Emergency Alpha 1 tutorial!

WizeOne

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Mar 23, 2008
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'tis the weekend before the annual Boy Scout crab trip. Scoutmaster, not having had his boat out all year, takes it out on the Columbia River for a test run. A short distance before returning to the launch ramp, he hits a rock. He raised the outdrive and all seems ok. He proceeds to the launch ramp, loads the boat on his trailer and to his surprise, there is a two inch hole knocked out of the front of the propshaft bullet.

This morning we proceeded to pull it apart until we ran out of time due to a prior commitment he had. We got the waterpump and shift rod out. We got the big castle nut around the propshaft out and that is where we left it. We did notice that the vertical driveshaft and bearing wanted to come up but it was being stopped by something.

It is also apparent that the big cast webbed propshaft support needs to come out. Does that need to come out, along with the propshaft, before the vertical drive shaft comes out?

Does the webbed propshaft support just pop out? The whole thing is very clean with no noticable corrosion. I'd hate to see what it would be like to disassemble a high hour saltwater, or moored outdrive. This one is a relatively low hour freshwater 1986 140 hp Alpha 1 drive.

We need to hurry up and find a replacement lower housing so we can get this back together for next weekends trip.
 

45Auto

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May 31, 2002
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Re: Emergency Alpha 1 tutorial!

I'm sure somebody else will correct me very quickly if I'm wrong, but you may want to start looking for a complete used replacement lower or complete outdrive. I believe the list of special tools required to re-assemble a lower correctly is about a page long, and would cost you more than a brand new lower. If you put it together without the right equipment (gear lash, bearing play, etc) then don't expect it to last very long.

Factory Manual #6 under the Adults Only sticky at the top of this forum has the complete rebuild procedure in it.
 

Bondo

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Apr 17, 2002
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Re: Emergency Alpha 1 tutorial!

We need to hurry up and find a replacement lower housing so we can get this back together for next weekends trip.

Ayuh,... Have an SEI lower shipped overnight.... Seriously...
$600. is Cheaper than you can fix 1...

Have you read thru the manual,... Lots of tolerances,+ stuff to watch puttin' it in a new/ used housing...
We did notice that the vertical driveshaft and bearing wanted to come up but it was being stopped by something.

You'll see the bolt holding the pinion gear to the vertical shaft,...
After you Pull the propshaft,+ it's carrier,... It should slide out...It's keyed, not pressed...
 

joncrisler

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Sep 25, 2009
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Re: Emergency Alpha 1 tutorial!

The proper fix is to remove the lower gearcase since it has an impact hole in it, and either replace the entire assembly, or obtain a new gearcase housing and replace the parts back into the new housing. There are a lot of special tools and knowledge required- one of the above posters mentioned a $600 complete lower gearcase- this sounds like a really good deal, and you can replace it yourself.

The webbed thingy you describe is probably the bearing carrier, which i believe screws in and out using a special tool.

I hope you have a quality repair manual- its a must-have in this situation.
 

WizeOne

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Mar 23, 2008
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2,097
Re: Emergency Alpha 1 tutorial!

You'll see the bolt holding the pinion gear to the vertical shaft,...
...

We did and out it came. How in heavens name are you supposed to re-torque that nut?
 

WizeOne

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Mar 23, 2008
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Re: Emergency Alpha 1 tutorial!

Thanks Don, every little time saver helps.
 
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