Removing Outdrive bell housing wont come off!!!

[JoeFo86]

Hi guys i got a alpha 1 gen 1 i/o i took the out drive off, now trying to get bell housing (i believe thats the name) off and it wont come of easy is that normal? i dont want to break anything else. I am replacing the trim sender and the other puck. i attched pictures. please help new to this whole boat thing. seems everything i touch to replace brakes now so rather ask before breaking

 

[Grub54891]

At this point you need to remove the 2 pivot pins on each side of the drive. They look like 12 point pins, where the pucks go in to. A 1/2" allen wrench fits them nicely. They make a tool for them also, but I've had better luck with the allen wrench. If they won't budge, you need to remove the driveshaft bellow and apply heat with a torch to the backside of the pin. They are locktighted in, and the heat helps them come loose. You may as well replace all the bellows, gimble bearing and lower shift cable now, as they are probably getting old and weak, When it's all done, you will be much safer on the water. Good luck!

 

[Bt Doctur]

http://www.boatfix.com/merc/Servmanl/6/6A3R3.PDF upper
http://www.boatfix.com/merc/Servmanl/6/6B3R3.PDF lower
http://www.boatfix.com/merc/Servmanl/6/6B4R3.PDF transom

 

[JoeFo86]

No Title

OK got, i missed the hose clamps.... also took the hinge pins out already, do i need to remove the gimble as well? i plan on replacing outboard next season with newish one so i dont want to change everything if i dont have too. also running the new lines for the pucks can i just slightly unbolt the cover just enough to slip new wiring through or do i need to remove completely? my hand is big and i have just barely enough room to get my hand to first bolt.

 

[devildogae]

OK got, i missed the hose clamps.... also took the hinge pins out already, do i need to remove the gimble as well? i plan on replacing outboard next season with newish one so i dont want to change everything if i dont have too. also running the new lines for the pucks can i just slightly unbolt the cover just enough to slip new wiring through or do i need to remove completely? my hand is big and i have just barely enough room to get my hand to first bolt.

You don't have to remove the gimbal ring to get to the trim sender clamp. It's either 1 or 2 bolts you will have to remove, and it's not easy. Not a lot of room up in there. The gimbal bearing bellows will have to come off, IMO.

 

[Bt Doctur]

Remove the main bellow completely, remove the exaust bellow from the gimbal, remove the SS bonding wire by removing the screw,
remove the shift cable from the shift plate inside the boat, remove the water hose connection from the gimbal, allow gimbal to slide down

With various tools, extentions, swivel sockets and universal joints, and flexible cable extentions remove the 1 or 2 bolts depending on your housing,
remove the retainer plate, Tie a string on the old wires inside the boat and pull old wires out of the boat, attach string to new wires , pull them inside the boat.
Now pay attention!
using RTV put the 2 halves together , AND LET CURE
Now install the mated plugs into the housing with some RTV,
Install retaoner and bolts