Merc. 5.7/Alpha 1 rebuild

[1kwik72]

I've just acquired a new boat project and I already know it needs a new engine. The previous owner, by his own admission, failed to winterize the engine and it cracked the block. I've rebuilt my fair share of engines but I'm strongly considering a long block 5.7 from Rapido Marine, Daddyos Marine or US Engines for several reasons...mainly the fact that these are all much cheaper than rebuilding one myself, plus they have warranty. Either way I'm doing the R&R so it would also be a shorter down time. Any experience with these three shops?

The outdrive-
The P.O. said that he had lots of work done to the outdrive just before he found out the block was cracked...he might have, but I'm assuming it needs a complete rebuild or replacement. I've never done an outdrive so that will either be a local marine mechanic's job or I'll replace the whole thing with an SE 106. The main rub for me against doing a rebuild is that I've had a hard time finding a GOOD marine mechanic. If I replace the whole drive I can do the whole job myself.

Anyone been down this road before? What did you do? What would you do? I know opinions vary widely but I like em' all.

Thanks!

Oh, here she is-

 

[ziggy]

Re: Merc. 5.7/Alpha 1 rebuild

i got my ol boat after it sat for 15 years in storage. allegedly.
1st, all rubber is suspect. water hose, drive shaft bellows, shift cable and bellows. impeller.

at the very least R&R the impeller so ya know where yer at with that. they are once a year or every 100 hrs for service interval. i replace mine yearly.

as for the drive. i'd drain the lub out of it. paying close attention to the first few drops. feel for metal fragments. looks for water intrusion in the gear lub. if ok. then i'd pressure test it. if it holds. the seals are good. no metal fragments and the metal parts are intact. then go use it...

that's what i did anyways. last year was my 3rd or 4th year with my boat. so far so good.
all rubber was replaced, impeller is replaced yearly. pressure tested at least once a year.

good luck.

oh, my drive is a mc-1 drive, pre alpha. so a shade older than yours, including older technology in the mc-1 than the alpha1. so they can be old and still work....

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

All the rubber, hoses, lines, belts look great, even the bellows. But I'm replacing all of that regardless. I agree, the impeller is a yearly given for me too.

I'll pull the drive and check the oil to see how it looks, I'll also do a pressure check. What is it? 15psi? I haven't looked in the book.

Thanks for the reply!

 

[ziggy]

Re: Merc. 5.7/Alpha 1 rebuild

I'll pull the drive and check the oil to see how it looks, I'll also do a pressure check. What is it? 15psi? I haven't looked in the book.

ya don't need to pull the drive to check the gear lub. just drain it. bottom screw is drain, top screw is vent. fill from bottom screw till it comes out the top vent. (assuming ya don't have a gear lub monitor)
do pressure tests w/o gear lub in drive. i test mine at 14psi + or - a lbs. it has to hold indefinitely. rotate drive shaft and prop shaft while testing.

i don't think the pressure test info is in the book. i think it's a vp thing. it just happens to be a good idea for mercruisers too. there is a vac test too. i test @ 4 or 5hg. i've read it may not be a great idea to vac. test a merc. possible seal damage? i can't remember. so i test it on the low side. still gotta hold vac. too though.. maybe someone else can enlighten ya further..

if it were me, and i didn't have issues. like gear lub in the bellows and no rusty's on the ujoints or gimble brg. myself. i'd leave well enough alone and go boating. 'if' it looks good upon inspection...

get the proper service manuals for your rig if yer gonna be working on it. indispensable tool imho..

edit. ya do need to pull the drive to do pm (ujoint lub, coupler lub, feel gimble brg, alignment check etc.)and inspections though.. so yer still gonna be pulling the drive.

 

[Bondo]

Re: Merc. 5.7/Alpha 1 rebuild

Ayuh,... It sounds like you've got a pretty good handle on it,....
I'd go over what you've got, replace the motor, 'n Run it....

If, 'n when the drive becomes a Problem,...
Replace it Then,....

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

ya don't need to pull the drive to check the gear lub. just drain it. bottom screw is drain, top screw is vent. fill from bottom screw till it comes out the top vent. (assuming ya don't have a gear lub monitor)
do pressure tests w/o gear lub in drive. i test mine at 14psi + or - a lbs. it has to hold indefinitely. rotate drive shaft and prop shaft while testing.

i don't think the pressure test info is in the book. i think it's a vp thing. it just happens to be a good idea for mercruisers too. there is a vac test too. i test @ 4 or 5hg. i've read it may not be a great idea to vac. test a merc. possible seal damage? i can't remember. so i test it on the low side. still gotta hold vac. too though.. maybe someone else can enlighten ya further..

if it were me, and i didn't have issues. like gear lub in the bellows and no rusty's on the ujoints or gimble brg. myself. i'd leave well enough alone and go boating. 'if' it looks good upon inspection...

get the proper service manuals for your rig if yer gonna be working on it. indispensable tool imho..

edit. ya do need to pull the drive to do pm (ujoint lub, coupler lub, feel gimble brg, alignment check etc.)and inspections though.. so yer still gonna be pulling the drive.

I've got a Seloc manual from a previous boat we had. One of my mechanics said they're not as good as the merc manuals. Any ideas there.

Yeah, the drive is coming off for sure, I take my boats to Mexico Beach Fl every June to go King and Snapper fishing so it's gotta be right.

I've got an evacuator and filler pump for the drive lube. I'm going to make a drive stand while I'm at it, I've got an old engine stand in the shop so it should be a quick little project.

Thanks Ziggy and Bond-o, I like the idea of doing an extensive service and running it...We start boating in late March/Early April so I'll have a few months to shake down the drive and the other systems.

I'm also concerned about the fuel tank, fortunately the floor panel that covers the tank is removable and it appears that the tank will come right out. I'd like to at least have it cleaned out and coated internally, but I may even try to find a direct replacement composit/plastic tank. I'm sure the fuel is varnish after 2 1/2 years.

 

[Bondo]

Re: Merc. 5.7/Alpha 1 rebuild

I'd like to at least have it cleaned out and coated internally,

Ayuh,... Clean it,... If it needs Coating,.. Replace it...

I'm a believer in plastic tanks, myself....

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

Ayuh,... Clean it,... If it needs Coating,.. Replace it...

I'm a believer in plastic tanks, myself....

Gotcha, sounds good to me. I don't want issues in the future so replacing the tank is more of a "do it one time right" kinda fix.

Thanks!

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

Its been a while, I pulled the drive and the u joints are brand new, the gear lube is also brand new looking. That being the case, im going to let one of the local mechanics do an impeller and pressure test the drive....ill paint it too. The lift arms are good but the hydraulic lines are freyed a bit. Anyway, I figure that's some money saved on this deal. Its a good thing too, cause I found some rot in the transom. The boat is headed to a fiberglass shop this week to fix that. Id do it myself but im in the middle of a 68 GTO project which is taking all my time.

Im also pulling the engine today getting ready for a replacement motor. Still haven't decided who to buy the longblock from...

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

I have the engine completely unhooked and un-bolted from the boat now.

I'll pull it out tomorrow with the rest of the drive/transom assembly. Many of the fasteners (bolts) are pretty badly corroded and proving to be a pain to remove. Here's a pic from today...

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

Well I only got the motor out today...geesh what a crazy day! Anyway, it's out now and I pressure washed the bilge area...what a sludge filled nasty mess that was!

Here's the old motor right after taking it out.

Here's the bilge area ready to be stripped-

 

[Bondo]

Re: Merc. 5.7/Alpha 1 rebuild

Ayuh,... Those risers are Nasty looking, 'n probably rotted out...

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

Yeah, they match the transom...I have someone looking into it right now to determine if it'll be fixed or just scrapped for another project.

 

[1kwik72]

Re: Merc. 5.7/Alpha 1 rebuild

Looks like the transom is going to be done this week so the rebuild is a go!

I've stripped most everything off of the old engine now, most all of it was trashed. I can use the intake, brackets, flywheel/shield, bellhousing, all the tin covers.

How can I tell if my coupler is good or bad? It was dirty and greasy but there was no scoring in the splines.

When I drained the oil pan it was 90% pure clean water until the last little bit. The cracks in the block are about 1/2" below the deck and 3-4" long on both sides. I haven't pulled the intake yet, but I'm betting the lifter valley has cracks too.

I've been looking on eBay, but do you guys have a good source on all of the accessories? (e.g. water pump, alt., fuel pump, ps pump, starter...etc)