Volvo Penta 120S Workshop Manual Download Page 3 | Manualshive

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Reverse gear

MS2, MS2B-A, MS2B-L, MS2A-D

MS2A-E, MS2L-D, MS2L-E, MS2V

Sailboat drive

120S, 120S-B, 120S-C, 120S-D, 120S-E

Contents

Safety information

......................................................... 2

Introduction ................................................................. 2
Important .................................................................... 2

General information

...................................................... 5

About the workshop manual ........................................ 5
Spare parts ................................................................. 5

Repair instructions

........................................................ 6

Our common responsibility .......................................... 6
Tightening torque ........................................................ 7
Torque-angle tightening ............................................... 8
Lock nuts .................................................................... 8
Strength classes ......................................................... 8
Sealants ..................................................................... 8
Safety rules for fluorocarbon rubber ........................... 9

Special tools

................................................................ 10

Other special equipment ............................................ 13
Chemicals .................................................................. 13

Design and function

..................................................... 14

History ....................................................................... 16

Disassembly - upper and lower gear housings
120S, 120S-B, -C, -D, -E

................................................ 18

Repair of MS2 reverse gear, upper gear housing
120S, 120S-B, -C, -D, -E

................................................ 20

Repair of MS2V reverse gear

....................................... 51

Repair - lower gear housing
120S, 120S-B, -C, -D, -E

................................................ 61

Pressure testing ......................................................... 80
Inspection and painting .............................................. 80

Technical data

.............................................................. 81

References to Service Bulletins

.................................. 83

7752950-1 English 01-2001

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Summary of Contents for 120S

Page 1: ...MS2 MS2B A MS2B L MS2A D MS2A E MS2L D MS2L E MS2V 120S 120S B 120S C 120S D 120S E Workshop manual 2 0 A ...

Page 2: ......

Page 3: ... tightening 8 Lock nuts 8 Strength classes 8 Sealants 8 Safety rules for fluorocarbon rubber 9 Special tools 10 Other special equipment 13 Chemicals 13 Design and function 14 History 16 Disassembly upper and lower gear housings 120S 120S B C D E 18 Repair of MS2 reverse gear upper gear housing 120S 120S B C D E 20 Repair of MS2V reverse gear 51 Repair lower gear housing 120S 120S B C D E 61 Pressu...

Page 4: ...ng engine a careless movement or a dropped tool can lead to personal injury in the worst case Be careful with hot surfaces exhaust pipes turbos charge air pipes starting heaters etc and hot fluids in pipes and hoses on an engine which is running or which has just stopped Re install all guards which have been removed during service work before re starting the engine Make sure that the warning or in...

Page 5: ...osive when mixed with air in the correct ratio Do not smoke Provide good ventilation and take the necessary precautions before you start welding or grinding in the vicini ty Always have a fire extinguisher easily avail able near the workplace Make sure that oil and fuel soaked rags and used fuel and oil filters are stored in a safe place Oil soaked rags can self ignite in certain circumstances Use...

Page 6: ...ngine In a diesel engine poor fuel can cause the regu lation rod to bind and the engine will over rev entailing a strong risk of personal injury and ma chinery damage Poor fuel can also lead to high er maintenance costs The existing lugs on the engine reverse gear should be used for lifting Always check that the lifting devises are in good condition and that they have the correct capacity for the ...

Page 7: ...ve systems and can do the tasks of a mechanical or electrical nature associated with the trade Volvo Penta constantly improves its products so we reserve the right to make modifications without prior notification All information in this manual is based on product data which was available up to the date on which the manual was printed Any material changes introduced into the product or service meth...

Page 8: ...nse A clean workplace and a clean engine elimi nate many risks of both personal injury and malfunc tion Above all when work on fuel systems lubrication systems induction systems turbocharger bearing caps and seals is done it is extremely important that no dirt or other kinds of foreign particles are able to get in since this would otherwise cause malfunctions or shortened repair life Our common re...

Page 9: ...rk ings on the screw head A marking with higher number indicates stronger material For example a screw marked 10 9 is stronger than one marked 8 8 For this reason when fasteners are removed it is important that the screws are put back in the correct places when they are re installed When you change screws please check the spare parts catalogue to ensure that the correct versions are obtained Tight...

Page 10: ...h gaskets such as sealing gasket joints or are brushed on gaskets RTV preparations are fully visible when the component has been disassembled old RTV compound must be re moved before the joint is sealed again The following RTV preparations are mentioned in the workshop manual Volvo Penta part no 840879 1 Loctite 574 Volvo Penta part no 1161099 5 Perma tex No 3 Remove old sealant with denatured alc...

Page 11: ... be cut with a flame torch during disassembly or burned in un controlled circumstances afterwards Always use chloroprene rubber gloves gloves for chemicals handling and goggles Handle the removed seal in the same way as cor rosive acid All residues including ash can be strongly corrosive Never use compressed air to blow components clean Put the remains in a plastic container seal it and apply a wa...

Page 12: ...r Removal of outer bearing race Used together with 884761 884723 8 Drift Splitting of rear bearing housing Special tools 884724 6 Hook wrench Removal assembly of nuts 884725 3 Drift Removal assembly of retention ring halves 884726 1 Expanding mandrel Removal of outer bearing race 884728 7 Drift Removal of bearings gear wheels 884729 5 Drift Installation of bearing 884730 3 Drift Disassembly of out...

Page 13: ...748 884750 1 Expanding mandrel Removal of outer bearing race 884752 7 Drift Installation of seal rings in rear bearing housing 884753 5 Fixture 120S 884754 3 Drift Installation of bearing 884755 0 Drift Installation of roller bearing lower gear housing 884756 8 Drift Installation of outer bearing race in rear bearing housing 884757 6 Drift Installation of outer bearing race in lower gear housing 8...

Page 14: ...tion of rolling bearing on tubular shaft MS2V 884836 8 Ring Installation of rolling bearing on pin ion MS2V 884855 8 Plate Installation of bearing race in cov er MS2V 884856 6 Plate Removal of bearing race from gear housing MS2V 884857 4 Plate Removal of bearing race from cov er MS2V 884859 0 Shaft MS2V 884860 8 Hook wrench Installation removal of nut on tubular shaft MS2V 3858852 1 Counterhold Re...

Page 15: ...ressure testing drives Chemicals RTV preparations Volvo Penta part no 840879 1 Loctite 574 Volvo Penta part no 1161099 5 Permatex No 3 Anaerobic preparations Volvo Penta part no 1161053 2 Loctite 243 Polymer preparations Volvo Penta part no 1141570 0 white Water resistant grease Volvo Penta part no 828250 1 9985472 9985494 9999683 9999701 3810152 ...

Page 16: ...14 Design and function Reverse gear MS2 Forward position Reverse position ...

Page 17: ...15 Design and function Sailboat drive 120S Forward position Reverse position ...

Page 18: ...id ing sleeve New color gray History sail boat drives Model 120S Model 120S B Model 120S C 3 2 1 1 2 1 1 Adapter loose 2 Rubber sleeve 3 Gasket 1 Adapter integrated into gear housing 2 Adapter plate 1 Dipstick new version Production rationalization changes ...

Page 19: ...17 Design and function 1 Model 120S E 1 Rubber mounting new version Shot blasted gear wheels Fully synthetic oil ...

Page 20: ...he locking wire from the four screws Then remove all the screws 10 pcs below the division line of the drive Model 120S Also remove the four nuts on the front and rear of the upper gear 3 Split the drive and save the spacer ring 1 shims 2 and gasket 3 Model 120S Remove the rubber sleeve 4 NOTE The rubber sleeve must be changed every 5 years 4 Model 120S Remove the adapter section Tap carefully with...

Page 21: ...er sleeve Prize carefully Use a tool with no sharp edges Remove and scrap the O ring on the sleeve of the adapter plate Repair of the lower gear housing please refer to page 61 Reverse installed drive 180 Remove and scrap the O ring 1 on the adapter plate 1 1 6 Remove the slipping clutch 1 Check that the clutch is not damaged ...

Page 22: ...upper gear housing sailboat drive Gear shift mechanism disassembly 1 Disassemble the gear shift mechanism 2 screws 2 Remove the dog 1 and spring 2 3 Drive in the spring pin so far that the pin 1 is re leased 4 Pull the pin out 1 1 2 ...

Page 23: ...e gear shift mechanism and check for wear Change components as necessary Gear shift mechanism assembly 8 Oil all components before assembly starts Install the seal ring Align the side with the spring inwards Use tool no 884679 or a pipe whose diameter is slightly smaller than the outer diameter of the seal ring 9 Install the eccentric piston 1 and press the pin 2 in Lock it with the spring pin 3 8...

Page 24: ...2 turns and install the gear shift mechanism in the housing Check the position of the dog The screw must be displaced backwards i e to the right in the illustration Disassemble the screw remove the shim and re tight en the screw It will now be impossible to turn the out put shaft round Install one shim at a time until the shaft can be turned without resistance After adjustment apply sealant with V...

Page 25: ... shims 15 Reverse gear MS2 Disassemble the rear bearing housing 6 screws Also tap carefully here with a plastic faced mallet until the bearing housing comes away from the reverse gear Save the shims 16 Drive 120S 120S B C D E Remove the cooling water valve Remove the gear shift cable holder and the rear cover with rubber mounting Change the O ring on the cover 17 Unscrew the oil filler cap and rem...

Page 26: ...cover 4 screws Scrap the O ring 19 Reverse gear MS2 Remove the slipping clutch Remove the sleeve bear ing from the vertical shaft In some cases the bearing might remain in the slipping clutch NOTE If there is any fault in the slipping clutch it must be replaced as a unit The clutch is only avail able as a complete spare part Change the roller bearing as necessary Please refer to items 73 83 20 Tur...

Page 27: ...th the bearing race NOTE On the sailboat drive the shaft is loose since there are no bearings 24 Put the vertical shaft in a press and press the large washer with tool no 884725 to release the re tention ring halves Remove the halves 9991801 884733 1 2 3 4 5 884725 25 Remove the lock washer 1 the large domed washer 2 the three smaller domed washers 3 any spacer washers 4 and the needle roller bear...

Page 28: ...vise Press a screw driver into the seal ring Then place a thick piece of rubber or leather between the screwdriver and the bearing housing casting Prize out the seal ring and scrap it 9991801 884728 884724 Input bearing seal housing disassembly 27 Remove the circlip using circlip pliers 28 Press out the taper roller bearing Use tool no 884728 and standard shaft 9991801 Then wash the gearbox housin...

Page 29: ...er bearings are damaged they must be changed Remove the large outer bearing race from the bearing housing using tool no 884726 and shaft 884143 33 Drive out the small outer bearing race using tool 884728 and shaft 9991801 NOTE Be careful to offer up the tool against the bear ing race 34 Remove the roller bearing from the input shaft us ing a knife type extractor Then remove the washer Clean the co...

Page 30: ... outer bearing race into the bearing housing Use tool no 884732 36 Press the large outer bearing race into the bearing housing Use tool no 884731 and shaft 9991801 Input bearing housing installation 37 Put the metal sheet 1 on the drive shaft 38 Press the large roller bearing onto the drive shaft Use tool no 884729 ...

Page 31: ...e disappears 40 Screw a new nut on Turn the chamfer inwards NOTE The nut must always be changed Use tool no 884724 Start off with low torque Please refer to the following chapter 41 Test the pre load with a spring balance Fix the gear wheel or shaft in a vise with soft jaw pads Wind a string round the bearing housing and pull with spring balance no 9985494 Pre load 10 18 N 2 25 4 05 lbf Not enough...

Page 32: ...ing in tool no 884723 and press the gear wheel out Use tool no 884733 and shaft 9991801 Save any shims 44 Remove the circlip using circlip pliers 45 Put the bearing housing in tool no 884723 and press roller bearing out of the bearing housing Use tool no 884728 and shaft 9991801 884723 884733 9991801 884723 884728 9991801 ...

Page 33: ... not go in crookedly 47 Install the circlip using circlip pliers Turn the chamfered side down towards the gear housing Make sure that the circlip is securely seated in the groove 48 Put shims on the gear wheels for the upper bear ing housing and gear housing Start off with 0 50 mm for each gear wheel This is a value which is based on experience 49 Press the gear wheel into the gear housing Use too...

Page 34: ...emble the propeller shaft flange Use tool no 884078 wrench dimension 19 mm or a claw pull er Pull the seal ring off the propeller shaft flange 50 Press the gear wheel into the upper bearing hous ing Use tool no 884728 shaft 9991801 and 884739 as a support for the inner race 51 Install the upper bearing housing on the reverse gear 884739 9991801 884728 884078 ...

Page 35: ...imilar tool NOTE Use rubber or leather to protect the edges of the bearing housing Clean off all traces of sealant 54 Press the output shaft out of the bearing housing Use tool no 884730 57 Remove the ferrule 1 from the output shaft 884730 1 2 1 56 Remove the O ring 1 and ball bearing 2 from the bearing housing ...

Page 36: ...using Use tool no 884726 and shaft 884143 60 Check that the cooling water pipe is in good condi tion Change as necessary Remove the screw and lift the manifold off 61 Remove the O rings from around the cooling water pipe and screw hole The O ring for the screw hole is mounted on the screw Press the cooling water pipe out from the bearing housing Clean off all traces of sealant 884726 884143 ...

Page 37: ... not go in crookedly 63 Turn the bearing housing over and press in the other bearing race Use tool no 884731 and shaft 9991801 64 Install the cooling water pipe and install the two larger O rings 1 Press the small O ring 2 onto the screw 65 Apply sealant Volvo Penta part no 840879 1 on the mating face against the bearing housing Install the cooling water union Check that the O ring is correctly al...

Page 38: ...other roller bearing on using tool no 884729 NOTE Do not press the bearing until it bottoms Some clearance must be left When the nut is torqued to the correct value the bearing housing is pre loaded and the clearance disappears 69 Apply sealant Volvo Penta part no 840879 1 on the mating face of the seal ring against the bearing housing Install the seal ring in the bearing housing Press the outer d...

Page 39: ...e and check with a spring balance Please refer to item 71 71 Use spring balance 9985494 to check that the cor rect pre load has been obtained Pre load 8 5 16 0 N 1 91 3 60 lbf Tighten the nut progressively until the correct pre load has been obtained 1 2 Reverse gear MS2 Lower bearing cover disassembly 72 Disassemble the outer bearing race with tool no 884720 Remove the shim and the O ring 1 91 3 ...

Page 40: ... E dimension Let us assume that the D dimension 88 82 mm and the E dimension 61 30 mm NOTE The D dimension is based on 88 00 and only the decimals are stamped The E dimension is based on 61 00 to which the stamped value should be add ed Thus 88 0 82 88 82 and 61 00 0 30 61 30 The example below shows how the shim thickness is calculated Example D 88 82 NOTE only 82 is stamped E 61 30 NOTE only 30 i...

Page 41: ...the gear wheel bearing to 37 10 mm This gives us 65 00 37 10 27 90 mm Since D E 27 52 mm this gives the shim thickness 27 90 27 52 0 38 mm 78 Press the large ball bearing onto the slipping clutch Use tool no 884732 and tool no 884733 under the small gear wheel Use the original shims when only new ball bearings have been installed In other cases the shim thick ness must be calculated as in items 76...

Page 42: ...8 10 mm for example This gives C B 18 10 16 05 2 05 mm This should be subtracted from the A dimension which we measured as 2 5 mm 2 50 2 05 0 45 mm NOTE To obtain the correct pre load shims with a thickness of 0 45 0 05 0 50 mm should be put in the cover 81 Put the slipping clutch into the housing and place the outer bearing race loose on top of the bearing 82 Calculate the shim thickness as follo...

Page 43: ...nce 0 10 0 25 mm 0 004 0 010 Adjust the flank clearance if necessary Not enough clearance Add more shims to the out put bearing housing Not enough clearance Reduce the shim thickness in the bearing housing 84 Put in shims of the calculated thickness plus a further 0 5 mm in the cover and install the bearing race Put a plate on the bearing race and press NOTE Align the bearing race carefully to ens...

Page 44: ...s correct The pattern should be located at the centre of the tooth in height but displaced towards the small end 90 If the marking pattern is similar to B the output shaft must be moved inwards by removing shims from the bearing housing If the flank clearance is too small after this operation the lower drive must be moved downwards by reduc ing the shim thickness underneath the bearing race in the...

Page 45: ...nstall the slipping clutch and tighten the cover Turn the housing over and install tools 884735 and 884736 Turn the shaft round with tool no 884735 in both directions to make the bearing seat itself Wind a string round tool no 884736 and measure the pre load with a spring balance 9985494 Preload new bearings 15 30 N 3 37 6 74 lbf Too much pre load Reduce the shim thickness in the upper cover Not e...

Page 46: ...O ring The illustration shows the location of the bearing 1 and O ring 2 Gear housing 96 Install the lower roller bearing in the housing NOTE Align the narrow ring by the arrow upwards The ring has a sharp edge which would cut into the casting if it were installed crookedly For this reason be careful to ensure that the bearing is correctly aligned in the bearing seat Use tool no 884731 and shaft 9...

Page 47: ...ear wheel 101 Turn the gear housing upside down Press the other gear wheel down and do the same operations as in the previous item 102 Apply marking dye to the gear wheel Turn the in put shaft round in the direction of engine rotation Pro tect the splines on the input shaft with a rubber sheet etc Brake with tool no 884738 103 Check whether the marking pattern corresponds with marking pattern A wh...

Page 48: ...d and check the contact patches 105 If the marking pattern is similar to C move the input gear housing and gear wheel in the opposite di rections to what was specified in item 104 When the correct flank clearance and marking pattern have been obtained the input gear housing and upper gear housing should be disassembled and all marking dye washed off NOTE Keep the reverse gear upside down when the ...

Page 49: ...ve 109 Reverse gear MS2 Put the shaft in the housing Put the calculated thick ness of shims on followed by the outer bearing race Press the outer bearing race on with tool no 884732 110 Align the TOP marking upwards and install sliding sleeve 1 and needle roller bearing 2 111 Put a new O ring in the groove in the upper bear ing housing Then install the bearing housing on the housing 1 2 TOP 884725...

Page 50: ...utch 112 Measure the distance between the gear wheel and the bearing Also refer to item 106 113 Put on from the left the measured spacer wash er three small domed washers a large domed washer and the lock washer 114 Press down the large washer so far that the re taining ring halves can be put in the groove Use tool no 884725 884725 1 ...

Page 51: ...sing with screws Turn the shaft slightly to allow the gear teeth to mesh Install the gear bracket with two of the screws 118 Drive 120S 120S B C D E Put on a new O ring and install the rear cover and gear bracket on the upper gear Install the sea water valve Use sealant Volvo Penta part no 1141570 on the threads 119 Put a new O ring and the tested thickness of shims on the input bearing housing NO...

Page 52: ...rade and viscosity Check the oil level with the dipstick and install the oil filler cap 125 Drive 120S 120S B C D E Install the dipstick and oil filler cap The lower gear must be installed before the oil is put in Please refer to Technical Data for oil volume grade and viscosity 120 Install the gear change mechanism in the reverse gear housing Please refer to items 10 13 ...

Page 53: ...ponents Please refer to the MS2 informa tion for general information about the reverse gear 1 Clean the outside of the reverse gear Remove the drain plug 1 and drain the oil 2 Undo the 4 nuts the 2 socket cap screws and re move the angle gear from the reverse gear Tubular shaft disassembly 3 Undo the six screws which hold the tubular shaft in the housing and drive out the tubular shaft with a lead...

Page 54: ...84859 Save the shims be neath the bearing race 7 Screw two screws into the tubular shaft and fix it by putting the two screw heads in a vise Undo the tubu lar nut with a hook wrench When the tubular nut is re moved remove the outer ball bearing as well Please refer to item 8 8 A claw extractor must be used to free the bearing fully from the tubular shaft Grip round the tubular nut 884859 884856 ...

Page 55: ...and press out the tubular shaft which also removes the crown wheel and the inner roller bearing 10 Remove the seal ring from the cover The seal ring must always be replaced by a new one 11 Remove the bearing race from the cover Use tool no 884857 and shaft 884859 884637 884859 884857 ...

Page 56: ...he pinion in sleeve 884723 and press out the pinion which also removes upper roller bearing 14 Remove the roller bearing from the pinion using a knife extractor and press 15 Remove the two bearing races in the pinion hous ing with tool no 884720 16 Remove the needle roller bearing in the pinion nut with mandrel 884859 884720 884723 884859 ...

Page 57: ...st be left When the nut is tight ened the bearing housing is pressed together and the clearance disappears 20 Apply thread locking fluid Volvo Penta part no 1161053 2 on the threads of the nut and install it with the chamfered side upwards Start off with low torque and check the preload with a spring balance 9985494 and a piece of string wrapped round the bearing housing Pre load 10 0 17 5 N 2 25 ...

Page 58: ...ing torque 140 Nm 103 26 lbf ft 884859 Bearing and tubular shaft assembly 22 Apply sealant Volvo Penta part no 1161099 5 to the gearbox housing and install a new seal ring Use tool no 884834 and shaft 884859 Wipe some grease Volvo Penta part no 828250 1 on the lip of the seal ring 23 Put shims with a total thickness of 0 70 mm in the housing and install the bearing race with tool 884834 and shaft ...

Page 59: ...ease Volvo Penta part no 828250 1 on the lip of the seal ring 25 Install the bearing race in the cover with tool 884855 and shaft 884859 26 Put the cover in the tubular shaft and press the roller bearing on with sleeve no 884833 Press the bearing all the way down to the step on the shaft 27 Press the crown wheel on with sleeve no 884833 884833 884833 884859 884855 884859 884834 ...

Page 60: ... thickness of 0 70 mm be tween the cover and the housing Install the tubular shaft in the housing and fix it with two diagonally opposed screws Tightening torque 25 Nm 18 44 lbf ft Check the pre load with a spring balance 9985494 and a piece of string wound round the tubular shaft Pre load 10 16 N 2 25 3 60 lbf Too low pre load Increase the shim thickness under the upper cover Too high pre load Re...

Page 61: ...pinion in the opposite directions to what was specified in the previous item When the correct flank clearance and marking pattern has been obtained wash off all marker dye from the crown wheel and pinion B C A 31 Install the pinion in the gearbox housing without an O ring and with a total shim thickness of 0 35 mm between the pinion and the gearbox housing Install two of the socket cap screws diag...

Page 62: ...htening torque 9 Nm 6 64 lbf ft Angle drive final assembly 37 Install the tubular shaft in the gearbox housing to gether with a new O ring Tightening torque 25 Nm 18 44 lbf ft Install a new seal ring on the tubular shaft 38 Assemble the angle drive and reverse gear Use a new O ring Tightening torque 28 Nm 20 65 lbf ft ...

Page 63: ... the gasket at the division line Remove the shims Note the number of shims Remove the spacer ring 1 Tap the shaft lightly with a plastic faced hammer 4 Fix fixture 884753 in a vise Install the lower gear housing in the fixture so that the four pins fit the cut outs in the shaft nut Fix the gear housing with four of the socket cap screws Install tool 884264 or 884830 on the shaft Use a 17 mm socket...

Page 64: ...4161 and extractor 884611 8 Lock the pinion nut with tool no 3858852 Press the shaft down and make sure that the pinion nut en gages in the tool Fix the tool to the rear bearing hous ing using socket cap screws 9 Install tool 884264 or 884830 on the vertical shaft Unscrew the pinion nut Remove the pinion If the pinion has got stuck it will come loose when the shaft is pressed out later on in item ...

Page 65: ...e steel ball so that it presses the vertical shaft up Wrench size 24 mm Then dis assemble the tool 12 Disassemble the outer bearing race from the upper part of the gear housing using tool no 884761 in combination with tool no 884721 13 Remove the bearing race with expander 884750 and shaft 884143 The expander is inserted from underneath and the shaft from above 884743 884750 884143 884761 884721 8...

Page 66: ...e roller bearing race on the verti cal shaft should not be changed If the roller bearing is damaged the entire shaft must be changed Then clean all components Change worn or damaged components Vertical shaft assembly NOTE Oil all components before or during assembly 17 Put a new ferrule 1 on the vertical shaft 18 Install a new roller bearing with mandrel 884755 NOTE Press until the bearing touches...

Page 67: ... bearing can be pressed off at the same time Please refer to item 22 22 Remove the gear wheel with tool no 884753 Use a socket to protect the end of the shaft NOTE The gear wheel and pinion are classed togeth er and can only be changed as a complete unit Rear bearing housing disassembly 23 When the seal rings are changed the outer bear ing race should also be changed Put the bearing housing on too...

Page 68: ...tance In other cases the shim thickness can be calculated as in items 27 29 27 Put the outer bearing race on the front ball bear ing Press it hard against the bearing and measure distance X with a caliper gauge between the rear plane of the gear wheel and the outer front plane of the bearing race In this case the distance is 100 20 mm 28 Dimension T is stamped on the starboard side of the gear hou...

Page 69: ... 100 20 101 Constant Shim thickness 101 T K X 100 Shim thickness 101 0 17 0 05 100 20 Shim thickness 101 0 12 100 20 Shim thickness 0 92 mm 30 Put shims of the correct thickness in the lower gear housing Add a further 0 05 0 10 mm In this case we put a total of 1 00 mm shims in the housing Shims are available in the following standard thick nesses 0 10 mm 0 15 mm 0 35 mm 0 50 mm 884754 31 Install ...

Page 70: ...the propeller shaft We call this dimension Y 34 Shimming alternative 2 Alternatively we can add shims until the outer bearing race is flush with the gear housing Clean off all traces of sealant from the mating surface of the gear housing against the bearing housing IMPORTANT Make sure that the surface is not damaged Do not use steel tools Use a steel rule or caliper gauge to check 35 There is a di...

Page 71: ...ch other 38 Apply some grease to the seal rings Volvo Penta part no 828250 1 39 Put shims of the correct thickness in the bearing housing In this case they are 0 45 mm 40 Assemble the outer bearing race with tool no 884756 Oil and install new O rings 2 pcs 41 Install the propeller shaft in the gear housing NOTE Turn the shaft carefully to avoid damaging the sealing lips on the seal rings Tightenin...

Page 72: ...bearing Use tool no 884746 The tool consists of three sections Please refer to the Special Tools section NOTE The needle roller bearing has loose rollers For this reason the new bearing has a transport shield Press bearing retainer 884747 into the needle roller bearing The transport shield foam rubber is then pressed out Insert the screw with flange 884748 from above and the bearing retainer with ...

Page 73: ...sealing lips on the seal rings Apply sealant Volvo Penta part no 1161231 4 to the mating face between the bearing housing and the drive Then install the propeller shaft and bearing housing on the gear housing Apply thread locking fluid Volvo Penta part no 1161231 4 to the screws Tightening torque 30 Nm 22 13 lbf ft 48 Install the upper nut on the vertical shaft NOTE The chamfered side of the nut m...

Page 74: ...hould be removed from the vice and fixed vertically instead Let the tool re main on the gear housing Install dial gauge 9999683 on the propeller shaft splines Tap the vertical shaft from above so that it comes as far down as possible Turn the propeller shaft forwards and backwards Flank clearance 0 04 0 10 mm 0 002 0 004 If the clearance is too small the nut must be tight ened a further turn 1 4 t...

Page 75: ...isassemble the propeller shaft and check that the marking pattern on the gear teeth corresponds with the marking pattern in the illustration above or the figures in items 55 and 56 55 If the marking pattern is displaced in relation to the figure above the thickness of the shims under neath the front bearing race must be reduced and the thickness of the shims behind the bearing race in the rear bea...

Page 76: ...bearing race in the rear bearing housing must be re duced to the same extent NOTE In this case the propeller shaft will be dis placed backwards away from the pinion which means that the flank clearance will be too large This can not be changed in any other way than by remov ing the vertical shaft pressing off the roller bearings and changing the ferrule Install a new ferrule Then re install the be...

Page 77: ... The text on the gasket must face upwards The hole pattern in the gasket only fits one way round 63 Install the adapter housing with rubber sleeve on the lower gearing housing Apply MoS2 based grease Volvo Penta part no 1161029 2 to the socket cap screws Put washers on the six socket cap screws and use a torque wrench to tighten them Tightening torque 30 Nm 22 13 lbf ft NOTE Torque the screws diag...

Page 78: ...division plane down to the spac er ring 1 1 64 Install the adapter section on the upper housing Torque the socket cap screws alternately Tightening torque 40 Nm 29 50 lbf ft Only tighten bracket 1 by hand 65 Put a new O ring on the adapter section neck Check that the slipping clutch is in place in the upper gear housing and then fit the housings together NOTE Put washers under the screw heads Tigh...

Page 79: ...as 0 30 mm c Flange height C is measured as 3 85 mm A B C shim thickness 5 70 0 30 3 85 2 15 Shim thickness 2 15 mm 70 Install the calculated thickness of shims and gas ket on the division plane of the lower gear housing NOTE The text on the gasket must face upwards The hole pattern in the gasket only fits one way round 71 Put the rubber sleeve on the upper gear housing Install the cooling water t...

Page 80: ...s and distribute the screws with holes in the screw heads so that there are two on each side Tightening torque 30 Nm 22 13 lbf ft 73 Install the adapter plate on the upper gear hous ing Apply MoS2 based grease Volvo Penta part no 1161029 2 to the three socket cap screws Put wash ers on the socket cap screws and use a torque wrench to tighten them Torque the screws alternately Tightening torque 30 ...

Page 81: ...t be allowed soak in oil for about 15 minutes before assembly Leakage would otherwise occur Pressure test the drive please refer to the Pressure Testing section Fill up with engine oil Please refer to Technical Data for oil volume grade and viscosity Check the oil level with the dipstick and install the oil filler cap IMPORTANT When the drive is installed on the engine the screws must be dipped in...

Page 82: ...anded Paint with Volvo Penta original primer plus a top coat Give the paints time to harden The drive should be coated with Volvo Penta anti foul ing paint to prevent the growth of weed and barnacles Apply in accordance with the directions on the pack age IMPORTANT The protective anodes on the drive and propeller must not be painted over Pressure testing When the drive has been removed it must be ...

Page 83: ...ft bearings slipping clutch 15 30 N 3 37 6 74 lbf Propeller shaft bearings No slack up to 35 N 7 87 lbf measured on propeller shaft Pinion bearing Only MS2BV 10 0 17 5 N 2 25 3 93 lbf Tubular shaft bearing Only MS2BV 10 0 16 0 N 2 25 3 60 lbf Lubrication system Oil grade MS2A E MS2L E API GL5 SAE 75W 90 synthetic Oil grade 120S E API GL5 SAE 75W 90 synthetic Oil grade other reverse gears and drive...

Page 84: ...ism 12 Nm 8 85 lbf ft Rear bearing housing reverse gear 23 Nm 16 96 lbf ft Upper gear housing adapter housing engine 40 Nm 29 50 lbf ft Oil drain plug 10 Nm 7 38 lbf ft Drive 120S 120S B 120S C 120S D 120S E Lower nut vertical shaft 160 Nm 118 00 lbf ft Propeller bearing housing 25 Nm 18 44 lbf ft Zinc ring 12Nm 8 85 lbf ft Rubber pad drive old model 23 Nm 16 96 lbf ft Rubber mounting 120S E M8 25...

Page 85: ...83 References to Service Bulletins Group No Date Refers to ...

Page 86: ...84 Notes ...

Page 87: ...copy of this page write your comments down and send it to us The address is at the bottom of the page We would prefer you to write in English or Swedish From Refers to publication Publication no Date of issue Suggestion Motivation Date Name AB Volvo Penta Teknisk Information 405 08 Göteborg ...

Page 88: ...7752950 1 English 01 2001 ...

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