Alignment tool will not fit into coupler

[bart98stang]

Greetings everyone! So I've been trying to get my engine aligned for quite a while now. I had some one come over and find out what's wrong and he found that my motor mounts needed to be replaced. So last weekend I replaced them and I still can't get the engine to align. After ruining my exhaust and u-joint bellows and water inlet hose I took my gimbal housing off, pulled out the gimbal bearing and tried to put the tool inside of the coupler and of course the tool is to big. It will not slide into the coupler. I took a calibrated dial caliper and the measurement was the same as the diagram in the Adults Only section, 1.01".

WTH is going on here? I'm really about to sink this boat into the Chesapeake Bay. My engine and outdrive info is in my signature. Thanks ahead of time.

 

[Don S]

Re: Alignment tool will not fit into coupler

Is it a new coupler? I had a couple of couplers from EDP, EMP, or whatever that company is,. that I couldn't put an alignment bar in. Returned them and went OEM and all was good.
If an old coupler, it may have burrs on the coupler, or even dried up hardened grease that needs to be cleaned off.

 

[bart98stang]

Re: Alignment tool will not fit into coupler

No it's an old coupler, whether it was replaced in the past or not I don't know. I'll figure out a way to remove the burrs and/or hard grease if applicable. Thanks.

 

[garyfink]

Re: Alignment tool will not fit into coupler

I work in a machine shop and I made my alignment tool. I got the measurments from this site, but I came to find out that the small end measurment that fits int o the coupler is wrong. I think it says 1.05 when in actuality it is more like .970. I measured across my outdrive input shaft to find the minor diameter but not trusting that measurement totally I got a piece of scrap round stock and and just took .01 of at a time till it just slid into the coupler. If you want the xact size I can measure mine and get back to you, all the other measurements were good.

 

[ktbarrentine]

Re: Alignment tool will not fit into coupler

I work in a machine shop and I made my alignment tool. I got the measurments from this site, but I came to find out that the small end measurment that fits int o the coupler is wrong. I think it says 1.05 when in actuality it is more like .970. I measured across my outdrive input shaft to find the minor diameter but not trusting that measurement totally I got a piece of scrap round stock and and just took .01 of at a time till it just slid into the coupler. If you want the xact size I can measure mine and get back to you, all the other measurements were good.

Hmmm...did you "just slide into the coupler" through the gimbal bearing? I imagine I could easily machine my alignment tool down (before correctly adjusting my engine mounts) until the alignment tool fit through the gimbal bearing and into the coupler.... But I chose to use the correct diameter (1.01) alignment tool and adjusted my engine mounts until the alignment was correct. Drive and engine run much more happily now. And installing my drive was a breeze compared to how it was before I did the alignment.
So I hope I am just not reading your post correctly.

 

[garyfink]

Re: Alignment tool will not fit into coupler

yes I had already installed the gimbal bearing bottoming it out agains the seat in housing. I followed the drawing fro making an alignment tool but for mine the 1.01 was too big. So grabbed a long piece of of 1in. round stock and turned the end till it just fit in the engine couple (this is done just for sizing purposes) after I established the correct size I turned that size onto the small end of my alignment tool I had alread made to size according to the drawing. I'm thinking that the engine couplings pepending on the brand will vary on the minor diameter and still work. When the splines are toleranced they never mesh point to point each has a small flat at pointed end of the spline. If that makes sense.

cheers
Gary

 

[colinpegrum]

Re: Alignment tool will not fit into coupler

I work in a machine shop and I made my alignment tool. I got the measurments from this site, but I came to find out that the small end measurment that fits int o the coupler is wrong. I think it says 1.05 when in actuality it is more like .970. I measured across my outdrive input shaft to find the minor diameter but not trusting that measurement totally I got a piece of scrap round stock and and just took .01 of at a time till it just slid into the coupler. If you want the xact size I can measure mine and get back to you, all the other measurements were good.

Sir, could you post the small end measurement you discovered? My newly purchased alignment tool is 1.014" and will not fit into the coupling either. From the outdrive input shaft I measured approx 15/16 (certainly closer to the 0.970 you mention above) but wanted the exact dimension so I can have the alignment tooled turned down accurately. Many thanks.

 

[Don S]

Re: Alignment tool will not fit into coupler

Welcome to iboats.
The dimension of 1.01 is correct. Machining it smaller just makes it a large diameter pry bar.

Also, if you have a question, please start a new thread and ask it, don't reply to an old thread. See the forum rules and the announcement at the top of the page.

 

[colinpegrum]

Re: Alignment tool will not fit into coupler

Welcome to iboats.
The dimension of 1.01 is correct. Machining it smaller just makes it a large diameter pry bar.

Also, if you have a question, please start a new thread and ask it, don't reply to an old thread. See the forum rules and the announcement at the top of the page.

Thank you for the welcome, the reply and the advice Don, much appreciated. I will ask in a new thread.
Cheers, Colin

 

[garyfink]

Re: Alignment tool will not fit into coupler

I had the option of taking my motor out to find out exactly what was going on and my finding is that I think on some couples the points of the splines are higher probably because when manufactured this is a forming process rather than a cutting procress so if the diameters are off a few thousandth's when they press the forming hru the opening it makes the ridges a little higher ( same principal as a thread forming tap vs a thread cutting tap) my guess is that the chineses tolerances are not as high as OEM thus the variations in ID diameter. Doesn't effect the operation just a PITA when assembling. So the easy remedy is if you have access to a metal lathe just run the small end down to .97 and be done with it. But off topic I did find out that Mercury had a production problem in some of there outdrive units (mine is a 1985 alpha one) in that the rear motor mounts were too short and you just barely can align the motor without running out of adjustment on the front motor mount (this is why I pulled the motor out of my boat) the fix is to buy the aftermarket motor mounts and double stack the the spacer washers in the casting. There is enough room and the rear motor mount will not stick out of the casting (all this will be clear when you get it apart) then when you align the motor after reinstallation you will have enough room to get tools in there to tighten everything and the motor will have a more natural look when viewing from the side of the boat just a slight aft tilt and the alignment tool will go in and out with ease. You can use your own analigy.

Cheers
Gary

Hope to see some you on the Chesepeake this summer.

 

[Don S]

Re: Alignment tool will not fit into coupler

Ahhh yes, the good ole method of if the alignment bar won't go in the couple, machine the bar so it will. A much easier method than actually getting the engine aligned properly. Of course that method won't make the coupler last any longer, it will actually shorten the couplers life because the engine is out of alignment. :facepalm: :facepalm:


Funny, I have NEVER heard of any production problems that you mention. Had there been a problem, Merc would have had a bulletin on such a thing, and a fix. Probably the correct mounts and hardware.

 

[ktbarrentine]

Re: Alignment tool will not fit into coupler

Often makes you wonder just how the "layman" boat owner "finds out" that Mercury had a production problem..... Sounds like Facebook...if you post it, people will believe it! :facepalm:

 

[Bondo]

Re: Alignment tool will not fit into coupler

But off topic I did find out that Mercury had a production problem in some of there outdrive units (mine is a 1985 alpha one) in that the rear motor mounts were too short and you just barely can align the motor without running out of adjustment on the front motor mount (this is why I pulled the motor out of my boat) the fix is to buy the aftermarket motor mounts and double stack the the spacer washers in the casting. There is enough room and the rear motor mount will not stick out of the casting (all this will be clear when you get it apart) then when you align the motor after reinstallation you will have enough room to get tools in there to tighten everything and the motor will have a more natural look when viewing from the side of the boat just a slight aft tilt and the alignment tool will go in and out with ease. You can use your own analigy.

Nope,.... That ain't a production problem,.... That's just a sign of Failed motor mount bushings....

It happens all the time on 25 year old parts....

 

[Grub54891]

Re: Alignment tool will not fit into coupler

Never had one not fit when aligned correctly! I shure wouldn't shave the tool down to fit.Thats like grinding off your brake pads because you can't get the caliper to push in!
Grub

 

[fairshopperguy27]

Re: Alignment tool will not fit into coupler

This guy is looking for a little help here not harsh criticism & attitude. I am having the exact same problem with aligning my 1988 3.0. I bought my tool off ebay & it just will not go in, I finally pulled the motor out and checked & sure enough too BIG! This tool slides right into my dads 4.3 which is on as stand in my garage. I contaced the seller on ebay & he said hes never heard of that happening. Im at a loss on this & put it on the backburner for another weekend.

Ahhh yes, the good ole method of if the alignment bar won't go in the couple, machine the bar so it will. A much easier method than actually getting the engine aligned properly. Of course that method won't make the coupler last any longer, it will actually shorten the couplers life because the engine is out of alignment. :facepalm: :facepalm:


Funny, I have NEVER heard of any production problems that you mention. Had there been a problem, Merc would have had a bulletin on such a thing, and a fix. Probably the correct mounts and hardware.

 

[achris]

Re: Alignment tool will not fit into coupler

I have a Merc genuine alignment bar. I'm 'out of the office' at the moment, but when I'm back, I'll measure it up and post the size. I am also one who has never had a coupler that the bar will not slide into, and the thought of machining it down.... Never happened! If the bar doesn't go in, something else is wrong, not the bar.

As for harsh criticism and attitude... Anyone botching up an alignment bar to fit this situation deserves to be told....

JMHO....

Chris....