Replacing cooling parts in Alpha 1 Outdrive

[69GTOby]

The drivetrain is a 1988 MerCruiser 5.7L 260HP Alpha 1. I am replacing the impeller housing and parts. Last time I did it was last season, and I want to do it again for peace of mind. I did it last season because it had overheated and was way over due. I put it together with a part I was a bit wary about, and I want to replace it this time around. The part is in the upper unit, attached with 4 bolts. It has the copper tube in it that brings water from the impeller housing below it. Here is a link to a replacement part: http://www.***************.com/mm5/images-sierra/reg/SIE-18-3219_med.jpg The problem is that my tube connection to the piece if off centered, while the one pictured in the link is centered... I cannot seem to find one that is off centered like mine.

 

[ziggy]

Re: Replacing cooling parts in Alpha 1 Outdrive

sounds like yer talking about a waterpocket cover.

item 2 from here.

if you are, be real careful with them 4 bolts. they're stainless steel screwed into cast alum. these bolts get electrolysis corrosion real bad and can break off real easy during removal of them. if you break the bolts off and can't get the stud out the upper is rendered useless.

edit. yer link don't work

2nd edit.
my mc-1 used the same part number waterpocket cover. 42724A3

it's offset too...

be careful with them 4 bolts. oh i said that, but i really mean it. i broke 3 off in my last drive. i've never drilled anything so hard as them bolt's. + they're recessed 12'' inside the drive so ya can't get at them to drill them. take heed when touching these bolts..

 

[Don S]

Re: Replacing cooling parts in Alpha 1 Outdrive

If you aren't having any overheat problems after you replaced the last impeller, leave the water pocket cover alone. If you break those bolts, you will probably be looking at a new upper housing minimum. Drilling out 1/4" diameter broken bolts down in that deep hole, most times turns into a disaster. That is one of those things that fits the "If it ain't broken, don't fix it" catagory.

In your link before, the part number is probably 18-3219 as shown at the end of your link.
http://www.iboats.com/Mercruiser-Wa...5327613--**********.414463489--view_id.269019

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

Thanks for the help guys. It looks just like your picture, ziggy, or at least it is supposed to! Here it is:

Believe it or not, but it is still fully functional, but could be on its last leg. I pulled it out before I read your replies. I am VERY grateful and happy to say that all 4 bolts came right out without issues. Looks like I dodged a bullet.

Don, the one in your link has the pipe centered, mine has the pipe offset. Again, ziggy, that PN you wrote, 42724A3, shows a picture of a unit with the centered pipe. The only one I can find with the pipe off centered like mine is this: http://www.iboats.com/COVER-KIT-WAT...1078721--**********.146810792--view_id.485461

 

[Don S]

Re: Replacing cooling parts in Alpha 1 Outdrive

The picture just make it look centered. There are not 2 different types. If you are going to get aftermarket parts, at least get the Sierra, not the Mallory.

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

Ohhhhh, okay I get it! Sorry for the confusion, haha. I just ordered a Sierra. I have a few more questions. The driveshaft going thru the impeller has some play. It has end play, I can pull it up and down a bit, and I can wiggle it around in a circle. Does this indicate a bad bearing, or is it normal? Also, the main bellows is full of outdrive oil. Where is the leaky seal, is and is it a big job?

 

[Don S]

Re: Replacing cooling parts in Alpha 1 Outdrive

Yes, the shaft will move up and down, but when the engine is running, and the shaft turning it will be pushed up against the bearing in the lower unit.

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

I just received the new Sierra water tube kit. It looks nice, much better than the old one!

What about the gear oil in the main bellows? What seal is responsible for that, is it a major problem, and is it a big job to repair it?

 

[Fishermark]

Re: Replacing cooling parts in Alpha 1 Outdrive

You will need to pressure test the drive to find where it is leaking. Your upper yoke seal is probably the culprit... if the yoke is pitted or grooved, you will need a new one. Probably better to start a new thread with this new issue. You will receive a little more help that way.

 

[achris]

Re: Replacing cooling parts in Alpha 1 Outdrive

...What about the gear oil in the main bellows? What seal is responsible for that, is it a major problem, and is it a big job to repair it?

There is only one seal that will allow oil into the uni bellows, the front seal in the top box. Not a big job to replace IF you have the right tools (Merc special, of course). There is also a procedure to follow and maybe a rolling torque to set up (depends on the main bearing pack in the front of the drive, early or late). Do you have the GENUINE manual?

If not -> http://www.4shared.com/document/zz_5pj9o/Service_Manual_06.html

Have a read through the section relevant and decide for yourself. Starts on page 3A-11....

Cheers,

Chris......

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

Thank you, thank you, thank you! I didn't know there was a free downloadable manual, that's great! So, the special tool is the bearing retainer wrench? If that's the case, can I just chisel it off? Tap it with a chisel and hemmer. If not, I'll buy the tool. I definitely don't want to mess it up. Looks easy enough. Which particular seal do I need to replace? Lol, there are like a hundred of them.

 

[Don S]

Re: Replacing cooling parts in Alpha 1 Outdrive

You need the tool, hammer and chisel will not do the job. Putting it back together with 200 ft lbs of torque is not going to be done with a hammer and chisel. Besides if you damage those tabs or break one off, the seal between the bellhousing and the drive will not hold and you will get water in the bellows.

Here is the tool
http://www.iboats.com/Mercruiser-Sp...3232819--session_id.207874966--view_id.269858

 

[ziggy]

Re: Replacing cooling parts in Alpha 1 Outdrive

I definitely don't want to mess it up.

read the s/m for the job your getting ready to undertake. the instructions are very precise. make sure ya understand what your getting ready to do.

Looks easy enough

don't know if i'd call that one easy, but it's not to bad to do the deed.

Which particular seal do I need to replace?

2nd from right is the part that has the seal in it. if i remember right i didn't have to install the seal, it came as a preassembled part. use mercruiser parts.com to lead ya to the part number. or, your mercruiser dealer will know what part ya need.
in the pic. the ujoint yoke should be to the right of the furthest right part to put it in sequence. and turned and pointing left.

for sure use the proper retainer nut wrench imho. it's torqed to 200 ft. lbs.

 

[achris]

Re: Replacing cooling parts in Alpha 1 Outdrive

Check the seal surface on the yoke, it may be grooved (which could be why the seal failed). If it is grooved, set the seal about 20-40 thou deeper in the carrier and you will be setting the seal on a new area of the yoke. If the surface is really bad, replace the yoke.

Chris.........

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

Awesome, guys. Sound advice. Like I said on my carb thread, my Dad really wants to get the boat out on the water, and I agree! He wants me to just put it together and we'll deal with resealing the upper unit next season. As long as we keep the oil full it shouldn't be a problem. I do want to fix it next winter tho.

 

[dubs283]

Re: Replacing cooling parts in Alpha 1 Outdrive

He wants me to just put it together and we'll deal with resealing the upper unit next season. As long as we keep the oil full it shouldn't be a problem. I do want to fix it next winter tho.

you'll be replacing the drive before next winter if you don't reseal it now

 

[Don S]

Re: Replacing cooling parts in Alpha 1 Outdrive

Awesome, guys. Sound advice. Like I said on my carb thread, my Dad really wants to get the boat out on the water, and I agree! He wants me to just put it together and we'll deal with resealing the upper unit next season. As long as we keep the oil full it shouldn't be a problem. I do want to fix it next winter tho.

You can lead a horse to water, but you can't ..................... Oh never mind :facepalm:

 

[Pete104]

Re: Replacing cooling parts in Alpha 1 Outdrive

Ever feel like your talking too spam?

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

You're not talking to spam. I didn't think it was that big of a deal. Spring is here and Dad is anxious to get the boat out. I am going to fix the darn thing, I was just hoping I could postpone it until next winter. Geez...

 

[69GTOby]

Re: Replacing cooling parts in Alpha 1 Outdrive

I am ordering the seal kit and the tool now. Any recommendations on what kit to get? There are several brands and quite a price range...