Exhaust Bellows Are a Pain to Replace

[ShaneCarroll]

So, I'm about 90% done with the work on my Gen II. I replaced gimbal bearing, u-joints, and working on my last bellow now. The exhaust bellow. Once I can get this on, it's time to put outdrive back on and hopefully take the boat out for the first time in 5 or 6 weeks or so.

Now, I attached the transom side first, and I am now in the process of trying to attach the outdrive side. I do not have the bellows expander tool, but I am really considering getting it. Before I buy this tool, does anyone have any suggestions on something to get it on smoother?

I guess being 6'3" with big hands doesn't help, I can't get my fat hands back there to try to do it. I tried using some tongs for the grill today, but to no avail. What do I do now?

 

[Don S]

Re: Exhaust Bellows Are a Pain to Replace

I do not have the bellows expander tool,

I see great amounts of frustration, bloodshed, and cursing in the near future. Unless you get the tool.
One other note. Make sure the bellows and the bellhousing is perfectly clean of any grease or oil.
Have a can of Mercury power tuner ready along with the tool. Shape the new clamp in the rough shape of where it's going. Put it on the bellows spray some PTune on the bellow and the bellhousing.
Pull the bellows on with the tool and secure the clamp.
The Merc service manual is your friend for clamp position, believe what it says.
Get the clamp on and do not pull on the bellows let it set there for a bit. Walk around, have a cool drink. and let the power tuner evaporate. Then the bellows will stay on.

DO NOT USE BELLOWS ADHESIVE ON THIS BELLOWS (on the bellhousing side)

 

[Anchor Management 1]

Re: Exhaust Bellows Are a Pain to Replace

I would buy the newer style exhaust bellows that is open on the drive side and it is very easy to install.And it is cheaper than buying the tool.

 

[ShaneCarroll]

Re: Exhaust Bellows Are a Pain to Replace

Thanks again Don S, however, the frustration, bloodshed, and cursing have already ensued (along with a few flying tools). Ok, so is this Mercury Power Tuner something I can pick up at West Marine or Boater's World (if still open)?

I would buy the newer bellows you speak of, but then I would have to take everything apart again to attach it to the transom side. I'll fork over a few extra bucks for the tool.

 

[Don S]

Re: Exhaust Bellows Are a Pain to Replace

ANY Merc outboard dealer has the power tune. Haven't been to a WM or BW in years.

 

[ken_23434]

Re: Exhaust Bellows Are a Pain to Replace

Don,

Do you recommend using the Bellows Adhesive for both ends of the U-Joint Bellows and for the Shift Cable Bellows?

And, why do you recommend to NOT use the bellows adhesive to the one side of the Exhaust Bellows?

 

[hoot]

Re: Exhaust Bellows Are a Pain to Replace

what if you now remove the exhaust bellows from the transom side, turn it around, reattach it to the transom side, and does it hold its shape to better fit over the outdrive side?

 

[boatguya1]

Re: Exhaust Bellows Are a Pain to Replace

Thanks again Don S, however, the frustration, bloodshed, and cursing have already ensued (along with a few flying tools). Ok, so is this Mercury Power Tuner something I can pick up at West Marine or Boater's World (if still open)?

I would buy the newer bellows you speak of, but then I would have to take everything apart again to attach it to the transom side. I'll fork over a few extra bucks for the tool.

If you put the clamp in the correct location all you have to do is stick a screw driver through the hole that's there to access the clamp, loosen the clamp, remove long exhaust bellows, insert slip on bellows and tighten clamp. No need to dis-assemble anything.

James

 

[stonyloam]

Re: Exhaust Bellows Are a Pain to Replace

I did not have the tool either, so this is what I did: Searched through a bunch of threads here to find out what worked for others and picked out what I thought were the best ideas. shaped and positioned the clamp. removed the shift shaft (to give me more room). Turned the drive all the way to one side (to make it easier to get one side of the bellows on). used a long (8", 3/8") carriage bolt to pull the bellows on from the inside. The head of the bolt allowed me to stretch and pull the bellows onto the bellhousing. The round head gave me the 90 degree angle that I needed and did not damage the bellows. Once it was on, straightened out the drive and worked it into final position and tightened er down. Worked pretty well for me. Good luck!

 

[Commissionpoint]

Re: Exhaust Bellows Are a Pain to Replace

Yes, yes, the dreaded exhaust bellows.

Another thing to consider when doing this most unpleasent job is the ambient temperature you are trying to perform the work in. I've found that they go on much better when its scorching hot outside then they do when its 45 degrees in the spring or fall. Try warming it up a bit in your work space if you possibly can.

 

[ShaneCarroll]

Re: Exhaust Bellows Are a Pain to Replace

Well, as far as the climate goes, I am in Tampa. So, yesterday, the temp was 90+ and I even tried putting the bellows in boiling water. It would not go on still. All I did was burn my hand, drop the bell housing and in the process smashing my fingers.