Two questions - Shift cover and exhaust bellows

[swabbie63]

Hello all. I recently picked up a 1985 Bayliner with a AQ225D 5.0 Liter motor and a Volvo 280 outdrive. I checked the gear case oil and it seemed almost like it should but with just a bit of discoloration. I changed the oil and also put 5 psi in the gear case (which reminds me - the Clymer manual says to use 10-30 or 10-40 for the outdrive?). It lost pressure at about 1 pound every 3 minutes. I then sprayed the lower unit with soapy water and found that there was a slight air leak in the shift cover seal (not the gasket). I took out the four bolts but was not able to take the cover off. My Clymer manual just says to take the bolts out and remove the cover. Is there something else that I must do? Or should I just lightly tap on it with a block of wood and hammer to break the gasket loose? <br /> I then took the boat down to the ramp and put the boat in the water without taking it off of the trailer. As tempted as I was to go for a spin, I didn't want to suck any water into the gear case. I merely wanted to start the motor and check to see how it ran and also to check the outdrive. Everything seemed great. But when I took the boat out of the water, the exhaust bellows seemed to be leaking quite a bit of water out but I have not been able as of yet to find where it is coming from. The exhaust bellows seems about brand new. I changed the U-Joint bellows - so I know it is not leaking. Now, I have read on this forum that you can actually run your boat without the exhaust bellows without leaking water into the bilge. But if there is a hole or a leak in my exhaust bellows, will this cause damage? So, the two questions are about getting the shift cover off and also about the exhaust bellows. I appreciate your time.

 

[Don S]

Re: Two questions - Shift cover and exhaust bellows

In case it's cold where you are at right now, I would start a fire. That Clymers manual would make great kindling, just be sure to use all of it. That's about all it's worth.<br />Your best bet is to go to your local Volvo Penta dealer and order a manual for your engine and drive.<br />Engine manual # 7733511<br />Drive manual # 7731624<br />Together they won't cost much more than what you have already spent for kindling.<br /><br />1. Use a straight 30W oil in the drive.<br />2. The pressure check must be done with the drive oil drained. And pressure check it at around 12 PSI. Spray soapy water around seals to see leaks.<br />3. The cover on the back of the drive is not sealed, and is only held on by 2 screws. The upper only needs loosened to allow the catch to drop.<br />4. If you removed 4 screws and it took a 7/16" socket, put them back. You don't have a clue what you are messing with.<br />5. Your exhaust bellows has water in it all the time, and you can run it without problems with a leak. Why do you think there would be a problem.<br />6. You really need to get some real manuals, study them, better yet visit your local Volvo dealer and have them SHOW you how things work. Even if you have to spend a few bucks to learn, at least you know what is correct. Not some info from the worst manual on the market.<br /><br />

 

[rodbolt]

Re: Two questions - Shift cover and exhaust bellows

if I read it right the actual shift cam seal is leaking. that shift housing,once the 4 7/16th headed bolts are removed slips out, some are tough.<br /> however like DonS syas get the correct volvo manual and read it carefully. the shifter housing must be diaasembled and reassembled correctly.<br /> if you mess up the little roll pin that locks the shift detent pin in place you cannot remove the old pin and the shift housing becomes junk.<br />use a good fitting pin punch on it.<br />you will need the seal driver to install the new seal or it usually damages the seal. make sure you follow the instructions provided with the seal for correct orientation and on reassemble insure the shift shoe is correctly oriented.<br />and NEVER reuse that tiny roll pin.

 

[swabbie63]

Re: Two questions - Shift cover and exhaust bellows

Okay, thank you for the pointers. Don S, there is no doubt to where you stand with Clymers. I did notice this manual is not very detailed. Remember when Chilton's manuals were very detailed, then Haynes came out with their manuals and they are not very detailed? This is what it reminds me of.<br /> Rodbolt, thank you for your tips. I will definately not atempt to take off the shift cover without the Volvo Service Manual. Thank you both for your time.

 

[rodbolt]

Re: Two questions - Shift cover and exhaust bellows

you will find the volvo manual is lacking as well.<br /> swenglish is as bad as jinglish sometimes. read both and get an understanding of what is happening and why.<br /> biggest thing is terminology, I try to use whats in the manual that way no one is confused, sometimes I forget.

 

[swabbie63]

Re: Two questions - Shift cover and exhaust bellows

Rodbolt and Don S, thank you very much for your tips. I changed the seal tonight and it held 10 lbs pressure for 40 minutes before I took off the gauge (it didn't loose any pressure at all). Prior to this, it lost 1 lb. per 3 minutes. The actual seal replacement was no problem. I just needed to know what to look for! Now I can take the boat out fishing this weekend. Looking forward to a great weekend! Thanks again!