Struggling with bellows job...

[JASinIL2006]

I've begun the job of replacing the trim senders, shift cable and bellows (u-joint and shift cable) on my Alpha One Gen 2 drive. I hope to reuse the exhaust bellows and the water inlet tube, in addition to the gear lube monitor.

I've been able to get the shift cable out, the senders off, and the hinge pins removed. I have removed the u-joint bellows from the bell housing side, as well as the exhaust bellows (also from the bell housing side).

It looks like all that is left to remove so I can get the bell housing out of the way is the water hose and the gear lube monitor but I do not see instructions for how to get and remove these. I have the Mercruiser service manual for the drive, and I'm trying to follow the directions (in section 4), but I'm stumped.

How do I get at the water hose and gear monitor hose so I can take off the bell housing completely?

Thanks!

 

[achris]

How do I get at the water hose and gear monitor hose so I can take off the bell housing completely?

Don't! You risk breaking more than you gain by removing the water and oil line hoses. Just clean up the bellows mounting surfaces as best you can and fit the new parts. The parts that those hoses go on is plastic, and breaks far to easily. It might be a little more difficult to work with the bell-housing in place, but it's far easier than what's involved if you break the oil line feed-through.

Chris......

 

[JASinIL2006]

OK, but I thought the bell housing had to be out of the way to get at the hole where the sender wires pass through the transom. I can get to those without pulling the bell housing completely?

 

[Bt Doctur]

It can be done by just moving the items out of the way, a small area to work in but it is possable.

 

[Newbie@boats]

Why not replace the intake hose and gear fluid line? I recently did mine and it maybe added an additional 10 minutes to the job?

 

[JASinIL2006]

It can be done by just moving the items out of the way, a small area to work in but it is possable.

I will be removing/replacing the u-joint and shift bellows, but I was planning to leave the exhaust bellows connected to the gimbal housing (they're disconnected at the bell housing side). Any problem with leaving the exhaust bellows connected on one side while I do this? It seems like it would be easier if I don't have t reinstall them on both sides, unless they'll be in my way...

 

[Bondo]

Any problem with leaving the exhaust bellows connected on one side while I do this? It seems like it would be easier if I don't have t reinstall them on both sides, unless they'll be in my way...

Ayuh,.... You can decide how much it's in yer way,....

The "Problem" installin' the exhaust bellows is the Other end though,....
Transom end is Easy,....

 

[JASinIL2006]

Ayuh,.... You can decide how much it's in yer way,....

The "Problem" installin' the exhaust bellows is the Other end though,....
Transom end is Easy,....

Since I decided against going with the exhaust tube, I picked up the bellows expander for the exhaust bellows. I figured I had to get the dang thing back on some way or another, whether I replaced it or left in there.

I've pulled the u-joint bellows and it does look like it was starting to leak around the gimbal housing seal. Some of the grease around the gimbal bearing looks a bit milky, but the bearing itself still turns silky smooth. I'm going to pump some fresh grease into it just to make sure no moisture is in there.

In addition to the u-joint bellow, I've pulled the shift cable bellows, removed the old trim limit/sender wires, and I'm getting ready to try to clean it up and start reassembling. I want to get the surfaces (that the bellows attach to) really clean. What works best? Acetone? Lacquer thinner? In addition to old bellows adhesive, I'm sure I've smeared some grease and grime in there, too.

 

[JASinIL2006]

Also, Bondo, when installing the bellows sleeve ring into the u-joint bellows, I can get by with PowerTune and no bellows sleeve installation tool? I'm a bit worried about that maneuver... I remember reading you and Don S. did it that way.

 

[Bondo]

Also, Bondo, when installing the bellows sleeve ring into the u-joint bellows, I can get by with PowerTune and no bellows sleeve installation tool? I'm a bit worried about that maneuver... I remember reading you and Don S. did it that way.

Ayuh,..... That's Don'S trick, 'n it Works,....

Squirt some Power Tune in it, 'n push the ring in with yer fingers, hold it maybe 10 seconds, 'n it's a Done Deal,.....

 

[poconojoe]

I agree with Chris concerning the oil monitor line. That fitting that goes through the transom is made of plastic and breaks REAL easily. Ask me how I know....and it's a real pain to replace. I could bearly reach it with my finger tips behind my 4.3L engine. I almost gave up and plugged the line, but somehow got it done without pulling the engine. The water connection at the transom is plastic too, but a little more durable.

 

[JASinIL2006]

So... I've cleaned all the surfaces where the bellows attach. I've installed the shift cable sleeve into the shift cable bellows (that was fun!) and installed that on the gimbal housing.New trim limit/sender wires passed through their access hole and dogged down with the retainer and screw.

I still have to install the u-joint bellows and reattach the exhaust bellows to the bell housing. It looks like this is the correct sequence:

1. Install u-joint bellows to gimbal housing. The manual doesn't seem to address this step. So I have questions:
- do I use bellows adhesive on both surfaces or only the bellows surface?
- it looks like the adjusting screw on the band clamp should be placed at about 2 o'clock
(facing the transom from behind the boat); does it matter if the adjustment screw faces up or down?
I don't want it rubbing anything once everything is reassembled.

2. Install u-joint bellows to bell housing.
- no bellows adhesive on this end, correct? From the manual, it looks like the bellows is held in place entirely by the retainer sleeve.Yes?

3. Exhaust bellows - install to bell-housing using bellows adhesive

After that, I need to reinstall the bell housing, install and adjust the shift cable core, attach and adjust the trim limit and sender, and pop the drive back on.

Does all that look right?

Thanks!

 

[JoLin]

Just did all this...

1. You're right. Adhesive instructions don't tell you. FWIW, I put it on the bellow only. Yes, clamp screw at 2:00. I don't think orientation matters (tho the ones I took off were pointed up), but I could only use my flex extension with the screw head pointed up. At the 2:00 position the screw doesn't contact anything.

2. Correct. It's held in place by the retainer sleeve. Be careful to get it on straight (I sure hope I did!). I lost a gimbal bearing to some mechanic (before I bought the boat) who put the ring in a little cockeyed. It let water seep in and destroy the bearing.

3. I have tubes instead of bellows. Can't help ya.

My .02

 

[JASinIL2006]

Thanks! Got the u-joint bellows on. Looks OK... Now struggling with shift cable (but that will be it's own topic...)

Thanks so much!