Broken gear oil connector

[Merccoper]

So, I did exactly what Chris warned me to be careful not to do, I broke the needle on the gear oil connector (through the transom) while attempting to do a bellows and bearing replacement.

I understand it is a clip type connection in the engine compartment that holds the hose to the connector and once disconnected, pull the connector out the other side. It sure is cramped in the engine compartment. Anyone have suggestions on how to reach the hose clip? Or (fingers crossed) an alternate fix method?

This is on an Alpha one Gen 2.

 

[Bondo]

Anyone have suggestions on how to reach the hose clip?

Ayuh,..... Remove as much "Boat" is necessary to get the job done,......

 

[Merccoper]

Ayuh,..... Remove as much "Boat" is necessary to get the job done,......

Lol. Maybe I'll start with engine rather than the boat

 

[Bt Doctur]

didnt like my idea of cutting it in the middle? the hose is not crimped inside the boat, It has a push in to disconnect connector on it.Then remove the E clip and push it out the back of the boat. For access you will have to remove the inner panels and the steering cylinder and water inlet hose at the ransom

 

[muc]

Agree that you have to remove whatever is in your way.

Not that I’ve ever broken one, but sometimes I like to replace them for fun.

A couple of tips.
Use a 1/2” drill from the outside and drill the plastic, then you can push the stem through to the inside of the boat. That way you don’t have to get the C clip off in the boat.
Spray a little soapy water on the new fitting so it slides in easier.
Have a helper to push in from the back of the boat while you’re trying to get the clip back on.
Put some grease on the clip to “glue” it to the gimbal housing right above the fitting and use a long screwdriver you have bent to push it onto the fitting.
Some people will tie some fishing line to the clip in case they drop it. I think it gets in the way, but some techs like to. I just make sure to have extra clips.

 

[Merccoper]

didnt like my idea of cutting it in the middle? the hose is not crimped inside the boat, It has a push in to disconnect connector on it.Then remove the E clip and push it out the back of the boat. For access you will have to remove the inner panels and the steering cylinder and water inlet hose at the ransom

Opps, Sorry, I thought it was Chris who suggested to cut it. I was going to take your advice. I was finally able to go back to the project, was going to start by cutting the hose but I guess by that time I had already weakened the needle. No sooner did I start to cut it and it came off in my hand. Kicking myself.

I can just reach the e clip but can't get enough leverage to pull it.

Damn, my work just doubled. I'm going one step forward and 2 back. At this rate I'll soon be all the way up at the bow working no the navigation light!

Well, perseverance will hopefully get me there!

 

[Merccoper]

Agree that you have to remove whatever is in your way.

Not that I’ve ever broken one, but sometimes I like to replace them for fun.

A couple of tips.
Use a 1/2” drill from the outside and drill the plastic, then you can push the stem through to the inside of the boat. That way you don’t have to get the C clip off in the boat.
Spray a little soapy water on the new fitting so it slides in easier.
Have a helper to push in from the back of the boat while you’re trying to get the clip back on.
Put some grease on the clip to “glue” it to the gimbal housing right above the fitting and use a long screwdriver you have bent to push it onto the fitting.
Some people will tie some fishing line to the clip in case they drop it. I think it gets in the way, but some techs like to. I just make sure to have extra clips.

Hey, I like that idea. Thanks!
My only worry (other than being a straight driller) is that if I drill it from the outside and I'm not able to push it through, I'll have nothing to pull it out if this approach doesn't work.

 

[muc]

Hey, I like that idea. Thanks!
My only worry (other than being a straight driller) is that if I drill it from the outside and I'm not able to push it through, I'll have nothing to pull it out if this approach doesn't work.

I’ve done a lot of them this way and never had a problem. The fitting has a dimple where you drill and as you’ve already found out, that plastic is pretty fragile. If your worried about hitting the gimbal housing, use the new fitting and wrap some tape around the drill bit to mark the depth.

 

[Merccoper]

WOW, WOW. That is a PITA!!!

AMTECH, your idea to drill the end off worked great! THANK YOU.

I mentioned earlier about 1 step forwards and two back. I actually went 3 back.

My third step back was that I broke the L clip on the inside. It must have deteriorated over the last 19 years. I hardly touched it and it snapped. So, back to the marina I went.

Getting the e clip back on was tough. I could only reach the area with my finger tips. I actually tried crazy gluing the clip to my finger tip so I could reach back and attempt to set it in place. Then I tried tying fishing line to it and dangling it down while directing to the right place. That didn't work either. What ultimately worked was cutting a small slit on the end of a piece of dowel. I was able to wedge the clip in the slit then slowly line it up and set it in place. Then used a long screwdriver to push it in.

I'm only at minus one step now. I've got the L clip resting on the connector. I'm not able to press the clip and push it on at the same time. Do you know if I can just push it on. Or do I need to press the clip and push at the same time. (I know, I should have tried it before!)

 

[Merccoper]

Here is my e clip setting "tool"

 

[muc]

Here is my e clip setting "tool"

Never thought of that. Good idea, I’ll have to remember that trick.

I think you can just push the connector on but I’m not sure.

 

[JASinIL2006]

Here is my e clip setting "tool"

Nice! You're turning into a regular MacGuyver!