Replacing trim sender's without removing bellows????

[pmjr0987]

I just did complete bellow and gimbal service, new outdrive gasket and water pump (alpha one, gen one)

Now I'm realizing I might need a new sender so my buttons all work correctly as well as my gauge.

Is there a way to install new sender's without removing the bellows? If I remove the two large bolts for the Bell housing can I get a swivel extension in there to replace?

Just asking from people who may have been in the same boat I am in before (literally lol)

If not, I might just drill a small hole in the transom and run them through the side above the waterline. I am NOT doing that job again after only 4-5 hours of run time

 

[alldodge]

There is a couple ways of doing it, but as I remember both require the bell housing pins to be removed. Removing the bolt while tuff is doable, the issue comes with getting it back in. achris (PM Chris if he doesn't show up) has made a tool which allows him to do it. Another guy after removing the bolt, used a allen socket head bolt which made it much easier to get back in.

It may be getting late but I'm sure BT Doc, achris, Bondo and others will be here to help

 

[stonyloam]

If the wires are in decent shape, and the trim limit is not working, there is a good chance you can take the switch apart and clean the contact surfaces to get it to work again. Mark it so that you can get it back in about the right place.

 

[pmjr0987]

Thanks, looks like there is hope then lol.

The wire insulation comes apart like goo in my hand and all the copper is showing, they definitely need replacement. I wasn't thinking I needed to because I thought it was only for the gauge and I didn't really mind it not working I never had one before. But now I'm reading the trim buttons won't work with the sender's malfunctioning that's a whole new issue

 

[Fun Times]

Since you have an Alpha one transom assembly, there should be two bolts, the top bolt is pretty hard to get to even with the U-Joint bellows removed so without at the very least pulling the bellows away from the boat side of the transom, the room to work will be even less to get to.......Very few seemed to have mentioned being able to R & R the top bolt while most have reported they can't get at it with everything still connected. Below are some posts/quotes of members success and non success stories for you to evaluate as you're in there.

http://forums.iboats.com/forum/engi...ment-of-alpha-i-trim-limit-switch#post2698783

The only 'hard' part is getting to the little hold down plate that keeps the thru-transom plug that holds the wires. The older models had 2 bolts and the top one was a bit*h to get to but they can be done without removing the drive.
The other problem that you'll probably encounter is twisting off the head of the sending unit hold down screws. You'll have to drill and tap for new screws. Even if you no longer use the trim senders, you should have those sender mounted and greased to keep water out of the hinge pins.

There is a small retainer plate holding and sealing the trim wires in place as they pass into the boat.
This plate is held in place with either one or two small bolts.
Newer Alpha Gen II's and Bravo's only have one bolt and this makes life much easier.
The top retainer plate bolt is very difficult to access on the Alpha One.
Mercruiser techs usually bend an open ended 7/16" wrench into an offset "S" shape.
Removing the top screw without a customized wrench is near impossible.
NOTE: These screws might be corroded in place. Use patience and take your time removing the screws
being careful not to snap them off.
After both screws are removed you can remove the retainer plate and set it aside.
http://sterndrives.com/replacing_trim_senders2.html

^^^ Hopefully you can make something work but be prepared should you not be able to.

Below is a photo of achris's tool mentioned earlier by AllDodge.
http://forums.iboats.com/forum/engi.../615290-handy-tip-for-trim-sender-replacement

I've successfully replaced the later models with the one bolt without removing the drive but never tried doing the older alpha's without a full teardown due to other items were being replaced as well.
Hope you are able to get this job done without to much trouble, let us know, good luck.

 

[Watermann]

I was looking around the other day and found this video... so it is possible!

 

[pmjr0987]

Yikes! I really don't know if I can do that lol. My hands are huge and this guy seems to have more patients than I do. I might this winter take the outdrive off anyway to check out the gimbal and bellow work I did and store it inside. I do have some holes in my transom from old things that have been sealed. I really might just run the new wires up the transom and seal it into an existing hole. I do have a full length fiberglass swim platform so it won't be an eye sore it would just be a fact of properly sealing the hole so I have no water intrusion

 

[stonyloam]

That should work, the thing to watch out for is to make sure you secure the wires so they don't get pinched and you have enough slack. Check with the drive all the way up, down and full right and left.

 

[bts2]

Have you seen this kit:

https://www.youtube.com/watch?v=Q70Fc2gWgZQ

especially if you already have holes in the boat.

 

[Jez4]

Can't wait to try this one! Just bought a 1997 CHAPARRAL SS2135 last summer and the trim sending unit doesn't work but the trim limit does, so of course it is necessary to replace both. Hope I can get, or fabricate, a tool to fit without removing the lower unit.

 

[Bondo]

September 13th, 2015, 01:19 PM

Ayuh,....... Welcome Aboard,....... Please respect our postin' rules, 'n guidelines,......

This thread is clearly well over 90 days old,.....