Volvo DP-A bellows and upper unit

[thomasalva]

I recently purchased a 1989 Cobalt with a Volvo DP-A outdrive. The marina where I bought it greased the u-joints, replaced the u-joint bellows, and replaced the shift cable. I've only had it out a couple of times, but I noticed a water drip at the raw water intake hose so I decided to replace the hose connector and hose.

I removed the upper unit last night, and everything so far looks pretty clean. I did however notice a very small amount of water in the u-joint bellows, probably a couple of eyedroppers full. No rust or oil mixing though, and it really looked more like condensation. This makes me wonder if the bellows needs to have any type of sealant or grease when I put it back together. The Volvo manual I've found online doesn't mention anything other than clamping them on.

Here are my questions:

1. Any grease or sealer on bellows?

2. Replace o-rings between upper and intermediate housing? I think the part numbers are 925259 and 125017.

3. Any tricks getting the raw water hose through the transom? This looks pretty tricky since the inboard access is very limited.

4. Any grease or sealant between the upper and intermediate housing?

5. Should I pressure test the outdrive?

6. Anything else I should do while I have the upper unit off?

Thanks

 

[Don S]

Re: Volvo DP-A bellows and upper unit

1. Any grease or sealer on bellows?

Shouldn't be needed, check to make sure the engine side of the bellows is in the groove properly. also make sure the clamp was installed in the proper location so it doesn't poke a small hole in the bellows. and check the bellows for holes in the drive side. Without the helmet attached the drive could hit the steering fork and poke a hole in the bellows.

2. Replace o-rings between upper and intermediate housing? I think the part numbers are 925259 and 125017.

Yes, that's it.

3. Any tricks getting the raw water hose through the transom? This looks pretty tricky since the inboard access is very limited.

No tricks, yes, they can be a pain.

4. Any grease or sealant between the upper and intermediate housing?

Very thin coat of gasket sealer. More corrsion prevention than sealing.

5. Should I pressure test the outdrive?

Only if you want to make sure it doesn't leak.

 

[thomasalva]

Re: Volvo DP-A bellows and upper unit

Thanks Don. This is my first boat so I'm not very familiar with any of this yet. Clamp positions were wrong on the bellows, but I'm not seeing any holes. I got the hose out, cleaned up the mating surfaces on the outdrive, and got the new hose pulled through the transom. I haven't begun reassembly yet since I need to order the o-rings, but it should be pretty easy from this point.

For the pressure test, do you happen to know if the plug threads are a standard plumbing thread? I already have a gas test gauge with a Schrader valve, so I just need to find a fitting to adapt it. The threads are very coarse compared to several brass plumbing fittings I happen to have on hand. I'll try and check around at some hardware or plumbing stores tomorrow.

Thanks again.