Another alpha 1 gen 2 loosing gear lube

J

jamespjackson95

Seaman Apprentice
Joined
Jan 21, 2012
Messages
30
Okay guys so I recently purchased a 1997 sylvan 20' boat with a 5.7 carbed mercruiser engine. The boat runs great except the gear lube reservoir leaked pretty fast on our fist lake outing. I mean the reservoir was full, and empty in about an hour. When I noticed it got to the bottom of the reservoir I put it back on the trailer and headed home.
I noticed that most of the bellows were trashed so I removed the lower unit to begin replacing parts. I noticed that not only was the gear lube low, there was also water getting into it making it milky colored when I drained it. There was water in the large u joint bellow so I am replacing the gimbal bearing as well... Anyways today I pressure tested the lower unit while it was off the boat... I sent about 15-20psi of pressure and immediately noticed bubbles here... I assume I have to tackled this by removing the top plate on the out drive but I was looking for someone who knows what tools I may need to replace that gasket/seal and what the part number for the seal is called so I can order it. Is this a common place for leak? Air was coming out around the shaft.

 
Rick Stephens

Rick Stephens

Admiral
Joined
Aug 13, 2013
Messages
6,118
I think you want to limit your pressure testing to about 12 PSI. 20 is too high.

Unfortunately, it takes some special tools and a complete disassembly of the upper to replace the output shaft seal. The seal itself is the first piece to go into the case.
 
Fun Times

Fun Times

Moderator
Staff member
Joined
May 16, 2009
Messages
9,238
While providing your stern drive serial number would be best to confirm your stern drive model, being a 1997 year model, here should be your parts catalog to the stern drive for you, http://www.mercruiserparts.com/alpha-one-gen-ii-1996-1997-0f680000

Search online for a full version of "Mercruiser service manual number 14" as that will be the manual you'll need to follow for the correct steps needed to repair other parts of the stern drive if ever needed. Plus it will help give you the info needed about what special tools you may need to do other jobs properly as well.
http://www.boatfix.com/merc/Servmanl/14/14a3.pdf
See item number 5, http://www.mercruiserparts.com/bam/subassembly/30860/1942/100
 
Bt Doctur

Bt Doctur

Supreme Mariner
Joined
Aug 29, 2004
Messages
19,446
There are 2 seals in that area and they are replaced from inside the unit.
UntitledSI1_zpsszhxqv9l.jpg
 
Last edited:
J

jamespjackson95

Seaman Apprentice
Joined
Jan 21, 2012
Messages
30
Okay guys I just finished replacing all of my bellows and gimbal bearing. The u joint bellow had a large cut it it which rusted the gimbal bearing. So I replaced it as well. I decided to pressure test the drive again (a different method) and pumped 10psi of pressure and noticed a big leak around the ujoint oil seal carrier. So I took off the u joint assembly and here's what it looks like...



I have an upper seal kit and am trying to figure out what I need to order to put this thing together properly. I need an in-Lb dial torque wrench to set the pre-load... Any recommendations on where to get one of those this small? Also when reading up on this (outside of the service manual) many people mention a speedi sleeve... How do these work and based on the pics do you recommend me getting one?
 
Bondo

Bondo

Moderator
Staff member
Joined
Apr 17, 2002
Messages
71,291
Do you think I need a speedi sleeve or am I good to go as it is?
Click to expand...

Ayuh,...... Ya need a SKF 99225,...... 2.249" - 2.55",.....
 
J

jamespjackson95

Seaman Apprentice
Joined
Jan 21, 2012
Messages
30
Picked this up today from CL... Paid $60 and got it and a whole 5 gal bucket full of specialty tools. Ordered the speedi sleeve today and should be here Friday or Monday... Thank you Bondo for the part number.
 
Last edited:
You must log in or register to reply here.
Top