Upper Gear Housing Removal, Volvo Penta 280 Outdrive, Im Struggling!!!

[boatingmark]

Hi all

Today i had a go at removing the upper gear housing from the intermediate housing, drained oil, removed the bolts and nuts, hose clamp etc.

I read on this site in another thread its meant to lift straight up, i can only get it to move 1-2mm upwards away from the intermediate housing, its like theres something behind preventing it lifting up any further.

Any ideas please chaps? Im stuck and need to get these bellows changed over!!! Have i missed something?

Thanks in advance!

 

[PatinIdaho]

Make sure your bellows are lose. I like to even push it off the Transmission just to make sure. With the Transmission un bolted it lifts up and kinda back at the same time.
If it wont come off, It may be stuck to the drive shaft in the transom. But im no expert!

 

[Fishermark]

You can also put something under the front studs and use the nuts as jamb nuts to push the gear box off. (As you turn them off, they push against the block you have under them).

 

[boatingmark]

Thanks for the response. I have indeed got the bellows completely off so the u joints are visible. It just doesn't seem to want to budge, if I use my hand to knock it upwards the maximum cap I see is only a few millimetres.

Could something of seized together?

If I use the studs as a way to force the upper housing upwards could I cause internal damage to anything? Im not clear of the layout of whats inside and how the drive shaft sits. I could do with seeing some pics if anyone has any!?

 

[boatingmark]

Does the u joints have to be rotated in a certain position in order for it to lift up ok?

If it is stuck on the drive shaft then what? :blue:

 

[captmello]

There is nothing holding the upper gear box to the intermediate assembly except the four fasteners. Hard to say what could be holding it unless it is somehow wedged in because of pressure from the ujoints...I would try to shim it up as high as you can and give it a couple wacks on the side with a rubber mallot and see if you can work it off that way...How did the oil look when you drained it.

 

[Fishermark]

I just went through this with mine. It was STUCK! In addition to the jamb nuts, I had to take a block of wood and a hammer - knocking it up and off. Once it breaks loose it should be fairly easy. You will have to push the coupler down - it is simply a collar that attaches the upper and lower shafts together. (You can see it in pic 2 and 3). Here's some pics:

 

[boatingmark]

Great! Thanks for the response chap!

Ive had success and made progress, I used a aluminium flat bar and stuck it under the stud and then hit it with a soft mallet and after a few blows it worked its way upwards, it looks like there was bad oxidisation around the studs so they were stuck solid!

Captmello, the oil was still yellow in colour but you could see some evidence of water mixed in with it, I did an oil change 10 months ago.

So now its off im able to changed the bellows as planned, Ive also inspected the u joints and they do have light surface rust, they seem to move freely and theres no play in them at all.

Should I still replace these or based on their condition leave well alone? Should I disassemble to see their bearing condition?

Thanks again!

 

[boatingmark]

Any ideas chaps?