AQ275 Outdrive in ignorance removed Gear housing cover

[ThePirate12]

Two years ago when I purchased my first boat I ignorantly removed my Gear Housing Cover on a Volvo Penta AQ275 Outdrive and immediately replaced it. At the end of the season I had slight milky gear fluid so I ignored it and hoped for the best. Midway through this season I checked the fluid and it was clear. Now at the end of the season it is extremely milky. Obviously I have a seal leaking. Could it be the Gear Housing Cover? I know I need to pressure check it but what I'm actually asking is there any specs on the torque of the screws and what else should I check before I try to reseal the cover. Thank you in advance for any support.

 

[PiratePast40]

Torque specs for the main bolts on the upper gearbox are on page 123 of the manual, 28 ft. lb. ft. As you're already mentioned, you really need to do a pressure test to find out which seals are leaking. Pressure test instructions are on page 124. The rear shift shoe seal and forward washer seal are known problem areas, but it could be anything. Probably best to do the pressure test first and then order the parts you need. There is a pressure tester on ebay, or you can make your own. When mine had milky oil, had to change it a couple of times to get it to come out clean. When you order seals, might want to order extra o-rings and washers for the fill connection, dipstick, and drain. You'll probably need them in the future anyway.

Now for some bad news. If the front seal is bad, and you have water in the bellows, you need to take a good look at the u-joints. The PDS bearings will be suspect as well.