Upper Drive Unit Leak

Brew2

Chief Petty Officer
Joined
Jan 12, 2004
Messages
427
2004 Mercruiser 5.0 MPI with Alpha Drive

Replaced the impeller a few weeks ago and immediately thereafter developed an gear lube leak that required me to top up the lube monitor every few days. Assumed that it was the o-ring between the upper and lower gear drives that got misaligned, however, it now doesn't appear that that is the problem.

When I dropped the lower unit a second time to replace the o-ring, I discovered that lube was dripping out of the upper unit where the upper/lower drive shaft splines mate. I assume I shouldn't be seeing any lube in this location (this is my first I/O, so I'm a little in the dark).

It would appear that the oil seal in the upper gear case has gone bad. I had a look at my manual with regard to replacing this, but it seemed rather more involved that I had initially hoped.

A few questions....could lube dripping out of the upper drive unit drive shaft area be anything other than the oil seal going/gone bad? How difficult is this to take apart, replace the seal and reassemble? Any idea on how many hours and/or $$ this would typically be for a professional to repair?

Many thanks.
 

Don S

Honorary Moderator Emeritus
Joined
Aug 31, 2004
Messages
62,321
Re: Upper Drive Unit Leak

Did you loose or forget to install a new quad ring that seals the passage between the upper and lower units. Just to stbd. of the raw water pump. Only about a 1/2 OD quad ring.
 

Brew2

Chief Petty Officer
Joined
Jan 12, 2004
Messages
427
Re: Upper Drive Unit Leak

That ring was actually my first thought as well. I bought a new one from a dealership and dropped the lower unit again to install it. The ring I installed that came with the impeller kit looked fine, but I put in the new one just in case. No change...still have the leak.

Next step for troubleshooting this?

Thanks in advance.
 

Bondo

Moderator
Staff member
Joined
Apr 17, 2002
Messages
71,251
Re: Upper Drive Unit Leak

I went to a local machine shop but they asked for specs.

Ayuh,....

There's a couple of Seals inthat area,...
Yes,.. The Repair is Very Involved,... I have no idea what it'll co$t you, in Your area.....
 

Brew2

Chief Petty Officer
Joined
Jan 12, 2004
Messages
427
Re: Upper Drive Unit Leak

Can the upper drive unit be pressure tested separately from the lower drive unit?

Would you just insert an air line/gauge into the gear lube passage on the bottom of the upper drive unit?

Thanks.
 

JustJason

Vice Admiral
Joined
Aug 27, 2007
Messages
5,327
Re: Upper Drive Unit Leak

brew2 said:
Can the upper drive unit be pressure tested separately from the lower drive unit?

yes

you take your gear oil pump plastic adaptor and put it on the end of a pressure pump, such as a mityvac pressure pump.
Block off the gear lube passage with your thumb. It should hold 6-8psi. be carefull not to overpressureize the drive when testing it.
 
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