How to assemble top and bottom housings 96 volvo sx cobra

[haigskid]

Hi, i`m working on a 1996 Volvo SX Cobra single prop out drive. I took the top housing off the lower unit and found the 2 O rings - one on the oil screen hole and the other on the drive shaft bearing retainer Damaged.
The larger one was crushed flat and cut. The smaller one was probably ok but I am replacing both. Whoever worked on it before me used what looks like contact cement to seal them. When I put the new O rings in place and install the top housing onto the drive there is no place for the O ring around the retainer nut to fit into other than a large chamfer around the bore in the top housing. When I put the bolts in and torque them to spec there is a big gap between the upper and lower housings.What am I doing wrong? The service manual is not very specific about the procedure. Thanks in advance for your input.

 

[haigskid]

Anyone?

 

[haigskid]

so it says I have to have 3 posts to post photos

 

[haigskid]

I am beginning to think i might have a different year upper and lower? Is that possible? It all bolts up nicely without the o ring. The lower part has a recess for the O ring around the oil passage, but there is no groove for the larger one.
Do I have a mix of OMC and Volvo?
The paint colors dont match so Im sure one or the other has been swapped. I cant seem to include any photo`s for some reason.

 

[Horigan]

You're probably right that the upper and lower are different years. When researching what duo props work on my boat I recall reading that they moved the O ring groove from upper to lower, or vice versa, around '96 or '97.

OMC and Volvo were the same units during the joint venture years, so I suspect the groove change happened right after that, ~'96.

 

[haigskid]

Thanks for the reply. It looks like a groove could be machined into the upper housing and it could work. Ive been searching the internet for info and there`s not a lot out there. Im sure Im not the first person to encounter this issue and I have the capability to machine the groove, Just want to confirm before I do it.

 

[Lou C]

https://www.crowleymarine.com/johnson-evinrude/1125.cfm

Since the OMC and Volvo product were the same from 1994-1998 you can look at OMC's part catalog since it is much easier to navigate than the inscrutable Volvo catalogs which to me are difficult to use to look up parts #s. So go from 1994-->1998 and see if the parts in question changed, that may help answer your question....

 

[haigskid]

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[haigskid]

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