Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

[KVH]

Guys, I need some help. I seem to recall an old "recall notice" from Evinrude about the top flywheel bolts, or the upper head and bearing assembly, possibly coming loose and suggesting they be checked. This issue was the torque and threadlock. I had mine checked, and they were "OK."

Just now I was spraying fogging oil in my cylinders and manually turning the flywheel to move the cylinders. As you might have guessed by now, I can see my upper casing/engine cap beneath the flywheel (whatever that part is) wobbling, and the small bolts all appear loose. In other words, as I turn the flywheel, I can see that upper assembly wobbling to each side.

I'll get a mechanic on this, but finding good ones willing to work on an outboard hasn't been easy.

My engine is a '96 Evinrude 200 HP Vindicator. Any advice or help would be appreciated. Thank you.

 

[daselbee]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Wow...what to say here.....

That upper bearing carrier/crankcase head is very tight in there when assembled. There is no room for it to wobble back and forth.
IF the large o-ring is gone...worn out...missing....maybe it could wobble.
Also, why would it wobble in the first place? The crank should be straight. The only way I can see that it is wobbling would be if the crank was bent or something.

The job is easy. Remove flywheel, un-bolt the ignition components (leave connected and lay to the side), remove 8 bolts and gently pry the crankcase head out of it's opening.
The bearing is available separately from www.promarineusa.com, and the old one can be pressed out, and new one pressed in.
It costs about 95 bucks if I remember right.
Re-assemble. No timing adjustments will be necessary unless you have to replace the whole crankcase head. That part carries the WOT timing adj screw.

But why all that play? What damage has been done to #1 cylinder? That crankcase head seals up the crankcase for #1 and is critical for #1 to operate properly.

If you are close to Mims, FL I would be glad to help you on this task. Can be done in less than 2 hrs.

 

[clanton]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

If there is no damage, to the housing, bearing, or block. Replace the bolts with new bolts. I do not know grade of bolt, look on top of bolt head for grade. Clean threads in block with loc-tite thread cleaner, use loc-tite red to lock the bolts, bolts must be torque to specs. These bolts should be checked at ever service check.

 

[KVH]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Thanks guys. I'm handy with tools and I've rebuilt engines. Will this be beyond my ability here? I've never worked on an outboard motor. Will pulling the flywheel and replacing that head bearing assembly get beyond me? Time for a mechanic?

I'm not afraid to tackle it, but I may need a decent shop manual. Any suggestions or other thoughts? Thanks in advance.

 

[boobie]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

If the holes on the upper brg head are longated out, you'll have to replace it.

 

[Faztbullet]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

They are grade 7 bolts from the update(same as Ficht bolts,have a diamond in top of them)

 

[Haffiman]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Be careful if just changing bearing in that head. Just pressing out the old and pressing in the new will probably ruin the press-fitting.
Heat the head in an oven to around 400C and the bearing will probably fall out by itself.
Re-heat the head, keep the new bearing in a freezer while heating the head, then drop the new bearing into the assembly. Give a final check with a press that it is seated correctly.

 

[KVH]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

OKAY guys, I have more information, and need more advice.

The assembly that is loose does appear to the the upper head bearing assembly. It bolts to the crankcase with eight small bolts. The bolts are all loose. I just tightened 7 of them gently just for a test. Guess why not the eighth? Because the bolt head was just sitting there, sheared off.

This is a '96 engine barely used. It is staring at me, gleaming like new.

Now, about those bolts. The bolt heads are plain. No design or diamonds or anything. They are small. That seems odd. The bolt heads are tightened with a mere 3/8ths socket.

So, have I confirmed this is, in fact, the head bearing assembly?

Getting that sheared bolt off will be fun. Frankly, it may come right out if it's loose.

I hope this doesn't all add up to an engine rebuild. At least I'll have fun pulling the flywheel and all.

Any final observations or advice? Thanks all.

 

[Haffiman]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Here if you need any references:
http://www.marineengine.com/parts/j...urer=Evinrude&section=Crankshaft+&+Piston

As you can see when scrolling down, the original part has been replaced. Rule for superseded parts: Newer fits older but not the other way around.

 

[KVH]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Sorry, still need more help on that upper bearing housing.

WOW. I've got a sheered off bolt, one of eight on that top head bearing assembly, as I mentioned earlier, but I still don't have the flywheel off yet.

Question 1: Does the flywheel nut, that huge 1 7/16ths inch monster, come off counterclockwise? I sure hope I'm not going the wrong way.

Question 2: What on earth is my Seloc Manual saying when it says: "Remove the six bolts securing the flywheel and flywheel pulley underneath together." That sentence seems dropped in from the moon. There are no "six bolts," and the very next sentence says to remove the flywheel nut. As if there are six fastening bolts and a large nut. What's the deal?

Any help would be greatly appreciated. Thank you.

 

[Haffiman]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

It is a reason that most 'advisers' on this board never recommend Seloc/Clymer or other general manuals. Get an OMC factory manual from e-Bay or other source.
And yes, the nut comes off counter clock wise.
Then off to NAPA or similar to get a 3 bolt (NOT LEG!) puller and screws min Grade 8 that fits into the 3 holes in the flywheel.

 

[daselbee]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Seloc is bad for that kind of statement. Actually I think they are referring to the power steering pulley if so equipped.
I never saw one.

I use an air gun to get it off, never use an air gun to put it on. Always use a torque wench to 140 ft-lbs.

 

[KVH]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Very helpful thanks.

Are the shouldered bolts really that important? And what is that long bar used for?

How are things over there in Malay?

 

[Haffiman]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

The pick is an 'original' kit used for almost all mod's with different screw sizes and flywheel sizes. The long bar goes into a hole on the side of the disk to hold it steady when torquing the center bolt. There are simpler versions out, just be sure you get grade 8 or 10 bolts!!
In Malaysia all quiet and the usual 30++C degrees.

 

[clanton]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

The special bolt is to keep you from screwing the bolt thru the flywheel and ruining the stator. Just be careful using a regular bolt. The six bolt flywheel is on the 60 degree, V4 & V6 engines.

 

[KVH]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

I've got that puller all fastened up, center bolt and all, and I'm cranking down on that center bolt. Flywheel doesn't want to budge.

Of course, I'm being a bit delicate on the breaker bar, out of concern I'll strip out those aluminum threads.

Can I muscle it? Does it take tremendous force?

Last year a stripped out the threads in a car suspension part. Ruined my entire month. So I'm extra cautious.

thx

 

[Haffiman]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

Tighten HARD, give the center bolt a smack!!

 

[KVH]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

I'm seeing that I need to order the puller above. That long bar to hold things still is indispensable.

 

[AlTn]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

google...automotive flywheel turning tool....it'll work too

 

[boobie]

Re: Upper Head and Bearing Assembly Problems--I Think (Loose Bolts)

You're supposed to use the bar shown in the puller kit to hold it when using. Not the flywheel holder as using that puts side stress on the puller bolts.