Mercruiser 195...changing/repairing outdrive bellows?

Trent54

Cadet
Joined
Jul 25, 2004
Messages
16
Dear everyone,<br /><br />I'm new to this forum, but there seem to be some awfully knowledgeable people here. I hope this isn't a dumb question.<br /><br />I've got a 1973 Starcraft Islander with a Mercruiser 195 powerplant and the original outdrive. I believe the bellows leak. How difficut is it to change these? The dealsership said it would cost 175 for the new bellows plus 300-500 labor. They also said a special tool was required to remove the outdrive. <br /><br />I met a guy at the lake while float testing it on Saturday who said the parts are 100 bucks, and that he would perform the labor for 125.00. He had been drinking but I asked him and he said that no special tool was required for changing the bellows. <br /><br />Exactly how hard is this job and who should I trust? Both the mechanic at the dealership and the guy I talked to seemed reputable, but only the guy at the lake actually saw my boat. <br /><br />Obviously I'd rather pay 225 than 5-7 hundred. What do you guys say?<br /><br />Thanks,<br />Trent
 

JB

Honorary Moderator Emeritus
Joined
Mar 25, 2001
Messages
45,907
Re: Mercruiser 195...changing/repairing outdrive bellows?

Wrong question to ask on the Mercury Outboard troubles forum, Trent..<br /><br />I will move this to the Mercruiser forum.
 

djvan

Chief Petty Officer
Joined
May 3, 2003
Messages
411
Re: Mercruiser 195...changing/repairing outdrive bellows?

Can be done with no special tools. Use a hex key (allen wrench) on the hinge pins. To pull the exhaust bellows doesn't need a special tool, but it sure does make it easier. If you don't have a manual get one, in the meantime go back to merctuff.com and look in their how to section. If you are mechanically inclined or have friends that are I see no reason to pay somebody to do this.<br /><br />HTH's DougV>
 

Trent54

Cadet
Joined
Jul 25, 2004
Messages
16
Re: Mercruiser 195...changing/repairing outdrive bellows?

Thanks for the reply djvan. I did find the section there on how to change the bellows. I am somewhat mechanically inclined and my friend is more so, it is just definitely scary for me to be messing with this stuff! Having said that the instructions don't look terribly daunting I'm just afraid of breaking something. Sometimes you try to save money and you wind up really costing yourself!<br /><br />I really really appreciate all the help I can get here so thanks. <br />If I may clarify, here is what I understand so far: I can use a hex key to remove the hinge pins. I believe this is what the Mercruiser mechanic said was very difficult. The manual here:<br /> http://www.mercstuff.com/bellowsreplacement1.htm <br /><br />Says "Apply heat if neccessary during this step." Is that to break the pins loose? How should one apply heat? Is it OK to use WD40?<br /><br />Also, is the special tool you are referring to on the exhaust bellows this tool:<br /> http://www.mercstuff.com/page10.htm <br />The "Exhaust Bellow Expander?" I am curious if this is worth the 44 bucks. How much time does it save? <br /><br />Finally, let's say my buddy and I get to work on this. I'm not a good mechanic but he really is. How many hours should this take us and how many hours would it take a competent marine mechanic? I'm curious because I want to know what point to call it off and call in the professionals if things go really badly ;) <br /><br />Also, is there anything else I should check out when I have the outdrive off?<br /><br />Thanks very very much,<br />Trent
 

djvan

Chief Petty Officer
Joined
May 3, 2003
Messages
411
Re: Mercruiser 195...changing/repairing outdrive bellows?

Trent,<br /><br />As far as the hinge pin tool, that is step 4, and yes use a hex key (allen wrench).<br /><br />Yes the bellows puller is the one pictured. I made one for about 1.50 worth the scrap steel and 1 1/2 hours of my time. (must have a torch and welder)<br /><br />I did not have to apply heat to my hinge pins, so I don't know about how much is safe to apply. Try WD40 for sure.<br /><br />It does take some time and patience to change all the bellows and the water tube. So beware of that.<br /><br />Don't remember how long it took me but I tend to take my time and try to do it right the first time. I would say less than a full day for you to do it, unless you run into trouble or need more part than expected.<br /><br />DougV><br /><br />DougV>
 
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