replacing boot on alpha 1 lower unit?

[nola mike]

while trying to diagnose a shifting problem (having a hard time with SIS--PO had disconnected it), i seem to have sprung a leak in one of the boots in the lower unit (merc 170, alpha 1 outdrive). there appear to be 2 boots there; this is the upper boot. what is involved in the replacement, time/difficulty-wise? any special tools needed? anything else to do while i'm in there? i was reluctant to replace the shift cable, since i (still) don't think that's the problem, but i might as well if it isn't too much more work. any step-by-step guides anywhere? i'm not able to open the shop manuals for the alpha 1 on my computer, presumably the info is in there? thanks for the help!

 

[Bt Doctur]

Re: replacing boot on alpha 1 lower unit?

Thre manuals are LARGE and take some time to download, follow the new directions.
A complete changeover inc shift cable 3-4 hrs.
Extra deep 9/16 ths socket, alignment bar
http://www.boatfix.com/merc/Servmanl/6/6covr3.pdf

 

[nola mike]

Re: replacing boot on alpha 1 lower unit?

i'm on a non-windows computer, and get an error trying to open the files. i figured out a work-around though, and can now see them. job doesn't look too bad; i'm going to bring as many tools with me (boat is 1.5 hours from home) as i can, and hope i don't forget something too important.

what's a ths socket?
i read through the procedures a couple of times, and don't see mention of an alignment bar? i don't have one, so it would be nice not to need it...

 

[Haut Medoc]

Re: replacing boot on alpha 1 lower unit?

i'm on a non-windows computer, and get an error trying to open the files. i figured out a work-around though, and can now see them. job doesn't look too bad; i'm going to bring as many tools with me (boat is 1.5 hours from home) as i can, and hope i don't forget something too important.

what's a ths socket?
i read through the procedures a couple of times, and don't see mention of an alignment bar? i don't have one, so it would be nice not to need it...

If your u joint bellows was/is leaking, you may be in for more than a simple replacement of that part.....
The only way to know is to pull the drive off & inspect for rust damage....
You will have to have the normal tools, plus the shift cable socket tool, & a hinge pin tool.....
You also need to figure out why the SIS was disabled & repair it, they are generally simple to diagnose & you will not be able to get out of gear with the motor running.....
You should replace the shift cable at this time....

 

[Haut Medoc]

Re: replacing boot on alpha 1 lower unit?

Oh yeah, the alignment tool is not a neccessity but is highly reccomended to check the overall condition of your rear motor mounts....
Poor alignment will cost you a coupler.....

 

[nola mike]

Re: replacing boot on alpha 1 lower unit?

thanks for the help. i managed to do both repairs. i didn't need the hinge pin tool (bellhousing removal not necessary for the bellows replacement). the rip had just happened, so everything was in good shape internally, gimbal bearing nice 'n smooth. shift cable replacement + reattaching SIS also cured my shifting problems.

 

[Bt Doctur]

Re: replacing boot on alpha 1 lower unit?

9/16 ths:
nine sixteenths