Help! Water Leaking into Boat. Torn Bellows, Rusted U-Joints

[ebne0018]

Hello-

I recently acquired a 1983 Bayliner with an AQ125A and 270 Outdrive. The boat has been taking on water and when I did some looking water is coming into the boat where the engine meets up with the outdrive (see yellow circled area in first photo).

I pulled the U-joint bellows and it has an enormous tear in the top of it.

My main concern is the U-joint. The bellows must have been torn for years as the U-Joint is very rusted. Some of the needle bearings are gone in the crosses and there is a lot of play in the joint.

Some good news is the oil in the intermediate housing was clean and clear so at least I know water isn't getting into the lower unit.

So, here are my questions:

1. Water getting into the boat. Should I be looking at other seals between the motor and outdrive or will the bellows replacement be enough?

2. Is there any hope for this u-joint if I get new crosses? I really don't want to but a whole new U-joint.

3. Besides the Bellows, bellow adhesive, crosses, two o-rings between the intermediate and upper housing, and a seal between the upper gear housing and cover are there any other parts I should replace or think about replacing while this is apart?

4. Do I need special bearing grease or will any bearing grease work?

5. I looks like everywhere there is an o-ring they also used Permetex Red. Should I do the same when I put this back together?


Thanks for all your help

 

[Scott Danforth]

1 - fix the bellows
2 - buy a complete new shaft
3 - new input shaft seal, thrust washer and crush sleeve (usually comes with the u-joint shaft kit) inspect the bearings
4 - standard EP2
5 - follow the manual (factory manual, not a clymer or haynes or seloc)

 

[ebne0018]

Hi Scott-

Thanks for the input. By "u-joint shaft kit" do you mean something like the GLM 87730 kit?


What do you mean by EP2?

Also, I was trying to get the u-joint apart from the housing and the allen screw that goes into the shaft is larger than a 9mm but smaller than a 10mm. Do you know if it is a 9.5 or possibly not metric?

Thanks

 

[Bondo]

the allen screw that goes into the shaft is larger than a 9mm but smaller than a 10mm. Do you know if it is a 9.5 or possibly not metric?

Ayuh,.... Sounds like 3/8",....

 

[muc]

Might want to worry about the Primary Drive Shaft bearings. At the very least, pump a lot of grease thru them.

 

[kenny nunez]

AQ drives use fractional not metric size bolts. The sleeve that the input seal rides on has some thin shims on the inside. If you do not reuse them on the new sleeve you will bind up the bearings. The out put shaft only has 1 bearing and it is probably rusted. Pull the seal and remove the snap ring, clean out the old grease and remove the next snap ring, screw a slide hammer into the rear of the shaft and pull it out. The bearing and seal can be matched up at a bearing supply house.
Hopefully the shaft splines are not rusted into the flex plate. Good luck

 

[ebne0018]

Hi Everyone-

Given the cost of a new U-Joint I decided to first try to rebuild the old one. Surprisingly the old crosses came out and I managed to clean the joint up fairly nicely. I installed new crosses and preserved the shims. new o-rings where I could replace them were installed all around. The bearings in the upper housing all looked clean and frankly the whole upper housing looked to be in great shape. I couldn't even find any wear marks on the gears as shown in the manual.
I didn't pull the main shaft bearing yet. That sounds like a great idea.

I've added some pictures of the carnage. One of the crosses didn't even have any needle bearing left!

 

[kenny nunez]

Looks good, AQ’s are tough and are easy to repair. I am sure that the seal ring needs to be replaced. If you cannot get one it could be repaired with a “SPEEDY SLEEVE” that a bearing supply house may have.

 

[ebne0018]

I'm thinking of doing the intermediate bearing in the next few weeks. Am I looking for a special slide hammer or will any slide hammer kit do?

I'm confused how the slide hammer helps you get the shaft out? Is the hole on the end of the intermediate shaft threaded?

I don't need to pull the engine/bell housing, do I?

 

[kenny nunez]

There should be a threaded hole in the end of the shaft, I do not remember the thread size. Find the right bolt with a large washer that a 3 finger puller over the washer on the end of the slide hammer and bang away.
The engine does not have to come out for this unless the shaft is rusted in the flex plate.

 

[ebne0018]

Excellent. Thanks for the update!