intend to upgrade to the one with the internal flapper. There currently is a torn rubber flapper above the prop assembly (the original owner converted to a dual, counterrotating arrangement) that is riveted in place. I read in this forum that we don't need to have both if we use the flapper-equipped exhaust bellows.

I've discovered that the rear clamps for the exhaust bellows and the water hose are located in a hard to reach place so removing a few parts will facilitate their removal.

Are there any tips anyone can offer us that will expedite this task. Tips such as the fastest way to break down or expose the areas we need to check out, and/or replace?

All suggestions and advice is welcome.

Thanks for providing this great forum, I know I will use it as much, if not more than the service manuals.

WMoore

 

[Wmoore]

Re: Repair questions from a new boater

Thanks for the heads-up on the gimbal bearing, Bubba. I'll add it to "the list".
I'll have to review the service manual on the alignment thing. Is it fairly simple?

 

[Wmoore]

Re: Repair questions from a new boater

... It's one of those things where close just isn't good enough.

Thanks Bubba 1235. I agree, tolerances should be spot on.

 

[captmello]

Re: Repair questions from a new boater

That outdrive does not use an alignment bar or have a gimbal bearing.

So lets start over.

It does have two intermediate bearings on a drive shaft between the engine and outdrive. those commonly go out as a result of water in the ujoint bellows. The engine must be removed along with the upper gear box of the outdrive to replace those.

the alignment can be checked but not with a bar.

water is most likely making its way in through the seals in the upper gear box from the ujoint bellows area. You may need to have it resealed.

Most maintenence can be done by removing the upper gear box only.

If you have a shop manual read up on its removal, If you need a manual Let us know and perhaps we can get one for you.

I'd suggest reading and understanding the job before tearing into it. You may be making more work for yourself.

Keep us up to date on your progress and make sure to ask questions if your unsure.

Good Luck!!

 

[Wmoore]

Re: Repair questions from a new boater

OK. Between my last reply yesterday and this reply I went out and purchased a SELOC manual that covers the engine and outdrive of my unit. My son and I puzzled over a few of the notations in it regarding removal of the sub-units (upper,middle, and lower) but decided to remove the whole outdrive in one fell swoop rather than taking it apart from bottom to top.

Once we determined the hinge pins were the type we could drive out (rather than pull out) we were able to remove the pins and remove the whole unit.

As I mentioned before the u-joint bellow had many breaks and tears and I went ahead and pretty much ripped it apart the rest of the way during the removal process. Ugh. An ugly sight.

The seal at the back of the outdrive where the u-joint spline fits into the drive shaft is caked with crystalized salt and the seal is visably damaged.

The U-joint bearings on one yoke move smoothly but move stiffly on the opposing yoke. Should we attempt to replace the needle bearings and cups or just replace the whole u-joint? I'm leaning toward the latter.

Could the bad bellow also have been the cause of the water leaking into the lower gear box as well? We found emulsified oil when we drained the 30wt.

In your estimation how extensive do you think the damage could be? Is an engine removal needed to remove the outer seal?

I am tempted to replace those things I can reach now without pulling the engine - which I have no means to do and would have to tow the boat to a shop ($$$$$).

 

[captmello]

Re: Repair questions from a new boater

The upper and lower share the same fluid.

I would begin by removing the upper. This takes only a couple of minutes now that the drive is off. with it off you can see what the insides look like and help you decide the next move. If it looks clean inside, we can help you with the rest of the maintenence. If its corroded inside........

Yes, the engine must come out to replace the intermediate bearings and yours are shot I'll bet. Removing the engine is not that tough. We've all done it.

Plan to replace the ujoints as well.

Like I said, pull the upper and let us know what you find.

 

[Wmoore]

Re: Repair questions from a new boater

Well, It took a while but I finally got the boat in working order again. Being "under employed" at the moment, I didn't have the funds to have a dealer work on the problem and had to do the work myself (with my son as a helper). I looked up and old friend who happens to work at a local marine supply outfit in the Point Loma (CA) area. He put me in touch with another guy who use to work at Kettenberg Marine and had experience withe lots of different engines and outdrives. After beers and a BBQ he agreed to check out my boat (no charge). He did a visual inspection and said that the intermediate bearing (which was visable in the picture around the driveshaft spline), looked pretty good actually and assumed the other bearing would too, but agreed that, in practice, when you're doing a lot of work on the boat you should go ahead and replace them as a matter of course. He told me that I could hold off on replacing them until I was ready to spend the money (hoist rental, etc.) to pull the engine because he felt they would be OK - for now.

When he saw the u-joints and moved it around he said it would be best to replace rather than rebuild; he could do it, he said, but his labor and the parts would probably be costlier than if I replaced them myself. I ordered two Sierra heavy duty u-joints over the Internet (on sale at $29.95 ea). With shipping charges I paid just under $75.00.

I wish I'd known about the Sierra company before I went to a local dealer and bought Volvo bellows for my exhaust and u-joint! Yikes! I paid an extra $100.00 for the Volvo name. Next time I'll definitely buy the Sierras' as I've heard from others who have used them and they haven't had any problems with them. And they cost MUCH less.

I recently took the family out on an 85 mile round trip to the "Butterfly" mount west of the Coronado Islands for tuna and had a blast. The boat performed very well... but now I'm thinking about saving my money and swapping out the Penta 255 for a diesel, given the high cost of gasoline.
Anyone ever heard of a "D4" series? (I wish!)

Thanks for all your help guys!

 

[Wmoore]

Re: Repair questions from a new boater

Well, It took a while but I finally got the boat in working order again. Being "under employed" at the moment, I didn't have the funds to have a dealer work on the problem and had to do the work myself (with my son as a helper). I looked up and old friend who happens to work at a local marine supply outfit in the Point Loma (CA) area. He put me in touch with another guy who use to work at Kettenberg Marine and had experience withe lots of different engines and outdrives. After beers and a BBQ he agreed to check out my boat (no charge). He did a visual inspection and said that the intermediate bearing (which was visable in the picture around the driveshaft spline), looked pretty good actually and assumed the other bearing would too, but agreed that, in practice, when you're doing a lot of work on the boat you should go ahead and replace them as a matter of course. He told me that I could hold off on replacing them until I was ready to spend the money (hoist rental, etc.) to pull the engine because he felt they would be OK - for now.

When he saw the u-joints and moved them around he said it would be best to replace rather than rebuild; he could do it, he said, but his labor and the parts would probably be costlier than if I replaced them myself. I ordered two Sierra heavy duty u-joints over the Internet (on sale at $29.95 ea). With shipping charges I paid just under $75.00.

I wish I'd known about the Sierra company before I went to a local dealer and bought Volvo bellows for my exhaust and u-joint! Yikes! I paid an extra $100.00 for the Volvo name. Next time I'll definitely buy the Sierras' as I've heard from others who have used them and they haven't had any problems with them. And they cost MUCH less.

I recently took the family out on an 85 mile round trip to the "Butterfly" mount west of the Coronado Islands for tuna and had a blast. The boat performed very well... but now I'm thinking about saving my money and swapping out the Penta 255 for a diesel, given the high cost of gasoline.
Anyone ever heard of a "D4" series? (I wish!)

Thanks for all your help guys!