Alpha One Gen 1- Reassembly bellows questions...

[Fiat4Fun]

SO, finally got my trim sensors replaced, now it's time to reassemble the rest of the drive.

I have watched a few videos, looked over the factory manual, and I think I am ready! I got all Mercruiser original parts, adhesive, and tools on hand, but want to make sure I have the sequence down. Any advice would be appreciated.

Here is a water down version of sequence of the procedure.

1- Attach water line to gimbal housing, Attach u-joint bellows to gimbal housing with clamp pointing down opposite of shift cable bellow

2- Attach Exhaust bellows to bellhousing

3- Attach lower shift cable housing to bellhousing, slide shift cable bellows on outer housing

4- Feed outer shift cable into boat, secure. Attach shift cable bellows after mating bellhousing, connect water hose, attach side pins

5- Attach u-joint bellows to bellhousing using bellows tool, tighten clamp

6- Attach exhaust bellow to gimbal housing using bellows tool, tighten clamp aligned with acmes hole.

7- Assemble lower shift cable with inner housing and adjust length, grease cable to drive connector.

8- Reconnect trim sensors

9- Replace drive with new gasket and water o ring, Grease drive shaft where it goes into bearing and motor, fill with oil

One quick question that I have with the kit that I got, it came with two hoses for the water line. One is molded and the other is just a straight piece. The one that came off looked like a straight piece, but the new molded hose looks like it would fit well coming out of the gimbal housing. Which is the right one to use?

The kit came with additional o rings and parts, I assume they include everything for different drives.
What did I forget????
Any advice is appreciated.
Thanks
Bob

 

[Fiat4Fun]

Just as a side note, all the Quicksilver Mercrusier parts seem to be from the USA ;-)

 

[todhunter]

I just rebuilt my Alpha 1 Gen 1 transom assembly and I used the molded hose. I didn't need the bellows tool to get the u-joint bellows onto the bell housing - it popped in place when I pushed the bell housing onto it.

Make sure all your hose clamps are facing the right way when you put it together. It was still a pain to get to some of them.

I haven't figured out what all the extra o-rings are for yet, but I haven't gotten to putting the drive on yet either.

 

[Fiat4Fun]

Thanks for the feed back, I did use the molded water hose. Seemed easier to attach it to the bell housing first, then push the gimbal side into place. Hose clamp was a pain, but it worked. Now I am ready for the U joint bellows, and I don't see how to tighten the clamp. I checked the factory manual, and it says "3 o'clock" position ( same side as the shift cable), but still don't see how to get that tighten. The exhaust bellow looks a bit easier to get to. Any suggestions on the u joint bellows is appreciated!

 

[dubs283]

attach the exhaust bellows to the gimbal housing first

u joint bellows, water passage hose, shift cable assy and bellows should then be attached to the bellhousing

insert the shift cable through the gimbal housing (with the bellows already slid on the cable) and ensure it is routed properly around the rear engine mount and aft of the steering cable/actuator. then you can attach the water passage hose to the barb fitting at the gimbal housing. attach the u joint bellows to the gimbal housing next, then you can attach the shift bellows to the gimabl housing. install the hinge pins with blue loctite and torque to 100 lb/ft

the exhaust bellows requires a special tool to install it to the bell housing, it is a spanner tool that can be disassembled to fit past the shift shaft in the exhaust passage in the bellhousing

 

[Fiat4Fun]

Thanks for the response.
Looks like I am in trouble, since I attached the u-joint Bellows to the gimbal housing first, and now I am trying to put the bell housing on. I did get the water hose attached and shift cable installed. So, should I pull it all a part and start over, or is there a way to do the u joint bellows to bell housing and still tighten the clamp?
I do have the correct bellows tool, so at least I got that right.....

 

[dubs283]

or is there a way to do the u joint bellows to bell housing and still tighten the clamp?

probably but i can't say for sure, never tried it that way

 

[Fiat4Fun]

Anyone else have a magic tip on how to do the u-joint bellows when its attached to gimbal housing. I don't see a way to tighten the clamp.....
Any advice is appreciated

 

[todhunter]

Sorry, not sure - I also attached it to the bellhousing first.

 

[Fiat4Fun]

Ok,
Looks like the best route forward is to disassemble and reassemble with the u joint bellows attached to the bellhousing. Should I attach the exhaust bellows to the bell housing too?

 

[dubs283]

Should I attach the exhaust bellows to the bell housing too?

eventually, yes but...

see post #5

 

[Fiat4Fun]

Gotcha, I typed my response too fast.....
I do have the right tool too, so now I will wait to it cools down a bit to get on it. A bit warm in the Northwest ;-)
Thanks for the feedback, I appreciate it.