Resealing an alpha one, gen I

[nola mike]

Ok, I'm going to try to start a new thread on this, because I really haven't been able to find out what's involved in resealing an outdrive. Mine's leaking, but a pressure test doesn't reveal a leak. Vacuum test shows leaking at the input seal (at least), but that shouldn't allow water in the drive unless there's water in the bellows. I'm guessing I have another leak that I can't find because of the input seal leak being bigger.

1. Can I split the drive, plug up the oil passage, and leak test each half separately?
2. Where are ALL the seals that need to be replaced for a complete job? (Pics attached)
3. What special tools are needed? Is this just disassembly, or does it involve shimming, setting preload, etc?
4. If there is a procedure somewhere in the adults only section, manual, etc, please point me to it!

 

[Don S]

Re: Resealing an alpha one, gen I

4. If there is a procedure somewhere in the adults only section, manual, etc,

There are manual downloads in the Adults only sticky, click on the section called Mercruiser Service Manual download links and index you might find manuals there.

 

[Aviator5]

Re: Resealing an alpha one, gen I

1 - I've done it on mine, just make sure the vacuum won't suck your plugs in.
2 - you can buy seal kits for upper and lower, they will contain all necessary seals, o-rings and gaskets.
3 - you need a seal drivers to properly install seals. But they are fairly simple tools to make for the guy with a lathe.

 

[JustJason]

Re: Resealing an alpha one, gen I

how exactly are you pressure testing it? Can you post a pic of your tester? How long did you let the pressure tester sit for? You did drain the gear lube first right? 1 last thing, did you rotate the shafts while watching the gauge for a drop?

If I get a chance i'll post a pic of my pressure tester later.

 

[nola mike]

Re: Resealing an alpha one, gen I

There are manual downloads in the Adults only sticky, click on the section called Mercruiser Service Manual download links and index you might find manuals there.

yeah, i have the manuals. didn't know if they outlined troubleshooting a leaky drive anywhere.

how exactly are you pressure testing it? Can you post a pic of your tester? How long did you let the pressure tester sit for? You did drain the gear lube first right? 1 last thing, did you rotate the shafts while watching the gauge for a drop?

here's how i pressure tested it. used a rig similar to this. yes, drained lube. no, didn't rotate shafts. my tester isn't with me at the moment, so i can't post a pic...

i guess my question is related to which seals are the ones we're talking about (which part #'s in the diagrams?), and if it requires extensive drive disassembly/special tools to reach them or not. and i don't have a lathe.

 

[JustJason]

Re: Resealing an alpha one, gen I

what you'll need for tools besides basic hand tools

1. Input shaft bearing retainer nut spanner wrench
2. Reverse gear bearing carrier nut wrench
3. shift shaft bushing wrench.
4. bearing carrier puller.
5. oxy/acet torch if this is a salt boat.
6. some seal installer tools/drivers, home made or whatnot.