Alignment tool 91-805475A1 won't go into engine coupler.

[cecho]

This tool has the new dimensions, but it won't go into the coupler. The gimbal bearing is not currently in. I was test fitting the tool before moving to that step (thankfully). I've read the coupler splines may have old grease or burs that can prevent the tool from entering. Is there a good way to clean the out? Can I spray engine degreaser in there? I'm worried some of it might remain and cause a problem when I put new grease in there.

 

[natemoore]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

This tool has the new dimensions, but it won't go into the coupler. The gimbal bearing is not currently in. I was test fitting the tool before moving to that step (thankfully). I've read the coupler splines may have old grease or burs that can prevent the tool from entering. Is there a good way to clean the out? Can I spray engine degreaser in there? I'm worried some of it might remain and cause a problem when I put new grease in there.

I'd say, assuming the tool does fit, clean it out well with a wire brush and degreaser, then clean all that mess out with brake fluid cleaner, which will completely evaporate very quickly.

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

Thanks, that seemed to do the trick. The tool seems to go all the way in now. There doesn't seem to be any play between the tool and the coupler, but I am able to move the coupler and tool side to side and up and down like it's connected with very strong rubber. I assume I'm either feeling the motor mounts moving or the coupler is made of rubber. How much play is normal? With how easy it seems for a bearing to go out due to a misaligned engine, I was expecting a much tighter fit.

 

[dubs283]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I assume I'm feeling the motor mounts moving.

the flex you feel is the rubber hub portion of the coupler itself, it is there to absorb the shock of the shifting that the driveshaft exerts, it serves the same purpose as a flex plate on inboard engines

there is no spec for normal play as merc does not require one to check it, however the manual states you should be able to slide the tool in and out with ease (two fingers) with the gimbal bearing in place

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

Thanks, Once I get the gimbal bearing in I don't think it'll be a problem to slide in an out. After doing it a couple times with a wee bit o' force the tool is going in and out with ease. There's was a lot of old grease in there.

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I can already tell I'm going to have to adjust the front of the motor down a little bit. Should I go ahead and at least get it close before installing the gimbal bearing?

 

[Bondo]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I can already tell I'm going to have to adjust the front of the motor down a little bit. Should I go ahead and at least get it close before installing the gimbal bearing?

Nope,... Follow the sequence in the manual, start to finish....

Ya might spray the adjustin' jamnuts with penetratin' oil though,...

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

Nope,... Follow the sequence in the manual, start to finish....

Ya might spray the adjustin' jamnuts with penetratin' oil though,...

Will do! Thanks!

 

[Don S]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

http://forums.iboats.com/mercruiser...utdrives/engine-alignment-how-tos-443992.html

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I'm aligning the engine right now. I've had to lower the front about an inch, but I'm close now.Any tips for fine tuning the height? It's very very difficult to tell which tracks have more grease at this points, but I still can't insert the tool with just two or three fingers. I also noticed a bit of metal come off the end of the tool with some old grease. I'm assuming this is from burs in the splines. If I got some of those burs inside the splines will I have any trouble getting the outdrive back on?

Edit:
It's going in and out with ease now after I moved the gimbal bearing around a bit to "free it up/get grease in the gimbal" I guess the gimbal wasn't moving to the proper position after "banging" it into place per procedure.

Oddity: The shaft goes in and out with ease, but it looks like there's less grease on the bottom splines everytime.

 

[fat fanny]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

Might want to tweek the front jams to lower the front of the block a bit! And try it again!

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I test fit the top end. It when all the way in with ease. What happens if the alignment isn't perfect?

 

[achris]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

What happens if the alignment isn't perfect?

Goodnight coupler....

 

[fat fanny]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

Are you making sure your holding the bar steady as you pull it out? If it were me I would go the extra mile and fine tune it especially after all the work you have done!

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I've pulled it out quickly and slowly. The bottom splines do seem to have a bit less grease. I'll keep adjusting it after I get a smaller wrench.

Does the alignment go out on this slowly over time? Why do the couplers not give out then?

A little more adjustment with the ultra fat adjustable wrench and now I can insert and turn the tool with just my pinky... Still more grease on the bottom... Heading to the store to pickup an actual 1 1/8th inch wrench that's not the size of my fore arm.


I'm pretty sure I'll be able to get it adjusted perfectly, but what happens if I hit the bottom of the motor mounts?

 

[cecho]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

I swear, a butterfly flew by when I was getting ready to insert the tool all the way for a final check and the air current the wings created pushed the tool in all the way...

Well, maybe it didn't happen quite like that, but I can push it in with about as much force as it takes to move this half full glass of water across the desk. The suction the grease creates is enough to move the tool now. A slight upward pull gives me a bit less grease on the top. Letting gravity pull the end down gives me a bit less grease on the bottom. A slight pull to the left gives me a bit less grease to the left and a slight pull right gives me a bit less grease to the right. A few times I've gotten perfect grease all around but the minute play in the bearing makes it very difficult to do. I'm going to assume this is adequate alignment. I don't have much farther I can go on the mounts... maybe 3 full turns from the bottom now.

 

[dubs283]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

i think your fine, man

trust me, when you check over 200 alignments in a season you learn not to get too picky about it

if you are going to follow the manual, dont forget to rotate the engine 120 degrees and check the alignment again - if you do that you just end up going back and forth till your hair falls out

your best friend now is routine miantenance, checking the alignment and greasing the coupler annually during winterize - as long as you can fully insert the tool without major force, keep the coupler greased and you will be fine

 

[Speakrdude]

Re: Alignment tool 91-805475A1 won't go into engine coupler.

By-the-way, I don't think its a 1-1/8". It's a 33mm. Someone correct me if I'm wrong.