Alpha One Gen 1 Bellhousing Shift Shaft Bushing / Seal Replacement or Upgrade Kit?

[Zoomer]

I have a 1987 Alpha one Gen 1 that I am replacing shift cable, bellows and trim sensors. While I'm in there I want to replace anything that might cause a leak or other problems. I notice a little play in the upper bellhousing shift shaft (only front to back) and am concerned about the seal there. I went to my marine dealer and he didn't have the bushings in stock, so he was going to have to order them. When he looked up the parts, there was no mention of superseded parts or an upgrade kit. I've seen mention online of an upgrade kit that has 2 bigger seals pressed into a larger version of the bushing and it is supposedly better. I think the part number mentioned is 23-805041A2.

Should I replace the current parts with exact replacements or should I find this upgrade kit? If there is an upgrade kit, will it fit my 1987? Do I have the correct part number? Are aftermarket kits available and OK for this application if I can't get the OEM easily?

 

[stonyloam]

Find the upgrade kit! Here http://www.mercruiserparts.com/bam/s.../30870/2203/60 , http://www.mercruiserparts.com/805041a2-bushing-kit. There are less expensive aftermarket ones out there, but I would stick with the OEM.

 

[Speak]

i just installed Sierra 18-2622 with good success. I have not heard anything negative about this set up. Check out my conversion thread in my signature for pictures and comments.

 

[Zoomer]

Found a local dealer with the Mercruiser upgrade kit in stock. Ouch, $52.80 plus tax. I guess I could have gotten the Sierra part online a lot cheaper, but I want to work on assembly tonight so I pay the price.....

 

[Zoomer]

I took the new parts and tried the the shift shaft through them. :-( they don't seem very tight at all. The new bottom bushing appears to have more slop than my original, and the top one isn't very tight either. I tried it all along the shift shaft to check if it was just a worn section on my shaft, but it's the same along the length of the shaft.

Is this the correct part number (23-805041A2) for the upgrade kit?

Am I supposed to have a different shift shaft also?

Is there supposed to be some movement in the bushing (quit a lot lower, a little upper)?


Thanks everyone for the help!

 

[Zoomer]

I used my digital caliper to measure things the best I could (I know, not the best for measuring inside diameter) and this is what I ended up with:


Shaft - Pretty consistent all over at about 0.370"
Old Top Bushing - about 0.375" in largest location, a little less in other rotational positions (about 0.372").
Old Bottom Bushing - about 0.383"
New Top Bushing - about 0.375"
New Bottom Bushing - about 0.394"

It just feels looser to me than it should be. I expected it to tighten up some with the new bushings. Won't it damage the seals earlier with the play between the shaft and the bushing?


Maybe I should have just bought a new seal and called it a day....

 

[achris]

The bottom bushing needs to be 'loose' due to the way it 'connects' to the imtermidiate shift shaft... The upper shift shaft has very little dymanic movement, so bit of clearance in that one is also nothing to be worried about. I have installed many of the uprade kits, and they all work well.

Chris.....

 

[stonyloam]

I did my 87 years ago, but as I recall the lower bushing is not that tight. The important thing is that the seals make good contact with the shaft to keep the water out of the bellhousing.

 

[Zoomer]

OK, I guess I'll go with it. I know the manual doesn't say to, but should a person put a dab of grease on the seals during shaft installation?


What is lubricant 101 that the manual says to put on the bellhousing bushing bores during bushing install? Will my Quicksilver High Performance Extreme grease be appropriate?


Thanks for all your help, I appreciate it!

 

[stonyloam]

I think 101 has been replaced by 2-4-C grease. It is a waterproof grease with Teflon, and is used on places that contact water, prop shaft, gimbal ring pins and pivot shafts, should not be used for the gimbal bearing, coupler shaft or u-joints, use Quicksilver extreme for those. Back to your question, I think they want you to use 2-4-C, but extreme should be OK. A little on the shaft and seals should be OK.

 

[achris]

101 (no longer available) is an extremely waterproof grease. I use a product called Aqua-lube or Aqua-shield....

Chris......