Alpha one gen 2 oil leak after impeller replacement

[cnadler3]

I watched videos and did thorough research prior to taking on the task of replacing the impeller on a 96 alpha one gen 2. One thing I noticed when I separated the lower from the upper is that the face seal for the water pump housing was not on the drive shaft or at the base of the water pump. I looked up in the upper housing and could see a seal that was shot. I pulled the broken seal, but am confused as to where the face seal went as I can tell by the lines on the top of the water pump housing that it should stay seated at the base of the water pump..

It looks like there are two seals in the bottom of the upper housing where the drive shaft connects. There are two lines at the end of the drive shaft just before the splines that I am assuming are from the two seals at the top of the upper housing. I'm been looking at diagrams and cannot find one that shows these two seals...

We used one of the old seals from the water tube, but it doesn't fit right and have oil leaking from the weep holes after reassemblying. I can post pictures if anyone needs clarification as to what seals I'm referring to. Any help would be much appreciated!


Thanks,

Chris

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Attached is a picture of where the two seals would go that are in question. This picture isn't from my drive, but from a youtube video showing how to replace the impeller. Does anyone know the part # for the two seals that go in this location?

 

[dingdongs]

Re: Alpha one gen 2 oil leak after impeller replacement

how about no 5
Google Image Result for http://www.iboatsimages.com/mall/image/view/2/7/645_2.jpg and here
Google Image Result for http://www.mercstuff.com/images/sealkit2.jpg

 

[Don S]

Re: Alpha one gen 2 oil leak after impeller replacement

You will need the complete seal kit for the upper. You basically have to disassemble the upper to replace those two seals.
Seal kit PN 26-88397A1

 

[Bondo]

Re: Alpha one gen 2 oil leak after impeller replacement

One thing I noticed when I separated the lower from the upper is that the face seal for the water pump housing was not on the drive shaft or at the base of the water pump.

Ayuh,... Welcome Aboard,... Chances are, it's been run Dry since that seal was put there,...

It got burnt up, 'n blew out the exhaust path would be my guess...

If so,... Check yer shutters,... Their probably burnt too....

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Yes, I also found that diagram and thought it is seal #5. Don, why does the upper housing need to be taken apart to replace those two seals? I can get to them from the bottom of the upper housing...

Thank you,

Chris

 

[Don S]

Re: Alpha one gen 2 oil leak after impeller replacement

I can get to them from the bottom of the upper housing...

No you can't.

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Bond-o,

Just trying to understand your logic. I know you shouldn't run dry, but how would this cause the face seal to blow off? Correct me if I'm wrong, but the purpose of the face seal is to prevent water from entering the area of the drive shaft. How would the impeller spinning without water cause the seal on top of the housing to blow off?

Thank you,

Chris

 

[Bondo]

Re: Alpha one gen 2 oil leak after impeller replacement

Bond-o,

Just trying to understand your logic. I know you shouldn't run dry, but how would this cause the face seal to blow off? Correct me if I'm wrong, but the purpose of the face seal is to prevent water from entering the area of the drive shaft. How would the impeller spinning without water cause the seal on top of the housing to blow off?

Thank you,

Chris

Ayuh,.... Because there's Hot exhaust gases, 'n flames pourin' down on it when run Dry....

Everything in or near the exhaust path is raw Flames, from the tip point of the risers, on Out....

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Don,

Thank you for the information and I really appreciate your prompt response. What degree of difficulty would you say it is to disassemble the upper housing? Happen to have any links with directions?

Thanks again,

Chris

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Bond-o,

Don't quite understand your logic, but I'll take your word as its obvious I don't quite understand the internal workings of the outdrive. Where are these shutters you speak of and how do I check them?

Thank you,

Chris

 

[Bondo]

Re: Alpha one gen 2 oil leak after impeller replacement

Don,

Thank you for the information and I really appreciate your prompt response. What degree of difficulty would you say it is to disassemble the upper housing? Happen to have any links with directions?

Thanks again,

Chris

Ayuh,... Start Here...

It just takes Tools, 'n talent,.... 'n the Tools can get expensive...

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Yeah.... that doesn't really help me. I guess I will be dropping $$$ at the marine shop to get this fixed.

Thanks for your help,

Chris

 

[Don S]

Re: Alpha one gen 2 oil leak after impeller replacement

Section 3A of the service manual covers the upper.

#14 Alpha I Gen II Drives 91-.pdf - 4shared.com - document sharing - download - Don S

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Thank you Don. How many hours is reasonable for a shop to charge to replace the seals in the upper?

 

[Don S]

Re: Alpha one gen 2 oil leak after impeller replacement

Why do you want to replace the seals? because they are leaking, or because you think they are leaking?

Did you drain the gear lube and pressure test the drive to find the actual leak?

Are you planning on taking the upper to the shop and tell them to put new seals in it, or take the drive to them and tell them it's leaking somewhere.

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Well, let me start from the beginning. I took the boat to the lake 3 weekends ago and it ran fine for three days. No problems at all and did not dry run it. It sat in the garage since and took it to my friends house yesterday to perform the maintenance. We put the muffs on and ran the motor for 5 minutes to heat up the motor prior to changing the oil. However, I just read that apparently running the muffs with the outdrive in the trailer position is not recommended? We definitely did not lower the outdrive when running the muffs and kept it in trailered position. Any chance this could have caused the issue? The gear oil did not leak from the weep hole while running it on muffs.

We then drained the gear oil and took all of the bolts out. Separated the lower from upper and discovered that the face seal was missing. I looked up in the bottom of the upper housing and saw the bottom seal ripped. Not knowing any better, we put one of the seals from the water tube in place of the missing seal from the bottom of the upper housing.
We put the outdrive back together and started pumping gear oil in the outdrive, using the vent hole. Everything I read said to pump from the bottom until it comes out of the top, but my friend had already started putting it in from the top. The gear oil then started leaking from the weep hole.

So to answer your question, yes the outdrive leaks oil from the weep hole and am not sure the best plan of action. I have not pressure tested the outdrive as I do not have the equipment to do so. Don, I know you're probably shaking your head thinking, these knuckleheads.... but have please have patience with the newbies.

Also, I just think it is weird that the gear oil was not leaking prior to separating the outdrive and am not sure how the seal became damaged.... Do you think I'm better off taking the upper off and taking it in or just reassemblying the outdrive and dropping it off and telling them the outdrive leaks oil after replacing the impeller?

 

[Don S]

Re: Alpha one gen 2 oil leak after impeller replacement

We definitely did not lower the outdrive when running the muffs and kept it in trailered position. Any chance this could have caused the issue? The gear oil did not leak from the weep hole while running it on muffs.

No, it will not cause the drive to leak, but it could damage the ujoints, bellows, or even the transom shield.
Drives are never up when the boat is in the water, why would people think it ok out of the water? Every owners manual says put the drive down.

You need to pull the complete outdrive off the boat, drain the gear lube, then do a pressure test of the drive. There is all kinds of information in the stickies on doing this.

What DIYers need to do is stop listening to friends and using others short cuts, and follow the service manual. The oem manual, not the aftermarket junk. Then they learn the CORRECT way. After you know the proper way to do the job, you can take all the short cuts you want.

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Yeah... I think with all things considered, the last thing I need to be doing is pulling the outdrive. I think I already know the source of the leak since I can visibily see the seal missing from the bottom of the upper housing. Back to my orignial question, what would you say is a reasonable charge (in hours) to replace the seals in the upper housing? I suppose I'll just put everything back together and drop it off giving the shop the info I have....

Thanks again Don.

 

[cnadler3]

Re: Alpha one gen 2 oil leak after impeller replacement

Attached is a pic of the seal that busted. Look like the #5 oil seal that goes in the bottom of the upper housing? I figure this would definitely cause gear oil to leake out of the weep hole.