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Upper Gear Housing

Publ. 7746477

English

06-2008

Torque nut to 96-110 ft. lb. (130-150 N

•

m).

Push up on holding fixture shaft to remove end play in shaft.
Measure clearance between the top nut and upper gear.
Vertical clearance should be

0.002-0.010 in. (0,05-0,25 mm)

If clearance is high, install thicker nut.
If clearance is low, install a thinner nut.
Thickness of nut is determined by number on top of nut.

Retighten top nut to specified torque, measure clearance again.

NOTICE!

If proper clearance is not obtainable with any of the

four nut sizes, make sure the upper gear, bearing and

ring are correctly assembled. If no problems are found

in upper gear, also check lower gear.

Pinion Bearing Carrier Installation

Place required amount of shims for pinion gear position on pinion
bearing carrier. Do not install an O-ring at this time.

50498

50499

Number

Marking

Thickness

Part

Number

0.000 in.

0.00 mm

3852301

0.008 in.

0.20 mm

3852302

0.016 in.

0.40 mm

3852303

0.024 in.

0.60 mm

3852375

Содержание DPS-A

Страница 1: ...Workshop Manual AC 2 2 SX A DPS A Sterndrive Transom Shield ...

Страница 2: ... Americas Inc All rights reserved This manual may not be copied photocopied reproduced or converted to any electronic or machine readable form in whole or in part without the express written consent from Volvo Penta of the Americas Inc ...

Страница 3: ...Publ 7746477 English 06 2008 General Information 1 Sterndrive General Information 15 Upper Gear Housing 45 SX A Lower Gearcase 91 DPS A Lower Gearcase 123 Transom Shield Assembly 165 ...

Страница 4: ...Publ 7746477 English 06 2008 ...

Страница 5: ...of Contents to locate the section covering the system or assembly requiring service Each chapter s title page has an additional listing that will describe the chapter s contents in more detail Since models are subject to change at any time some images may not depict actual product This Workshop Manual contains technical specifications descriptions and instructions for the repair of the Volvo Penta...

Страница 6: ...le must be securely fastened to the shift bracket At the the shifter end follow the shifter manufacturer s instructions for cable attachment Sterndrives are heavy and awkward to handle To avoid injury before beginning sterndrive removal plan for supporting the sterndrive with a drive cart or overhead hoist before proceeding with removal Secure the sterndrive to a drive cart or overhead hoist capab...

Страница 7: ...ty Ensure the work area is well ventilated and take the necessary safety precautions before starting welding or grinding operations Always ensure that there are fire extinguishers on hand when work is being performed Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely Rags soaked in oil can spontaneously ignite under certain circumstances Environmentally dangerous...

Страница 8: ...care to avoid contact with hot surfaces e g exhaust pipes turbocharger air intake pipe start element etc and hot liquid lines and hoses on an engine which is running or which has just been stopped Reinstall all protective parts removed during service operations before starting the engine Check that all safety labels on the product are always clearly visible Replace labels which have been damaged o...

Страница 9: ... precautions when working on boats with AC systems Completely disconnect the system when making any repairs where the work could come permit contact with the AC system Make sure the boat AC system is connected to a proper and tested ground Use the lifting eyes fitted on the engine reverse gear when lifting the unit Always check that the lifting equipment used is in good condition and has the load ...

Страница 10: ...rsons using tools other than Volvo Penta special tools or approved Volvo Penta working methods as described in a Workshop Manual or Service Bulletin to acquaint themselves of the risk of personal injury or actual mechanical damage or malfunction that can result from failing to use the prescribed tools or working methods In some cases special safety precautions and user instructions may be required...

Страница 11: ... chapter and in the text where the chemical is used During service operations use the same agent or an alternative from a different manufacturer Make sure that mating surfaces are dry and free from oil grease paint and anti corrosion agents before you apply sealant or locking fluid Always follow the manufacturer s instructions for use regarding temperature range curing time and any other instructi...

Страница 12: ...ing a job to locate special tools or repair kits is a needless delay Clean Workspace A clean work environment and a clean engine or sterndrive will eliminate many risks of personal injury and engine malfunction Clean a sterndrive that is excessively dirty before work starts Cleaning will occasionally uncover trouble sources Above all when working on the fuel system engine lubrication system air in...

Страница 13: ...r specific tool is called for another item may be used However the substitute must have equivalent characteristics including type strength and material You must determine if incorrect substitution could result in product malfunction and personal injury to anyone To avoid hazards equivalent products which are used must meet all current U S Coast Guard Safety Regulations and ABYC standards Care of t...

Страница 14: ...eel wool Small pieces of steel wool become embedded in the aluminum and will cause severe corrosion 5 Rinse thoroughly with water The area must appear wetted or the surface is not clean and paint will not adhere 6 While the surface is still wet from rinsing treat all bare aluminum with DuPont 226S chromate conversion solution Brush the chromate solution as required for 2 to 5 minutes to prevent it...

Страница 15: ...ing the Sterndrive or Transom Shield with Antifouling Paint NOTICE On the sterndrive and transom assembly only use antifouling paint that is specifically designed for aluminum sterndrives Clean the sterndrive carefully Degrease and flush thoroughly with water Sand the surface with a water abrasive paper grit size 200 240 Make sure not to sand through the original paint of the sterndrive Damage to ...

Страница 16: ...e and Filling Sterndrive with Oil in chapter 2 3 Inspect the bellows when preparing your boat for use after storage Replace as needed or at least every second year See section titled Bellows in Transom Shield chapter 4 Inspect anodes for proper size Replace as needed See section titled Anodes in chapter 2 5 See Engine service manual for engine specific information Every other year every 24 months ...

Страница 17: ...ion No service required Check if trim tilt performance is poor Check for leaks and proper operation Use Volvo Penta Power Trim Tilt and Steering Fluid Sterndrive gear oil Drain and refill every 100 hours or once a year Check level frequently during boating season 1 N A Use Volvo Penta Synthetic GL 5 Gear Lubricant SAE 75W 90 U Joint Shaft Splines N A Remove drive Inspect shaft for wear Lubricate s...

Страница 18: ...General Information 14 Publ 7746477 English 06 2008 NOTES ...

Страница 19: ...ller Removal 21 SX 21 DPS 22 Propeller Installation 23 SX 23 DPS 25 Anodes 27 Replacing 27 Testing 28 Sterndrive Removal 28 Preparation 28 Remove Sterndrive 30 Sterndrive Service 31 Disassemble 31 Reassemble 32 Pressure and Vacuum Testing 33 Installing the Sterndrive 34 Prepare for Installation 34 Installing Drive Unit 38 Install Shift Cable 40 Start in Neutral Only Test 42 Shift System Test 42 Sa...

Страница 20: ...d white Locktite PST or 565 or equivalent Volvo Penta grease p n 828250 Sterndrive Lubrication Checking Gear Oil Level NOTICE Improper oil level under or overfilled can result in serious internal sterndrive damage Check lubricant oil level in sterndrive whenever possible Tool Name Part No View Tool Name Part No View Alignment Tool 3851083 Propeller Tool Rear 3862808 Drive Cart Solo 9990001 Wrench ...

Страница 21: ...nspect oil for signs of water intrusion The oil should be amber in color Milky looking oil indicates water mixed with the oil If present find cause and repair before operating drive Also check for metal or other debris in oil If present find cause and repair before operating drive Sterndrive Oil Capacity All SX A Models Capacity 90 oz 2650ml All DPS A Models Capacity 83 oz 2450ml NOTICE Quantities...

Страница 22: ...e oil level plug side of drive Discard o ring 7 Remove dipstick top of drive Discard o ring Removing dipstick and oil level plug vents sterndrive so oil will drain completely 8 Check magnets on plugs for metal A very fine metal powder on magnet is normal wear Larger particles that can be felt between your fingers indicate problems with metal parts in sterndrive Find cause and repair before operati...

Страница 23: ...drain hole Fill slowly to purge air Sterndrive is properly filled when oil appears at oil level hole NOTICE Filling sterndrive too quickly may form air pockets that will cause an inaccurate oil level reading Running the sterndrive with improper oil level can result in serious internal sterndrive damage 3 When oil is filled to oil level hole install and hand tighten dipstick and oil level plug this...

Страница 24: ... dipstick before operating drive If oil has been completely changed oil level must be rechecked after unit has been briefly run to purge trapped air Add oil through dipstick opening to bring oil up to proper level Alternate Fill Procedure If you cannot fill drive unit through oil drain plug you can fill drive by triming drive up a few degrees and adding oil through oil level plug When oil is at oi...

Страница 25: ...ry Make sure the engine can not start during work on propeller s remove ignition key s and shift drive into forward or reverse CAUTION Protect hands from sharp edges of propeller blades by wearing gloves when removing or installing propellers SX 1 Shift the sterndrive into forward to lock the propeller shaft 2 Remove the cotter pin P and keeper F 3 Remove the propeller nut E using a 1 1 16 wrench ...

Страница 26: ...h 06 2008 DPS 1 Shift the sterndrive into forward to lock the propeller shaft 2 Use propeller tool 3862808 or 30 mm socket and rachet to remove rear propeller nut Remove rear propeller 3 Shift the sterndrive into reverse to lock the propeller shaft 50155 ...

Страница 27: ...ft seals correct if leaking Propeller Installation WARNING Propellers turning with engine power can cause serious injury Make sure the engine can not start during work on propeller s remove ignition key s and shift drive into forward or reverse to engage neutral safety NOTICE Protect hands from sharp edges of propeller blades by wearing gloves when removing or installing propellers SX 1 Shift the ...

Страница 28: ...nner taper toward gearcase 4 Install propeller on shaft aligning splines and push propeller onto the thrust bushing until the splines are exposed 5 Install thrust washer D on propeller shaft splines 6 Install propeller nut E Torque to 70 80 ft lb 95 108 N m 7 Index keeper F on propeller nut until a slot is aligned with cotter pin hole 8 Install the cotter pin and bend the ends to secure use a new ...

Страница 29: ... if this is not done 2 Shift the sterndrive into forward to lock the propeller shaft 3 Install the front propeller Install the front propeller nut chamfered edge forward NOTICE Be sure the chamfered edge of the propeller nut is facing forward Failure to install the propeller nut correctly could result in a propeller coming loose and damge to the lower unit and or propeller ...

Страница 30: ...on 26 Publ 7746477 English 06 2008 4 Torque nut to 45 ft lb 60 N m Use prop nut tool 3862797 and torque wrench 5 Shift the sterndrive into reverse to lock the propeller shaft 6 Install the rear propeller 50155 VOLVO PENTA DUOPROP ...

Страница 31: ...th propellers should turn freely Anodes The drive anode is located on the top of the caviatation plate Replacing Anode erosion or disintegration in salt or brackish water indicates the anode is functioning correctly Anodes should be inspected and or replaced at regular intervals or corrosion of the drive will increase NOTICE Replace anode when it is reduced to two thirds of original size one third...

Страница 32: ...e coat the anodes This will prevent them from functioning properly If anode appears to be corroded on its surface but is not deteriorating it should be replaced Sterndrive Removal WARNING Make sure the engine can not start during work on sterndrive remove ignition key s shift control to forward or reverse to engage neutral safety WARNING Boat must be out of the water and safely supported on traile...

Страница 33: ... socket 2 Remove cover Disconnect Shift Cable 1 Remove cotter pin P and then washer W from cube C 2 Remove cube and cable from bracket Loosen jam nut N Thread cube off of cable Remove seal from cable Save seal 3 Loosen screw S securing anchor A Use 10mm box wrench Slide anchor outwards to release cable 50778 P W C N 50779 A S ...

Страница 34: ...rs out of the way during drive removal Remove Sterndrive CAUTION Sterndrives are heavy and awkward to handle Before disconnecting sterndrive from transom secure the sterndrive to a drive cart or overhead hoist capable of supporting at least 500 lbs 227kgs 1 Remove six locknuts securing upper housing to transom shield Use 5 8 swivel socket or 5 8 box wrench Protect painted surfaces from damage by t...

Страница 35: ...sassemble 1 Mount the sterndrive in a suitable holding fixture and clamp it securely NOTICE Fixture is not shown in the following images to provide clearer illustration of parts 2 Drain the oil from sterndrive See section titled Draining Oil from Sterndrive 3 Remove four spiral locknuts N from underside of lower gearcase Use 15mm box wrench NOTICE Save spiral locknuts they can be re used up to 50 ...

Страница 36: ...nsert in grooves in lower housing Also oil o ring R on retainer 3 Place intermediate shaft I on lower vertical shaft Oil splines on both shafts Groove should be oriented up 4 Place upper gear housing on lower Engage intermediate shaft in upper vertical shaft if needed rotate propeller shaft or u joint shaft to engage Line up studs in mounting holes in lower Protect painted surfaces from damage by ...

Страница 37: ... sterndrive with gear oil it must be pressure and vacuum tested to verify proper sealing Remove the oil level plug at the gear housing Make sure o rings are installed on other plugs and dipstick Install and tighten all other plugs and dipsticks Pressure Test 1 Attach pressure tester 3810152 or Stevens S 34 to oil level hole Pressurize sterndrive to 3 5 PSI 20 7 34 5 kPa Rotate propeller shaft and ...

Страница 38: ...cts In these instructions we recommend and describe effective procedures you should follow when installing Volvo Penta sterndrive products Some of these methods require the use of tools especially designed for the purpose These tools should be used whenever recommended Follow the steps and procedures described in this section in the order listed to perform a complete installation of a Volvo Penta ...

Страница 39: ...in oil level dipstick and gasket 2 Thread lifting eye into oil level dipstick hole 3 Use a suitable hoist to remove drive unit from work area and holding fixture 4 Make sure all attaching hardware is readily available 6 lock nuts 6 washers narrow 2 trim tilt pins 2 cotter pins 50367 50366 3886510 ...

Страница 40: ... unit cart do so now 6 Remove lifting eye bolt from upper housing 7 Reinstall dipstick and o ring Tighten dipstick 8 Inspect the tapered end of the bearing housing to ensure it is free of nicks and dents Apply a light coat of grease 828250 to tapered end of bearing housing Lubricate shaft splines o rings and water passage seal with grease 50368 50370 50371 ...

Страница 41: ...850609 slide alignment tool 3851083 through gimbal bearing Alignment tool must easily slide through gimbal bearing and into engine coupler If alignment tool binds going into coupler the front engine mount s must be adjusted either up or down until alignment tool easily slides in and out of coupler 11 Shift sterndrive into gear by rotating the eccentric piston arm 50372 3851083 3850609 50345 50373 ...

Страница 42: ...arge seal 4 and small seal 5 onto the shift cable Installing Drive Unit 1 Tilt the trim cylinders up above the upper gear splash plate 2 Slide u joint shaft through gimbal bearing Guide shift cable through opeining in sterndrive NOTICE Be careful not to damage the cable when installing the sterndrive 50374 5 4 50380 50375 ...

Страница 43: ...en the nuts in two steps Torque nuts to an initial setting of 25 ft lb 34 N m Start with the center nut 1 and work in a crisscross pattern 2 3 4 5 6 to secure the sterndrive to pivot housing Use the same crisscross pattern to torque all six lock nuts to a final setting of 50 ft lb 68 N m NOTICE Do not use pneumatic or electric impact type tools on drive attachment nuts The threads of the nut and s...

Страница 44: ...cking Gear Oil Level in this chapter Install Shift Cable 1 Cable should be routed through hole in pivot housing and upper gear housing with the end of the cable behind the shift bracket 2 Slide anchor in engaging slot in end of anchor with the anchor groove in the shift cable Lip on the anchor should face forward 3 Torque anchor clamp screw to 7 4ft lb 10 N m Use 10mm socket and torque wrench WARN...

Страница 45: ...ic piston arm back to neutral detent position then move gear shift to its neutral detent position 6 Thread cube C in or out on cable until it aligns with center of hole in shift bracket 7 Push shaft of cube C through hole in shift bracket Install washer W on shaft secure with cotter pin P Bend ends of cotter pin 8 Install jam nut N and tighten securely against cube to keep cable from turning in cu...

Страница 46: ...l fumes Open engine cover or hatch before starting engine if the boat is not equipped with a blower Leave it open until after engine has started NOTICE Make sure sterndrive is properly filled with oil before running engine sterndrive See procedure above Shift System Test With engine running shift unit into forward and reverse gear several times Ensure full forward and reverse gear engagement occur...

Страница 47: ...tall Shift Cover 1 After shift system tests are performed all adjustments are made and after final gear oil level check Reinstall the shift cover Carefully thread five screws in to housing Use 12mm socket and rachet to hand tighten then torque to 13 17 ft lbs 17 23N m ...

Страница 48: ...Sterndrive General Information 44 Publ 7746477 English 06 2008 NOTES ...

Страница 49: ...bly 62 Lower Output Gear Assembly 66 Upper Output Gear Assembly 67 Lower Output Gear Shimming 68 Upper Output Gear Shimming 69 Pinion Bearing Carrier Shimming 69 Upper Gear Housing Assembly 71 Lower Output Gear and Shaft Assembly 71 Lower Output Gear Installation 72 Upper Output Gear Installation 75 Shimming Vertical Movement Of Upper Driveshaft 75 Pinion Bearing Carrier Installation 76 Top Cover ...

Страница 50: ... Plug oil drain 6 U joint 21 Shift housing 7 Pinion bearing housing 22 Shift eccentric 8 Crush sleeve 23 Shift shoe 9 Bearings pinion 24 Shift cone 10 Seal pinion 25 Shift bracket 11 Reatiner and screw pinion 26 Shift rod 12 Pinion 27 O ring 13 Drive gear 28 Seal 14 Bearing drive gear 15 Ring upper gear 5060 8 6 9 SX A 1 1 7 9 10 11 13 12 14 19 14 18 17 20 27 13 28 21 22 4 26 25 23 1 5 15 1 27 28 ...

Страница 51: ...ons may have the OMC part no Tool Name Part No View Tool Name Part No View Assembly Tool 884932 Drift 884789 Dis assembly Tool 884933 Holding Fixture 3849658 Drift 884168 Retaining Ring Pliers 3850608 331045 Drift 884263 Seal Installer 885557 Drift 884266 Seal Installer 3850607 ...

Страница 52: ... Penta GL5 Synthetic gear lubricant 75W90 Loctite primer Volvo Penta thread locking compound p n 1161053 Volvo Penta grease p n 828250 Tool Name Part No View Tool Name Part No View Shim Tool 3849650 Plate Replaces original plate on 3860604 3861651 Shim Tool 3850600 Spline Socket 3850598 Sleeve 884938 Shaft 9991801 Sleeve 3862673 Upper Gear Housing Holder 3849651 Spanner Wrench 3850604 90 86 5 106m...

Страница 53: ...n the Sterndrive General Information chapter of this manual 1 Attach spline socket 3850598 to holding fixture 3849651 Tighten set screw securely 2 Mount upper gear housing on holding fixture NOTICE Rotate upper gear housing if fixture holes do not align with holding fixture Loosen locking screw A Rotate and lift fixture shaft B to engage upper driveshaft splines Install and securely tighten four n...

Страница 54: ...her attaching shift bracket 3 Remove bracket B and rod 4 Remove four screws securing shift housing NOTICE Shift housing is spring loaded and may pop out when screws are loosened 5 Remove shift housing from upper gear housing Note the position of shift shoe S during removal It must be re installed in the same orientation or shift system will not function correctly C B S 50452 S ...

Страница 55: ...ove pinion bearing carrier and u joint using two screwdrivers Be careful not to damage upper housing or bearing carrier mounting surfaces 3 Save any undamaged shims they can be reused Remove and discard O ring Output Gear Removal 1 If present remove and save dipstick discard O ring 2 Remove four screws securing upper cover Use 12mm socket Remove cover 50439 ...

Страница 56: ... with 30 mm socket 5 Lift upper gear bearing ring assembly out of housing Note and mark needle bearing orientation top to bottom then remove needle bearings from center of gear Remove and save shims They can be reused if not damaged NOTICE Needle bearings should be reinstalled in same gear bearing and in same orientation top to bottom as they were removed Do not switch needle bearings between lowe...

Страница 57: ... As screws are turned down alternate between two screws every two turns CAUTION The retainer ring is tightened to a high torque all parts and fixtures must be tightened securely before the ring can be safely removed Seat screws completely then tighten them securely Tighten the holding fixture securely 8 Attach a 3 4 in breaker bar to spanner wrench and loosen retainer ring 9 After it turns easily ...

Страница 58: ...aring and shaft assembly Remove and save shims They can be reused if not damaged 11 Turn lower bearing and shaft assembly over Remove O ring Push up on shaft to disengage shaft c clips from spacer 12 Remove upper driveshaft c clips and spacer from shaft 50447 50448 50449 ...

Страница 59: ...ng assembly into sleeve with gear facing down Press gear from bearing using drift 884789 Upper Output Gear Disassembly 1 Remove bearing gear from ring R 2 Place remover installer 3862673 large diameter end up in a press Place rag in tool to protect gear 3 Place ring gear bearing assembly into tool with gear facing up 4 Press gear bearing through ring use drift Volvo Penta p n 884789 5 Place sleeve...

Страница 60: ...her parts are also compromised The complete u joint must be replaced Pinion Bearing Carrier Disassembly 1 Secure holding fixture 3849658 in vise as shown 2 Place bearing carrier in fixture as shown 3 Use top cover screws to secure housing to fixture 4 Tighten screws to secure housing in fixture 5 Use prybar or large screwdriver through u joint and against bolt on fixture to prevent u joint from tu...

Страница 61: ...aring carrier from universal joint shaft If pinion bearing carrier is stuck a press may be used to remove universal joint shaft from pinion bearing carrier 9 Wear eye protection Remove seal retaining ring from pinion bearing carrier by using retaining ring pliers 3850608 10 Place sleeve 884938 large diameter up in press Place a rag inside tool to protect gear 11 Place pinion bearing carrier into t...

Страница 62: ...ve gear from bearing using drift 884266 NOTICE Do not remove bearing from input gear unless it is damaged Removal destroys bearing When replacing any tapered roller bearing corresponding race must also be replaced 16 Place pinion bearing carrier in press with seal facing down Press out seal and roller bearing using drift 884263 17 Install disassembly tool 884933 on end of shaft 9991801 18 Place pi...

Страница 63: ...g Passages check for corrosion build up that would restrict water circulation Shaft and Gear Bore remove all sharp edges that would cut O rings or seals Gears Shafts and Bearings inspect gear teeth for cracks and chips or discoloration If any gear is damaged all must be replaced They are replaced as a set Screw threads on end of shafts must be undamaged Replace shaft if lock patch is excessively w...

Страница 64: ...ew pin must be used if the pin is damaged do not reuse a damaged pin 7 Pry the seal ring out with a screwdriver NOTICE Take care not to damage the seal bore If the bore is damaged during seal removal a leak could develop when the drive is reassembled Repace the shift housing if the seal bore is damaged 8 Clean and inspect all components in the gear shift mechanism 9 Thread a new seal onto mandrel ...

Страница 65: ...tric piston Make sure not to damage the seal ring 15 Tap the pin in so far that the milled cutout is level with the hole for the spring pin 16 Tap the spring pin all the way NOTICE The spring pin will project a couple of mm when installed Be careful not to damage the edge of the eccentric piston 17 Do not install shift mechanism in housing at this time ...

Страница 66: ...ge diameter up and shaft 9991801 4 Turn pinion bearing carrier over and set it in press 5 Lightly oil outside of large bearing race with gear oil and set it in carrier 6 Assemble special tools used in previous step with large diameter of assembly tool 884932 facing down 7 Press race in until it seats 8 Coat pinion gear shaft with gear oil and set it in press Protect gear teeth 9 Position large tap...

Страница 67: ...NOTICE This is the starting point for determining rolling torque of the pinion bearing carrier Use caution Do not press the bearing on too far If the pretension sleeve is distorted by pressing the bearing on too far proper rolling torque cannot be achieved The carrier will have to be disassembled and pretension sleeve replaced 15 Place protruding lip of seal into recess of seal installer 3850607 1...

Страница 68: ...ts groove in pinion bearing carrier using retaining ring pliers 3850608 Make sure retaining ring seats completely 18 Coat seal lips with grease 828250 19 Secure holding fixture 3849658 in vise 20 Place bearing carrier in fixture as shown 21 Use top cover screws to secure housing to fixture 22 Tighten screws to secure housing in fixture 34712 34704 50799 50802 ...

Страница 69: ...te primer N and allow to air dry NOTICE Pinion gear screw must not be reused Use new screw supplied with u joint or order new screw from Parts Proper torque cannot be achieved with a used screw CAUTION Follow the manufacturer s safety precautions when applying Loctite Primer N from an aerosol container 25 Place pinion gear retainer on top of input gear 26 Apply thread locking fluid 1161053 to scre...

Страница 70: ...le tightening screw to seat bearings 30 Frequently remove assembly from vise to check rolling torque Stop when rolling torque reaches 9 14 in lb 1 0 1 6 N m NOTICE If the rolling torque is exceeded the pinion bearing carrier will have to be disassembled and a new pretension sleeve installed Lower Output Gear Assembly 1 Place lower gear in a press Protect gear face Lightly oil inside diameter of be...

Страница 71: ...ing in to ring 2 Place sleeve 3862673 large diameter end up in a press 3 Lightly oil inside diameter of ring with gear oil 4 Place ring R on top of the sleeve inner lip down 5 Place bearing B in ring R 6 Press bearing in place until it seats using drift 884168 7 Press bearing ring on to gear 884168 34754 50458 3862673 R 50472 R 50473 B 884168 50456 ...

Страница 72: ...t surface Protect gear cup surface Place shim tool 3849650 on assembly as shown Apply light pressure to hold shim fixture properly on gear Fixture should be level across top of gear shaft 2 Take a feeler gauge measurement B at outer edge of bearing Record this measurement in inches 3 Find etching on gear number is shimming allowance S Number represents thousandths of an inch 0 00X 2 in picture 0 0...

Страница 73: ...se the following information when adding or subtracting etching S from measurement M Example If etched number is 5 ADD 0 005 in to the feeler gauge mea surement A If etched number is 5 SUBTRACT 0 005 in from the feeler gauge measurement A If etched number is zero 0 use feeler gauge measurement A to determine shims Pinion Bearing Carrier Shimming 1 Position shim fixture 3850600 on top of pinion gea...

Страница 74: ... is zero 0 use dimension D in next step Example 2 189 in dimension D 0 002 in shimming allowance S 2 187 in Total T 3 SX 1 79 1 1 97 1 2 18 1 and DPS 2 11 1 and 2 32 1 Ratios Only Subtract the nominal figure 2 171 from the T All Other Ratios Subtract the nominal figure 2 244 from T This figure is thickness of shims required to properly position pinion gear in upper gear housing Example Subtract 2 ...

Страница 75: ... through lower output gear bearing assembly Groove must be on same side as bearing 2 Lightly oil lower needle bearings with gear oil 3 Install needle bearings onto upper driveshaft with same top to bottom orientation as when disassembled 4 New bearings can be installed with either end up 5 Push bearing all the way into gear 6 Place spacer on upper shaft with recess facing up 7 Place two c clips in...

Страница 76: ...o capture c clips in recess of spacer Lower Output Gear Installation 1 Mount upper gear housing on holding fixture 3849651 Secure housing to fixture with 4 nuts N on studs 2 Place required amount of shims for lower gear bearing into upper gear housing 50485 N 50486 50487 ...

Страница 77: ...e lower gear bearing assembly bearing down on shims 5 Loosen locking screw and adjust fixture shaft until there is a small amount of vertical play in drive shaft Re tighten fixture bolt 6 Lightly oil retainer ring with gear oil 7 Install ring in housing teeth upwards 8 Thread ring in by hand until it seats on bearing 50488 34959 50490 50491 ...

Страница 78: ...over screws Spanner must be updated with new plate 3861651 original plate will not mate to housing 11 Tighten cover screws down evenly alternating every two turns 12 Tighten cover screws securely 13 Torque retainer ring to 145 165 ft lb 196 225 N m 14 Remove two screws from tension arm then remove spanner CAUTION Use caution when removing screws from tension arm arm is under spring tension 50492 3...

Страница 79: ... the upper housing to the holding fixture to center the housing and shaft This will make installation of the upper output bearing assembly easier 3 Apply gear oil to upper needle bearings 4 Place needle bearing on top of shaft Maintain same top to bottom orientation as during disassembly New bearings can be installed with either end up 5 Push needle bearing all the way into gear Shimming Vertical ...

Страница 80: ... top of nut 4 Retighten top nut to specified torque measure clearance again NOTICE If proper clearance is not obtainable with any of the four nut sizes make sure the upper gear bearing and ring are correctly assembled If no problems are found in upper gear also check lower gear Pinion Bearing Carrier Installation 1 Place required amount of shims for pinion gear position on pinion bearing carrier D...

Страница 81: ... 15 20 ft lb 20 28 N m Top Cover Shimming 1 Measure in inches depth of bearing seat in top cover Save as measurement D 2 Measure in inches height of installed bearing above gear housing Save as measurement E 3 Subtract E from D Add 0 005 to determine shim thickness Top Cover Installation 1 Install cover and shims over bearing Do not install seal 50501 D D 50502 E S 512 ...

Страница 82: ...ar housing 2 Place indicator tip at midpoint of a lower gear tooth 3 Proper indicator placement is important for an accurate reading 4 Zero indicator 5 With your finger gently rotate gear first in one direction until tooth contact is felt then in other direction Do not turn gear far enough to rotate universal joint just far enough to contact pinion gear in both directions 6 Correct gear lash is 0 ...

Страница 83: ...on A first then at B C D and E in that order Determine amount of change by either subtracting range mid point from reading or by subtracting reading from range mid point A change to shim D affects gear lash of both upper and lower output gears A change to shim B affects gear lash of upper output gear only A change to shim A affects gear lash of lower output gear only One Gear Correct One Gear Requ...

Страница 84: ...iring Shim Change Condition A B C D E Upper gear greater than range max Lower gear less than range min Subtract Subtract Re shim Re shim Lower gear greater than range max Upper gear less than range min Add Add Re shim Re shim Lower gear less than range min Upper gear less than range min Add Lower gear greater than range max Upper gear greater than range max Add No Change Required ...

Страница 85: ...ition A B C D E Upper gear greater than range max Lower gear less than range min Subtract Subtract Re shim Re shim Lower gear greater than range max Upper gear less than range min Add Add Re shim Re shim Lower gear less than range min Upper gear less than range min Subtract Add Re shim Re shim Lower gear greater than range max Upper gear greater than range max Add Subtract Re shim Re shim No Chang...

Страница 86: ...size 1 in x 2 in x 6 in 25mm x 50mm x 150mm through the shift mechanism hole between the upper and lower gear cups Load the gears with the piece of wood while turning the input gear at least six times in the direction of engine rotation clockwise as viewed from the front of the drive This procedure will require the assistance of another person to turn the input gear 4 Dismantle the gear set and co...

Страница 87: ...ng parts see disassembly steps earlier in this section 1 Remove pinion bearing carrier Save shims for final assembly 2 Remove top cover from housing Save shims for final assembly 3 Remove top nut from upper gear 4 Remover upper gear bearing ring assembly Save shims for final assembly 5 Install cone clutch on shaft with the word TOP facing UP Slowly let cone clutch spin down shaft helix Upper Gear ...

Страница 88: ...ter the housing and shaft This will make installation of the upper output bearing assembly easier 4 Apply gear oil to upper needle bearings 5 Place needle bearing on top of shaft Maintain same top to bottom orientation as during disassembly New bearings can be installed with either end up 6 Push needle bearing all the way into gear 7 Re install top nut on shaft 8 Torque nut to 96 110 ft lb 130 150...

Страница 89: ...ver Installation 4 Make sure correct shims are under cover and shims are positioned correctly 5 Lightly coat gasket with gear oil 6 Place gasket around upper output gear assembly Orient opening in gasket as shown 7 Install top cover on upper housing 8 Install 4 screws in cover 9 Torque screws in a crossing pattern First pass to 6 9 ft lb 8 12 N m Final pass to 15 20 ft lb 20 28 N m G S 50510 50511...

Страница 90: ...housing Do not re use old O ring 2 Install spring and shift shoe in piston 3 Place shift mechanism in mounting hole Make sure shift shoe is oriented as shown with UP marking facing up 4 Install four bolts hand tighten in a crossing patter Torque bolts in a crossing pattern to 15 20 ft lb 20 28 N m 50494 S ...

Страница 91: ...moved it must be replaced 2 Torque screw to 15 20 ft lb 20 28 N m Make sure bracket moves freely 3 Install rod in hole in eccentric 4 Secure with cotter pin C Gearhousing Installation Proceed to Chapter 2 to Reassemble gearcase to the upper housing Pressure and Vacuum test the assembled drive Install the drive on the transom Install the propeller R W B 50464 S C B S 50452 ...

Страница 92: ... in lb 7 10 N m Dipstick 48 72 in lb 5 8 N m Studs upper housing 22 25 mm height 22 25 mm height Nuts upper to lower housings 30 38 ft lb 41 51 N m Screws upper to lower housings 30 38 ft lb 41 51N m Screws top cover 15 20 ft lb 20 28 N m Screws pinion bearing carrier 15 20 ft lb 20 28 N m Screws shift housing 15 20 ft lb 20 28 N m Screw shift bracket 15 20 ft lb 20 28 N m Screws shift cover 15 20...

Страница 93: ...8 72 in Lb 5 8 N m 60 84 in Lb 7 10 N m D B 15 20 ft Lb 20 28 N m D D D D 15 20 ft Lb 20 28 N m 15 20 ft Lb 20 28 N m 15 20 ft Lb 20 28 N m 15 20 ft Lb 20 28 N m C D 50528 A Volvo Penta Thread Locking Fluid 1161053 B No Gasket Sealing Compound required C Volvo Penta Propeller Shaft Grease 1141644 D Volvo Penta GL5 Synthetic Gear Lubricant 75W90 ...

Страница 94: ...Upper Gear Housing 90 Publ 7746477 English 06 2008 NOTES ...

Страница 95: ...opshaft Gear Removal 100 Gearcase Cleaning and Inspection 101 Lower Gearcase Assembly 103 Gearcase 103 Propshaft and Bearing Housing 103 Vertical Shaft Bearings 104 Pinion Shimming 105 Propshaft Gear 107 Vertical Shaft and Gear Installation 109 Setting Rolling Torque 111 Gear Lash 115 Gear Contact Pattern 118 Final Assembly 119 Lower Gearcase Installation 121 Specifications 121 Service Chart 122 S...

Страница 96: ...pshaft 5 Water passage 20 Plug oil drain 6 Water intake 21 Thrust washer prop 7 Anode 22 Spacer prop 8 Splined sleeve Drive Saver 23 Nut and cotter pin prop 9 Retainer vertical shaft 24 Magnet 10 Vertical shaft 25 O ring 11 Bearing vertical shaft 26 Seal 12 Pinion 13 Bearing pinion 14 Drive gear 15 Bearing drive gear 50605 8 10 5 2 3 24 6 7 23 16 21 1 15 14 4 13 12 22 1 25 20 25 18 1 26 25 26 26 9...

Страница 97: ...t No View Tool Name Part No View Adapter Puller 3849652 Handle 3850609 311880 Bearing Cup Installer 3850616 914695 Guide Plate 3850619 914700 Bearing Cup Installer 3850621 914703 Guide Plate 3849656 Drift 884263 Holding Socket 884830 or 3850618 914699 Drift 3855866 Pinion Bearing Installer 3850620 914701 3 6 92mm 4 245 ...

Страница 98: ...me Part No View Tool Name Part No View Pinion Bearing remover 3884360 Puller Bridge 3850611 432127 Pinion Nut Holder 3854864 914694 Puller Jaws 3850612 432129 Pinion Shim Fixture 3855098 Pusher Puller 3850623 914706 Propshaft Bearing Installer 3850617 Remover Tip 3855859 Puller 3855923 Rod Nut Washer 3855860 28mm 3855098 ...

Страница 99: ...rom upper housing Follow the procedures in the Sterndrive General Information chapter of this manual If only the lower housing is being serviced do not remove the sterndrive from the transom shield Tilt the drive up and then follow the procedure for separating the uppper and lower housings 5 Mount the gearcase in a suitable holding fixture and clamp it securely NOTICE The gearcase should be held i...

Страница 100: ...be used to replace it Flange type screws are not compatible with early propshaft bearing housings 2 Thread adapter 3849652 on end of propshaft 3 Attach slide hammer 884161 to adapter Use slide hammer to remove propshaft and housing from gearcase 4 Remove shaft bearing from housing 5 Remove shims S they can be reused if not damaged 6 Remove and discard o rings R Seal and Bearing Removal 1 Use a pun...

Страница 101: ... rod to pull out cup Propshaft Bearing Removal 1 Screw propeller nut on shaft to prevent thread damage 2 Support bearing in bearing splitter and press propshaft down and out of bearing Be ready to catch shaft when pressed out of bearing Vertical Shaft and Pinion Removal 1 Remove intermediate shaft and inspect splines 2 Inspect intermediate shaft for twisting If damaged replace 50514 50515 50516 ...

Страница 102: ...onto handle 3850609 6 Slide guide plate 3849656 over handle 7 Insert pinion nut holder in to drive gear 8 Turn vertical shaft to align pinion nut with holder 9 Slide socket 3850598 on to vertical shaft 10 Attach pull bar to socket 11 Hold pinion nut holder in place with handle and turn socket and shaft counter clockwise to loosen pinion nut 12 Remove and retain pinion nut 50517 50518 50519 50520 ...

Страница 103: ... 3 Remove pinion gear 4 Lift out vertical shaft bearings and upper cup 5 The pinion roller bearings may fall out of retainer Remove and retain roller bearings NOTICE Do not remove vertical shaft bearings unless you intend to replace them Removal process may damage bearings 1 Place socket 3850598 over splines to protect shaft 2 Using a bearing separator and press remove bearings Be ready to catch s...

Страница 104: ...y to catch gear when it is pressed out of bearing 4 Use a two jaw puller and slide hammer to remove drive bearing cup and shims NOTICE The shims will be damaged during removal and must be replaced on reassembly Lower Bearing Cup Removal 1 Assemble cup remover 3855859 R rod nut and washer 3855860 and guide plate 3850619 P 2 Place remover in to cavity under lip of bearing cup Place smallest step of ...

Страница 105: ...f plate in retainer bore 8 Using a hammer drive pinion bearing down and out of gearcase Gearcase Cleaning and Inspection Clean housing in solvent to remove all sealer from screw holes gasket surfaces and o ring bores Dry housing thoroughly Passages for Pitot If pitot speedometer is clogged use compressed air to clear the passages Apply air at opening to smaller passage on leading edge of gearcase ...

Страница 106: ...will damage Heli Coil insert and make replacement necessary Do not replace with standard non locking Heli Coils Retainer Threads lock ring must turn freely for full depth Cooling Passages check for corrosion build up that would restrict water circulation Propshaft Bearing Carrier Bore remove all sharp edges that would cut o ring Gears Shafts and Bearings inspect gear teeth for cracks and chips or ...

Страница 107: ...ngs must face forward 3 Install two screws from port intake side Torque screws to 44 62 in lb 5 7 N m The following steps assemble the gearcase so that gear shimming gear lash and wear contact patterns can be set Complete assembly is covered in see Final Assembly on page 119 NOTICE All references to gear oil in all assembly steps are referring to the same oil used to fill the drive Volvo Penta GL5...

Страница 108: ...sed lip of installer up it must contact rear of bear ing 4 Insert shaft in installer and press shaft into bearing until it seats Vertical Shaft Bearings 1 Apply gear oil to inner diameter of small bearing 2 Protect threads of shaft by installing a pinion nut on shaft 3 Slide bearing on shaft with taper facing pinion end 4 Place bearing installer 3850617 on open jaws of a press support Position rai...

Страница 109: ... until it seats Pinion Shimming NOTICE This procedure determines the amount of shims required to properly position the pinion in relation to the propshaft gear Record the following shimming measurement for the final gear lash check Measure for Shims 1 Clamp special tool 884830 S in a vice and place vertical shaft in socket Place cup C on small bearing Slide shim fixture 3855098 F on shaft with thr...

Страница 110: ...se number in 3 Example Add Subtract 0 009 in number from Step 3 0 005 in number etched on gear 0 014 in shims needed 6 Use this thickness of shims for pinion gear shimming NOTICE No less than one shim but no more than five shims should be used to obtain needed shim thickness 7 Record shim measurement for rolling torque correction in see Gear Lash on page 115 Install Shims 1 Install pinion shims in...

Страница 111: ...lide bearing on gear with taper facing away from gear 3 Position drift 884168 D upside down on inner ring of bearing with a sutible press plate and press bearing on gear until it seats NOTICE This procedure determines the amount of shims required to properly position the propshaft gear in relation to the pinion Shimming 1 Place gear and bearing on flat surface Place bearing cup C on top of bearing...

Страница 112: ...f the etched number is zero 0 use the dimension in Step 2 Example Add Subtract 0 057 in actual dimension in Step 2 0 005 in etched number 0 on gear 0 052 in total 4 Subtract number in Step 3 from a nominal dimension of 0 079 in Example Subtract 0 079 in nominal dimension 0 052 in total from Step 3 0 027 in shims needed 5 Use this thickness of shims for propshaft gear shimming 6 Record shim measure...

Страница 113: ...l bearings in pinion cup 3 Apply gear oil to pinion bearing 4 Install pinion bearing onto installer 3850620 N 5 Slide guide plate 3850619 P on rod nut and washer 3855860 6 Insert rod in gearcase and screw in to installer 7 Place smallest step of plate in retainer bore 8 Turn nut until pinion bearing is seated then unscrew and remove tools NOTICE If installer turns in bearing screw pinion nut holde...

Страница 114: ...ertical shaft in gearcase and engage pinion splines 5 Seat lower bearing in cup 6 Seat shaft in pinion bearing NOTICE Insert vertical shaft carefully so pinion bearing rollers aren t dislodged 7 Apply gear oil to upper bearing cup 8 Place cup in housing and push down until it seats on bearing 9 Place retainer over shaft and bearing cup start threads Screw in shaft retainer using spanner wrench 385...

Страница 115: ...holder 17 Slide socket 3850598 on to vertical shaft 18 Attach torque wrench to socket 19 Hold pinion nut holder in place with handle and turn socket and shaft to tighten pinion nut 20 Torque pinion nut to 150 160 ft lb 203 217 N m Setting Rolling Torque NOTICE This procedure will ensure bearing life by setting vertical shaft rolling torque Turn gearcase so that propshaft bore is vertical and gear ...

Страница 116: ...ainer to achieve a vertical shaft rolling torque of 2 4 in lb 0 22 0 45 N m 3 Record rolling torque setting 4 Apply gear oil to o ring for retainer 5 Install o ring over retainer 6 Return gearcase to normal position propshaft bore slightly above horizontal 50582 50623 ...

Страница 117: ...s 3 Place bearing housing over shaft and in to bore in gearcase 4 Install housing use original screws removed during disassembly NOTICE Use the same type of screw that was removed if any require replacement If a socket head screw was removed a socket head screw must be used to replace it Flange type screws are not compatible with early propshaft bearing housings 5 Tighten screws in small steps alt...

Страница 118: ...shim amount for the propshaft bearing housing Example 8 Remove bearing housing 9 Install shims and re install bearing housing 10 Install original screws and torque to 10 ft lb 13 5 N m Then tighten screws another 70 of rotation NOTICE Use original screws for all shimming rolling torque and other pre assembly work Use two NEW screws for final assembly and final torque L B G M 50610 Add Divide no 1 ...

Страница 119: ...ct the gear contact pattern then the lash must be rechecked before final assembly Checking 1 The propshaft must not turn during gear lash check If propshaft is hard to turn by hand no additional steps are necessary go to step 2 If propshaft turns freely install a propeller without thrust washer Install the brass spacer and prop nut Tighten prop nut by hand until propshaft does not rotate freely 2 ...

Страница 120: ...dicator Rotate tool shaft in other direction until gear teeth make contact Read dial indicator Correct gear lash range 0 005 0 012 in 0 13 0 30 mm Optimum gear lash range 0 0085 in 0 22mm 6 If reading is in range remove propeller and go to see Gear Contact Pattern on page 118 If reading is out of range follow steps in Correcting below Correcting 1 Gear shimming must be remeasured Disassemble gearc...

Страница 121: ...st thousandths of an inch i e 0 003 in if needed This example requires the addition of 0 003 in shim under the lower vertical shaft bearing cup and 0 003 in shim removed from behind the propeller gear bearing cup When Gear Lash Measurement Is More Than 0 012 in Subtract 0 0085 in optimum gear lash measurement from the actual gear lash measurement and divide by two Example Only 0 0148 in Gear lash ...

Страница 122: ...ld be completely covered with marking compound light coating from heel to toe and crest to root For right hand rotation applications use the convex side of gear For left hand applications use the concave side of gear 2 Reassemble gearcase according to earlier procedures Install propshaft bearing Install bearing housing and shims 3 Turn vertical shaft in direction of rotation While turning brake th...

Страница 123: ...hickness from the propshaft and vertical shaft bearings 8 If shims were changed to correct the gear contact pattern then the lash must be rechecked before final assembly Go to see Gear Lash on page 115 9 After gear lash and contact pattern are both correct clean all marking compound from gears and proceed to final assembly Final Assembly Propshaft Seal 1 Assemble pusher puller 3850623 and seal ins...

Страница 124: ... lb 13 5 N m Then tighten screws another 70 of rotation NOTICE Use original screws for all shimming rolling torque and other pre assembly work Use two NEW screws for final assembly and final torque Check Rolling Torque 5 Check for correct rolling torque for ratios 1 43 1 51 1 60 1 79 1 89 14 23 in lb 1 58 2 60 N m for ratios 1 66 1 97 2 18 11 18 in lb 1 24 2 03 N m 6 Correct as needed rolling torq...

Страница 125: ...rive on the transom Install the propeller Specifications Description U S Metric Nut pinion gear 150 160 ft lb 203 217 N m Screws anode 15 20 ft lb 20 28 N m Plug drain 60 84 in lb 7 10 N m Nuts upper to lower housing 30 41 ft lb 40 56 N m Screws upper to lower housing 30 41 ft lb 40 56 N m Screws propshaft bearing housing 10 ft lb 70 rotation 13 5 N m 70 rotation Screws water intakes 44 62 in lb 5...

Страница 126: ...Lb 130 150 N m 44 62 in Lb 5 7 N m D D A D D D C D D A 15 20 ft Lb 20 28 N m 60 84 in Lb 7 10 N m D 10 ft Lb 13 5 N m 70 rotation A Volvo Penta Thread Locking Fluid 1161053 B NO Gasket Sealing Compound required C Volvo Penta Grease 828250 D Volvo Penta GL5 Synthetic Gear Lubricant 75W90 ...

Страница 127: ...Propeller Shaft Service 137 Vertical Shaft Service 140 Gearcase Cleaning and Inspection 141 Lower Gearcase Assembly 143 Pinion Shimming 143 Forward Gear Shimming 146 Outer Propeller Shaft Shimming 146 Bearing Race and Shim Installation 149 Vertical Shaft and Gear Installation 150 Setting Rolling Torque 153 Gear Lash 157 Checking Tooth Contact Pattern 158 Adjusting Tooth Contact Pattern and Gear La...

Страница 128: ...Exhaust passage19 Bearing propshaft 5 Water passage20 Plug oil drain 6 Water intake21 Magnet 7 Anode22 O ring 8 Splined sleeve Drive Saver23 Seal 9 Retainer vertical shaft 10 Vertical shaft 11 Bearing vertical shaft 12 Pinion 13 Bearing pinion 14 Drive gear 15 Bearing drive gear 50606 8 10 5 2 3 21 6 7 16 1 15 14 4 13 12 1 20 22 1 23 22 23 23 9 17 11 3 DPS A 1 17 18 19 19 22 15 15 14 16 3 ...

Страница 129: ...ay have the OMC part no Tool Name Part No View Tool Name Part No View Attachment Tool 884940 Bolt 3850623 Bearing Cup Installer 3850621 Dismantling Tool 884803 Bearing Installer 3850617 Drift 884263 Bearing Installer 3855928 Drift 884143 Bearing Installer 3849670 Drift 3855866 3 6 92mm ...

Страница 130: ...me Part No View Tool Name Part No View Guide Plate 3849656 Puller 884832 Guide Plate 3850619 914700 Puller 884789 Handle 3850609 311880 Puller 3850623 Installation Tool 884975 Race Installer 3850616 914695 Lash Tool 3855873 Race Installer 3855864 Pinion Nut Holder 3849660 Race Installer 3855865 4 245 3 3 84mm 23mm 1 3 34mm ...

Страница 131: ...t No View Tool Name Part No View Race Remover 3855862 Seal Protector 884807 Remover Tip 3855859 Seal Protector 884976 Remover Installer Tip 3855868 Shim Fixture 3850600 Remover Tool 3849659 Shim Fixture 3849662 Rod Nut and Washer 3855860 Shim Fixture 3849663 Seal Installer 3849661 Shim Spacer 3849653 2 75 70mm 60mm 44mm 3849662 ...

Страница 132: ...he limits in the steps below the inner propshaft is worn or bent and must be replaced All related bearings and seals must also be replaced 1 Attach a dial indicator to tool 884940 Attach to outer propshaft with tip resting on inner propshaft as close to edge of outer propshaft as possible 2 Rotate shafts one turn and read dial indicator The reading should not exceed 0 0027 in 0 07 mm 3 To measure ...

Страница 133: ...arcase should be held in fixture throughout rebuild process Fixture is not shown in following steps to provide clearer illustrations of the steps Lower Gearcase Disassembly Propshafts and Bearing Housing Removal Bearing housing 1 Remove two screws securing propshaft bearing housing NOTICE Use the same type of screw that was removed if any require replacement If a socket head screw was removed a so...

Страница 134: ...ing from housing 5 The inner propshaft is a slide fit not pressed Remove innner propshaft Save shims Vertical Shaft and Pinion Removal 1 Remove intermediate shaft and inspect splines Inspect intermediate shaft for twisting If damaged replace 2 Using spanner wrench 3850601 unscrew retainer Remove retainer and o ring discard o ring S R 50633 50634 50516 50517 ...

Страница 135: ... 3 Slide socket 3850598 on to vertical shaft Attach pull bar to socket Hold pinion nut holder in place with handle and turn socket and shaft counter clockwise to loosen pinion nut Remove and retain pinion nut Vertical shaft removal 1 Pinion gear may slip off shaft if not Install puller 3855923 on vertical shaft Pull shaft and bearings up by tightening vertical screws NOTICE Hold the pinion gear wh...

Страница 136: ...mage bearings Gear and Bearing Removal 1 Remove forward gear and bearing Forward Gear Service Bearing Removal NOTICE Do not remove bearing from forward gear unless you intend to replace bearing Removal process may damage bearing 1 Use bearing separator to support bearing Use drift 884263 to press gear out of bearing NOTICE Be ready to catch gear when it is pressed out of bearing Installation 50522...

Страница 137: ...ed on reassembly Lower Bearing Race Removal 1 Assemble race remover 3855859 R rod nut and washer 3855860 and guide plate 3850619 P Place remover in to cavity under lip of bearing race Place smallest step of plate in retainer bore 2 Tighten nut to remove race and shims Shims may be damaged during removal and should be replaced Pinion Bearing Removal NOTICE Remove the pinion bearing only if it is to...

Страница 138: ... NOTICE Bearings should not be removed unless they are to be replaced Removal will damage the bearings 1 Place housing in press seal end up 2 Place tool 3849659 on seal Line up high spots on tool arrow with slots on housing 3 Install drift 884263 on tool Press out and discard the bearing and seals 4 Turn housing over bearing race facing up Insert race remover 3855862 with the tapered side facing u...

Страница 139: ...to remove all oil sealer and other debris from holes gasket surfaces and bores Dry housing thoroughly Seal bearing installation NOTICE Correct alignment of bearing and seals in housing bore is needed to insure proper installation The use of a hand press or other small press is recommended 1 Place tool 3849672 on press Place housing over tool as shown Center housing over tool The tool acts as a sto...

Страница 140: ...ly press seals in to place NOTICE If outer propshaft is grooved where seals contact shaft do not press seals all the way against the end of housing Stop seals approxiamtely 5mm from end of housing When bearing is seated it will position seals 4 Apply oil to outer surface of bearing Place bearing in housing Place press tool 3849670 in bearing 5 Use mandrel 884263 against tool lightly press bearing ...

Страница 141: ...ss race in to housing 7 Do not install o rings at this step Outer Propeller Shaft Service Bearing seal removal NOTICE Bearings should not be removed unless they are to be replaced Removal will damage the bearings 1 Screw puller 884789 on to end of propshaft to protect threads Place assembly in a press 2 Slide dismantling tool 884803 and drift 884143 in propshaft 50949 884789 43510 884803 43466 884...

Страница 142: ...earing on the propshaft unless it needs to be replaced The bearing will be damaged if removed plus the needle bearing race arrow on the propshaft will also have to be removed and replaced to remove the bearing 6 Clamp a bearing separator in position to hold bearing Thread puller 884789 on propshaft to protect threads Position propshaft in a press and press out bearing then use bearing to press off...

Страница 143: ...ace of bearing and place it on propshaft tapered side away from gear Press bearing in place using installer 3855866 3 Apply Loctite primer to inside of sleeve and its position on propshaft Allow to air dry Apply a small amount of Loctite 609 to propshaft 4 Place installer 3855865 on a press bevel up Place race in propshaft gear over installer Position race on propshaft Press in position using Inst...

Страница 144: ...ng compound to outer edges of seal Press seal in place until tool seats on end of propshaft 7 Turn installation tool over so that the stepped side is facing up Position single lipped seal on installation tool 884975 with open side of seal facing installer Apply white sealing compound to outer edges of seal Press seal in place until tool seats on end of propshaft 8 Remove tool Apply gear oil to sea...

Страница 145: ... jaws of a press support Position raised lip of Installer down Insert shaft and bearing in installer and press shaft in bearing until it seats 2 Apply a light coat of gear oil to inner diamter of large bearing Slide bearing on shaft with taper facing away from small bearing Place bearing installer 3850617 on open jaws of a press support Position raised lip of installer up it must contact nose of b...

Страница 146: ...ne gearcase service If the magnet is removed when reinstalling torque screw to 5 7 ft lb 7 9 N m NOTICE Most threaded holes in gearcase have Heli Coil inserts Do not use a thread tap to clean screw holes Tap will damage Heli Coil insert and make replacement necessary Do not replace with standard non locking Heli Coils Retainer Threads lock ring must turn freely for full depth Cooling Passages chec...

Страница 147: ... Intakes Reinstall water intakes if removed Place each intake in hole on correct side of gearcase Openings must face forward Install two screws from port intake side Torque screws to 44 62 in lb 5 7 N m The following steps assemble the gearcase so that gear shimming gear lash and wear contact patterns can be set NOTICE All references to gear oil in all assembly steps are referring to the same oil ...

Страница 148: ... three slots with feeler gauge and record each reading Measure between inner ring of fixture and horizontal gear surface Average feeler gauge readings Example 4 Remove pinion nut and discard Remove gear 5 The pinion gear markings etchings are on the outer propshaft Pinion gear mark is in the box marked P 6 Add or subtract shimming allowance number etched on gear from number found in Step 3 If numb...

Страница 149: ...rrection chapter Install Shims 1 Install pinion shims in gearcase where lower bearing race seats 2 Apply gear oil to bearing race Install race on top of shims with race taper facing up 3 Use pusher puller 3850623 guide plate 3850619 P and race installer 3850621 N to install race 4 Place installer on race Place smallest step of plate in retainer bore CAUTION Wear safety glasses Use a hammer to seat...

Страница 150: ...gear from number found in Step 2 If etched number is 5 you would subtract 0 005 in from dimension in Step 2 If etched number is 5 you would add 0 005 in to dimension in Step 2 If the etched number is zero 0 use the dimension in Step 2 Example Add Subtract 0 052 in actual dimension in Step 2 0 005 in etched number 0 on gear 0 047 in total 5 Subtract number in Step 3 from a nominal dimension of 0 07...

Страница 151: ...n a flat surface Place forward gear bearing race taper up inside fixture 2 Place forward gear bearing inside the fixture and position on race 3 Set shim spacer 3849653 on forward gear face 4 Insert inner propshaft bearing in forward gear Make sure spacer is seated between gearface and boss on propshaft 5 Place seal protector 884976 over outer propshaft seals 50971 50972 50973 50959 ...

Страница 152: ...shaft 8 Use a depth micrometer to measure from the top of the shim fixture to the machined ring on the outer propshaft Take a measurement by each of the three set screws Average the measurements Example 9 Subtract the amount of shims required to position the forward gear from the average depth measurement from step 8 Example Subtract 0 253 in average depth from step 8 0 032 in forward gear shims 0...

Страница 153: ...Add Subtract 0 221 in actual dimension in Step 9 0 002 in etched number 2 on gear 0 223 in total shims required 12 Record dimension example 0 223 in for the outer propeller shaft shims required 13 Remove parts from shim fixture Bearing Race and Shim Installation NOTICE Use the least number of shims possible to obtain the required shim thickness 1 Place needed thickness of shims in recess of bearin...

Страница 154: ... O guide plate 3850619 P on rod nut and washer 3855860 Insert rod in gearcase and screw in to installer Place smallest step of plate in retainer bore 3 Turn nut until pinion bearing is seated then unscrew and remove tools NOTICE If installer turns in bearing screw pinion nut holder 3849660 on handle 3850609 Slide guide plate 3849656 onto handle Insert into gearcase and hold pinion installer Pinion...

Страница 155: ...rs aren t dislodged 3 Apply gear oil to upper bearing race Place race in housing and push down until it seats on bearing 4 Place retainer over shaft and bearing race start threads Screw in shaft retainer using spanner wrench 3850601 to seat upper shaft bearing race Pinion Nut Installation 5 Apply Loctite primer to pinion threads on shaft and let air dry Apply thread locking compound 1161053 to thr...

Страница 156: ...9656 on handle Insert pinion nut holder in to drive gear Turn vertical shaft to align pinion nut with holder 7 Slide socket 3850598 on to vertical shaft Attach torque wrench to socket Hold pinion nut holder in place with handle and turn socket and shaft to tighten pinion nut Torque pinion nut to 78 87 ft lb 105 118 N m 50584 50585 ...

Страница 157: ... to achieve a vertical shaft rolling torque of 2 4 in lb 0 22 0 45 N m Record rolling torque setting 3 Apply gear oil to o ring for retainer Install o ring over retainer 4 Return gearcase to normal position propshaft bore slightly above horizontal Propshaft Bearing Housing Shimming and Rolling Torque NOTICE This procedure determines the amount of shims required to preload the propshaft bearings an...

Страница 158: ...eal damge then drive failure are possible if seals are damaged by the splines 3 Place seal protector 884976 into seals in outer propshaft 4 Apply gear marking compound to at least three teeth on outer propshaft gear 5 Slide the outer propshaft gear into place over inner propshaft Remove the seal protector when seals are past prop splines Seal protector will affect rolling torque if left in place 5...

Страница 159: ...se two NEW screws for final assembly and final torque 9 Tighten screws in small steps alternating top and bottom until vertical shaft rolling torque is for ratios 1 95 2 14 2 32 18 26 in lb 2 0 2 9 N m for ratios 1 68 1 78 and 2 11 26 35 in lb 2 9 4 0 N m 10 Measure M gap between bearing housing B and gearcase L Record in two places in the middle on each side Average the measurements NOTICE Do not...

Страница 160: ... from step 10 and re install bearing housing Do not install o rings at this step Remove seal protector 13 Install original screws and torque to 10 ft lb 13 5 N m Then tighten screws another 70 of rotation 14 Check for correct rolling torque see step 9 above Correct as needed rolling torque is too high add shim rolling torque is too low decrease shim 50964 50965 50966 ...

Страница 161: ...ator to read forward gear lash by setting the indicator tip on outer lash tool line 4 Rotate inner prop shaft back and forth to check the amount of lash for the forward gear Lash should be 0 006 0 012 in 0 15 0 30 mm 5 Record your measurements 6 Reposition Lash Tool 3855873 onto outer propshaft Stay away from the propeller splines 7 Set up a dial indicator to read rear gear lash by setting the ind...

Страница 162: ...he instructions found elsewhere in this section 3 Check the tooth contact pattern on the outer propshaft gear Check the tooth contact pattern on the forward propshaft gear 4 The contact pattern should be located towards the heel H with a slight displacement towards the root R of the tooth H Heel R Root T Toe C Crest 5 If the tooth contact pattern and gear lash are within specifications proceed to ...

Страница 163: ...orrected before attempting to correct gear lash If the contact pattern is too far towards the crest of the tooth and towards the toe of the gear change the shims as follows Subtract shims from position 1 Subtract shims from position 2 Add shims to position 3 If the contact pattern is too far towards the root of the tooth and towards to heel of the gear change the shims as follows Add shims to posi...

Страница 164: ...g the tooth contact pattern change the shims equally as follows Add shims to position 1 Subtract shims from position 3 Reassemble the gearcase and recheck the gear lash and contact pattern according to the instructions above When both are correct proceed with Final Assembly Final Assembly NOTICE All references to gear oil in all assembly steps are referring to the same oil used to fill the drive V...

Страница 165: ... 10 ft lb 13 5 N m Then tighten screws another 70 of rotation NOTICE Use original screws for all shimming rolling torque and other pre assembly work Use two NEW screws for final assembly and final torque 7 Check for correct rolling torque see procedure above Correct as needed rolling torque is too high add shim rolling torque is too low decrease shim NOTICE Failure to reset the rolling torque to t...

Страница 166: ...drive on the transom Install the propellers Specifications Description U S Metric Nut pinion gear 78 87 ft lb 105 118 N m Screws anode 15 20 ft lb 20 28 N m Plug drain 60 84 in lb 7 10 N m Nuts upper to lower housing 30 41 ft lb 40 56 N m Screws upper to lower housing 30 41 ft lb 40 56 N m Screws propshaft bearing housing 10 ft lb 70 rotation 13 5 N m 70 rotation Screws water intakes 44 62 in lb 5...

Страница 167: ...4 62 in Lb 5 7 N m A D A 15 20 ft Lb 20 28 N m 60 84 ft Lb 7 10 N m B D D D D C D D D D D D D D D D 10 ft Lb 13 5 N m 70 rotation A Volvo Penta Thread Locking Fluid 1161053 B NO Gasket Sealing Compound required C Volvo Penta Propeller Shaft Grease 828250 D Volvo Penta GL5 Synthetic Gear Lubricant 75W90 ...

Страница 168: ...DPS A Lower Gearcase 164 Publ 7746477 English 06 2008 NOTES ...

Страница 169: ...ose Removal 182 Water Tube Removal 182 Water Hose Removal 183 Anode Replacement 183 Trim Sender Removal 183 Hydraulic Lines Removal 185 Trim Pump Removal 185 Steering Bearing Gimbal Bearing and Seal Removal 186 Gimbal Housing Cleaning and Inspection 187 Gimbal Housing Assembly 188 Steering Bearing Gimbal Bearing and Seal Installation 188 Trim Pump Installation 189 Trim Sender Installation 191 Wate...

Страница 170: ...on and possible injury to the operator and or passengers Some screw holes have special Heli Coil inserts that provide a thread locking feature Do not clean Heli Coil holes with a thread tap This will damage the Heli Coil inserts and necessitate their replacement Special Tools Tool Name Part No View Tool Name Part No View Drive Handle 3850609 Gimbal ring steering shaft bushing installer 3849654 Gim...

Страница 171: ... shield and sterndrive 1 Remover hydraulic line retaining screw and keeper NOTICE The hydraulic lines should only be disconnected if replacing a trim cylinder Any other service of the transom shield does not require the removal of the hydraulic lines from the trim cylinders 2 Wear safety glasses Cover fittings with a shop cloth and disconnect trim tilt lines 3 Cut tie straps holding the front of t...

Страница 172: ... if they are leaking otherwise leave the O rings and retainers in the trim cylinders NOTICE New O rings and retainers come installed on new trim cylinders Trim Tilt Cylinder Installation 1 Coat the pivot pins with grease 828250 NOTICE If trim cylinder bushings are damaged replace them Align trim tilt cylinders with gimbal ring 2 Slide pivot pin through cylinders and gimbal ring ...

Страница 173: ...ng Dry System in Trim Tilt Hydraulic System section of this manual Gimbal Ring Removal Remove trim tilt cylinders and pivot housing following instructions elsewhere in this section NOTICE Proceed to step 3 if shot cable has already been disconnected 1 Turn sterndrive to port Loosen anchor clamp screw and slide clamp to starboard disengaging the remote control shift cable 2 Remove shift cable from ...

Страница 174: ...TION Do not attempt to pull the sender out of the transom shield as its leads are secured to transom shield 4 Disengage U joint bellows from lip of pivot housing and push it inside 5 Loosen hose clamp securing the exhaust bellows to the pivot housing through the access hole on the starboard side of the pivot housing 6 Disconnect exhaust bellows from the pivot housing ...

Страница 175: ...g water nipple through the port side access hole 8 Disconnect water inlet hose from the nipple 9 Turn the gimbal ring to port as far as possible and remove the starboard pivot pin locking pin and ground terminal 10 Using the socket end of a in socket extension gently push the pitot connector through the pivot housing mounting hole ...

Страница 176: ...bal ring retaining screws from the steering shaft NOTICE The screws use threadlocking compound to prevent loosening A small amount of heat may be necessary to loosen the screws If heat is used do not heat the part more than 250 F 121 C 14 Remove the gimbal ring and pivot housing as an assembly Pivot Housing Removal Remove the sterndrive following the procedure in Sterndrive Removal and Installatio...

Страница 177: ... pin locking screw 2 Remove the Trim Sender driver screw and driver arm from the pivot housing Pivot Housing Disassembly 1 Using the large cup and nut from special tool 3849647 press out the pivot pins NOTICE Do not use the bushing puller installer to remove the pivot pins 3849647 ...

Страница 178: ...discard if they re damaged Remove and inspect thrust washer underneath Cleaning and Inspection Clean housing in solvent and dry thoroughly Remove sealer and or adhesive from cooling passage opening U joint bellows opening and pivot bosses NOTICE Clean screw holes with solvent only A thread tap would damage the Heli Coil inserts and necessitate their replacement O ring Seal Groove Check for sharp e...

Страница 179: ... suspect components Pivot Housing Assembly 1 If a drive stud is damaged and requires replacement install the new stud to a depth of 43 mm 1 1 7 in 03 2 Install a new cooling and exhaust passage seal 3 Apply grease 828250 to a new O ring and install water nipple with special tool 3849648 Torque fitting 11 19 Nm 8 14 ft lb m 1 43m 1 7 in 03 ...

Страница 180: ...old pivot boss friction washers were removed make sure a thrust washer coated with grease 828250 is installed in each pivot 5 Replace the wear pads if damaged cracked or worn through Gimbal Ring Disassembly 1 Using special tool 3849647 press out the pivot pin bushings ...

Страница 181: ...shing Gimbal Ring Assembly 1 Lightly oil outside of a new pivot bushing and place it in bore Use installer 3889647 to seat bushing 0 1mm 0 03 in into the gimbal ring 2 Lightly oil the outside of a new steering pivot bushing and place it in bore Use installer 3889647 to seat bushing 0 1mm 0 03 in into the gimbal ring 0 1 m m 0 1 mm ...

Страница 182: ... pivot pin hole with hole in pivot housing Look inside to see if thrust washer is still in position and not blocking hole 3 Apply grease 828250 to pivot pin 4 Align and install the pivot pins Drive pivot pins in until the groove aligns with the locking pin hole 5 Install pivot pin locking pins and torque to 10 1 5 Nm 88 13 in lb Lock pin Pivot pin ...

Страница 183: ...lamp head when turning 7 Place clamp on small end of U joint bellows There is an internal rib that must engage a corresponding groove around opening s surface Push bellows on and engage groove then rotate clamp until screw fitting A is in the two o clock position Slide ground strap clip under hose clamp Tighten clamp securely 8 Place clamp on bellows in recessed area and align with locating tabs o...

Страница 184: ...llows does not have a specific position Mounting the worm screw on top allows access through an opening in the pivot housing Gimbal Ring Installation 1 Install the gimbal ring and pivot housing assembly to the steering shaft and align the lower steering pivot 2 Install the gimbal ring to steering shaft screws and torque to 85 15 Nm 62 11 ft lb NOTICE If reusing existing screws apply Loctite 241 be...

Страница 185: ...sh 06 2008 181 3 Apply grease 828250 to the steering pivot pin 4 Align gimbal ring with gimbal housing steering pivot hole and install the steering pivot pin 5 Install a new cotter pin and spread ends 6 Reinstall the pitot sensor port connector ...

Страница 186: ...eedometer hose to the shift cable tube 2 Use a 29 mm 1 1 8 in box end wrench and remove the shift cable tube from the transom shield Water Tube Removal 1 Loosen clamp on upper end of water inlet hose and remove hose from water tube 2 Remove the three retaining screws using a 10 mm socket NOTICE The water hose is trapped between grooved in the transom shield port and ribs molded into the water tube...

Страница 187: ...rs flat washers and anode 2 Clean mounting surface then install new anode and attaching hardware Tighten screws to 24 4 Nm 18 3 ft lb Trim Sender Removal 1 Disconnect trim sender connector at wiring harness on engine Record position of sending unit wires before removing Use socket removal tool 3854350 to push terminals out of rubber plug NOTICE The use of alcohol or equivalent will make socket ins...

Страница 188: ...out of the connector 5 Lift the locking tab A with a scribe or very small screwdriver Pull terminals from the rear of the connector to clear the housing 6 Remove terminals for the trim sender connector Pull wires and terminals through weatherpak gasket and retainer NOTICE Take care not to damage the gasket with the terminals when pulling through the gasket If the gasket is torn or damaged it must ...

Страница 189: ... wires 2 Using a pair of needle nosed pliers remove the red plastic insert in the connector 3 Using a probe lift the locking tab A for the connector terminals and remove the terminals through the rear of the connector 4 Disconnect hydraulic lines from trim pump See Hydraulic Lines Removal on page 185 5 Remove the six retaining screws on the trim pump housing 6 Remove pump from transom shield 7 Pul...

Страница 190: ...ng a 5 8 socket wrench remove the steering shaft bolt 2 Remove the steering shaft to tiller arm retainer nut 3 Install special tool 3591637 with the longer leg facing outward toward the rear of the transom shield 4 Screw the flange nut onto the special tool bolt and remove the steering shaft from the tiller arm ...

Страница 191: ...hat indicates a spinning bearing Pivot Bearing Inspect Teflon surface for wear or corrosion Gimbal Bearing Rollers must spin freely and hub must pivot in all directions inner diameter must be free of corrosion Hydraulic Manifold O ring grooves must be free of nicks and burrs all fluid passages must be clear Hydraulic Lines must be clear and fittings undamaged Mounting Studs must be tight and have ...

Страница 192: ...e installer will act as a stop to seat the bearing NOTICE The bushing should protrude 3 3 mm above the transom shield and the bushing should be flush with the counterbore 2 Screw installer 3850038 onto drive handle 3850609 Drive seal into housing until it seats Coat seal lip with grease 828250 3 Reverse the gimbal bearing seal installer 3850038 on the drive handle 3850609 Position the gimbal beari...

Страница 193: ...he tiller arm Install a new O ring C on the steering shaft bolt Apply Loctite 271 to the steering shaft bolt Thread the steering shaft bolt into the tiller arm nut and tighten to 81 14 Nm 60 10 ft lb Trim Pump Installation 1 Inspect the trim pump sealing surface of the transom shield for nicks cuts or corrosion that may cause leaking past the gasket If defects are found the transom shield housing ...

Страница 194: ...he grommet is completely seated in the opening 6 Insert the wires in the correct openings of the connector Slide the terminals in until the locking tab engages the stop on the terminals NOTICE The lock tab will click when the terminal is fully engaged 7 Install the terminal support into the connector 8 Fill trim pump reservoir See General Information section of this manual ...

Страница 195: ...ender leads under extension tube or hydraulic lines Leads must be free to move when drive unit steers otherwise sender or wire will be damaged 2 Attach retaining clip to grommet inside transom plate 3 Install Black Brown wire in position 1 Green Red wire in position 2 and Black wire in position 3 NOTICE The terminal numbers are moulded into the connector 4 Install terminal support block 5 Slide ga...

Страница 196: ...ting flange 3 Push the water hose and water tube assembly into the transom shield NOTICE You will not be able to fully seat the water tube by hand but you will have to insert it enough to get the mounting screws started 4 Install the mounting screws and tighten evenly to 10 1 5 Nm 88 13 in lb Water Hose Installation 1 Place a hose clamp on the water hose 2 Slide the water hose onto the water hose ...

Страница 197: ...sing 6 Push bellows onto exhaust port until it engages groove 7 Turn the clamp to the 12 o clock position 8 Tighten the clamp through the pivot housing access window Trim Sender Adjustment 1 Connect an ohm meter to the black and brown black wire on the sending unit connector Turn sending unit control nut until meter reads 11 1 ohm 2 With lower edge of pivot housing pushed in towards gimbal housing...

Страница 198: ...21 3 in lb 1 75 0 25 Nm Transom Shield Removal Remove engine lower exhaust pipe and steering cylinder following instructions in Stern Drive Engine Removal and installation section in the Engine Service Manual 1 Remove screw and washer securing transom plate ground strap to steering arm 2 Remove six nuts and washers securing transom plate inside boat Lift plate off studs 3 Remove two remaining nuts...

Страница 199: ...ble sleeve and connector assembly Discard connector O ring 2 Apply gasket sealing compound to a new O ring Slide it onto connector and position it against hex then coat connector threads with sealer 3 Install sleeve and connector assembly and use a crowfoot adapter to tighten connector to 44 4 ft lb 60 5 Nm ...

Страница 200: ...e around gimbal housing Start at top and firmly push new seal into groove Also apply 3M Scotch Grip Rubber Adhesive 1300 to the seal ends and butt them together to form a watertight junction at top of gimbal housing Transom Shield Installation 1 Thoroughly clean outer transom surface where gimbal housing seal makes contact 2 Make sure the outer transom seal I and exhaust outlet seal M are properly...

Страница 201: ... drilled holes in transom CAUTION Ensure the wires are not caught under the transom seal Failure to follow this instruction will result damage to wires and seal This may result in water leaking into the boat 5 Apply a light coat of grease 828250 to inside of transom plate alignment tube 6 Install inner transom plate over steering arm and water tube Install PN 828250 Do not tighten at this time ...

Страница 202: ... 2008 7 Tighten the eight lock nuts in a cross pattern starting with the two center nuts Tighten them to of 20 25 ft lb 27 34 Nm 8 Attach transom plate ground strap to steering arm and secure with screw and washer Tighten screw securely 1 2 3 4 5 6 7 8 ...

Страница 203: ...p 70 5 in lb 8 0 5 Nm Tilt Pivot Pin Lock Screw Trim Sensor Screw 88 13 in lb 10 1 5 Nm Shift Cable Attachment 88 13 in lb 10 1 5 Nm Steering Shaft Assembly to Gimbal Rin 62 11 ft lb 85 15 Nm Transom Shield Mounting Studs 59 7 ft lb 80 10 Nm Tiller Arm to Steering Shaft 60 10 ft lb 81 14 Nm Trim Pump Mounting 88 13 in lb 10 1 5 Trim Sender 21 3 in lb 1 75 0 25 Nm Water Outlet 88 13 in lb 10 1 5 Nm...

Страница 204: ...ansom Seal Exhaust Seal Lubricants Where Used Volvo Penta Grease 828250 Alignment Tube Inner Transom Plate Bushing Upper Steering Post Washer Pivot Housing Grommet Trim Sender Lead Grommet Trim Pump Power Lead O ring Upper Steering shaft Water Nipple Pivot Pin Trim Tilt Cylinders Seal Lip Gimbal Housing Thrust Washer Lower Steering Post Thrust Washer Pivot Pin Thrust Washer Upper Steering Bearing ...

Страница 205: ...ft lb B 10 1 5 Nm 88 13 in Lb 80 10 Nm 59 7 ft lb B 60 5 Nm 44 4 ft Lb C D A 24 4 Nm 18 3 ft lb B 11 19 Nm 8 14 ft lb 10 1 5 Nm 7 1 ft lb 2 7 0 5 Nm 23 4 in lb B 7 Nm 62 in lb 10 1 5 Nm 7 1 ft Lb A 43mm 1 1 7 in 03 50978 A Volvo Penta P N 828250 grease B Loctite 271 Thread Locking compound C Perfect Seal gasket sealing compound D 3M Scotch Grip rubber adhesive 1300 ...

Страница 206: ...Transom Shield Assembly 202 Publ 7746477 English 06 2008 NOTES ...

Страница 207: ......

Страница 208: ...Publ 7746477 English 06 2008 ...

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