Oil leak between the lower unit and where it joins the upper unit

benninj

Cadet
Joined
Jul 22, 2012
Messages
12
Good evening , my name is Joe and I recently (19 July) purchased a 1987 198F with a Mercruiser 165 4 cylinder married to an Alpha One stern drive serial number OB712228.
The motor runs magnificently and all of the functions on the stern drive work as they should. I wanted to make sure everything was good to go before putting it in the water so I went to my local marina and asked for the maintenance that I needed to do prior to putting it in the water. So far I have gone through and changed the oil in the motor, did a tune up (plugs, wires, cap and rotor), changed the oil in the stern drive and then asked on the Chaparral forum for additional maintenance that is recommended before splashing. I was told to change the water pump in the stern drive, which I am going to do this weekend. This is where I encounter my first problem, I am not entirely sure which is the correct water pump kit that I need to order. I would prefer to purchase one that has any and all seals that I should change while I am in there. Any direction that you can give in regards to the right kit would be greatly appreciated. Now on to my second and probably biggest problem... I pulled the boat to my father in laws house which is 2 blocks from my house to detail the boat and do some cosmetic maintenance. I had the stern drive in the trailer position for the trip, but when I walked around to the back of the boat upon arrival, I noticed an oil leak at the location indicated on the picture I have attached. You will be able to see the chunk of aluminum missing and this is where the leak was. It was a very small and slow leak, enough to trail down the lower unit and leave about 10 drops on the concrete. I saw the damage but no leak, when I purchased the boat and asked my local boat center if this was a serious problem and they told me not to worry about it, as it was probably damage done by hitting something in the water. I am starting to second guess the information they gave me and am once again looking to the forum members for help. So I guess my question is this a serious dilemma or possibly a seal/gasket issue that I can repair when I go in to change the water pump and seals. I deploy 15 August and really want to get my boat in the water before I have to lay it up until I return next April. Thank you in advance for any help and advice that you can give me.
leak.JPG
 

Pete104

Lieutenant
Joined
Apr 30, 2011
Messages
1,439
Re: Oil leak between the lower unit and where it joins the upper unit

Can't see anything in the pic.
 

benninj

Cadet
Joined
Jul 22, 2012
Messages
12
Re: Oil leak between the lower unit and where it joins the upper unit

I will try to get a better picture in the morning. The leak is no longer showing itself in the picture, after I wipe the oil off to see if it would continue to leak, it stopped. I was trying to identify the location that the aluminum was missing where the lower unit mounts flush to the upper unit and show the location where the leak had occured.
 

Grub54891

Admiral
Joined
Jun 17, 2012
Messages
6,175
Re: Oil leak between the lower unit and where it joins the upper unit

Is it possible that you had some spillage when you filled it and it ran down there when it was trimmed up? If there was no oil anywhere else it could be possible,also the shift shaft seal is up forward there also,that could be a place to check when you put the impeller in. And when replacing the impeller make sure the quad ring is in place when joining the halves back together.
 

NHGuy

Captain
Joined
May 21, 2009
Messages
3,631
Re: Oil leak between the lower unit and where it joins the upper unit

Welcome to the forum!
You will split the drive at that seam to do the impeller. When it's apart give it a good looking over and if any thing seems wrong take a pic. Don't wipe the area off til you get some good shots. If it's minor there are some measures you can take to avoid replacing the upper or lower drive housings.
And to answer your part question, you want the regular Alpha 1 impeller kit. Not Generation II.

Did you say deploy, as in military? Then thank you for your service to our country.
 

benninj

Cadet
Joined
Jul 22, 2012
Messages
12
Re: Oil leak between the lower unit and where it joins the upper unit

Thanks for the responses. I took the lower unit off yesterday, and the source of the leak showed itself immediately. The rubber seal in the shift shaft bushing was cracked and half out if the bushing, when I pushed on it oil squirted out of the slot in the bushing. Also the stbd oil tube gasket was deformed and had debris on it and I saw an oil trail from it right to the external source of the leak. I went ahead and replaced the water pump, base, and all seals/bushings that were replaceable in the lower unit, as well as the upper drive shaft seal. It had gotten late by the time I reinstalled and filled the lower unit so I am going to head outside shortly this morning and give it an optest. Thanks again for the quick responses.

Also, yes I am active duty Navy, 8 yrs active, Hull Technician 1st class. "Have torch will travel", and if you need it done I will weld the crack of dawn for you.

Joe
 

zlman1970

Seaman Apprentice
Joined
Jul 10, 2012
Messages
47
Re: Oil leak between the lower unit and where it joins the upper unit

Thanks for the responses. I took the lower unit off yesterday, and the source of the leak showed itself immediately. The rubber seal in the shift shaft bushing was cracked and half out if the bushing, when I pushed on it oil squirted out of the slot in the bushing. Also the stbd oil tube gasket was deformed and had debris on it and I saw an oil trail from it right to the external source of the leak. I went ahead and replaced the water pump, base, and all seals/bushings that were replaceable in the lower unit, as well as the upper drive shaft seal. It had gotten late by the time I reinstalled and filled the lower unit so I am going to head outside shortly this morning and give it an optest. Thanks again for the quick responses.

Also, yes I am active duty Navy, 8 yrs active, Hull Technician 1st class. "Have torch will travel", and if you need it done I will weld the crack of dawn for you.Joe

Who's Dawn?
haha

good luck on you're project!
 

ktbarrentine

Lieutenant
Joined
Dec 12, 2011
Messages
1,296
Re: Oil leak between the lower unit and where it joins the upper unit

Not that you have alot of time on your hands to do this next step: recommend you do a pressure test of the new seals you have put into your drive. Visit the "adults only" sticky at the top of this forum for more info. Also, what manual are you using to guide you through your work? KTB, MMCM/SS/LDO/LT/USN/RET
 

benninj

Cadet
Joined
Jul 22, 2012
Messages
12

benninj

Cadet
Joined
Jul 22, 2012
Messages
12
Re: Oil leak between the lower unit and where it joins the upper unit

So.... I did my optest and everything was good, except for not having reverse. So after cruising the forums for a little bit, I took it back apart and turns out I was one of those jack@$$es that didn't put the washer on top of the shift shaft bushing... I added the washer, reassembled and relubed and everything works awesomely. I am going to make a rig to do the pressure test and hopefully that will go as it should and I will finally be able to splash the boat. Thanks again everyone for the replies and the experience!
Joe
 
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