Volvo Penta Sterndrive DP-S - Consistent & non-changing grinding sound under load

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Jun 16, 2014
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We have a '97 volvo penta DP-S drive that is giving a grinding sound under load. Expected bearings to be worn down, but there's no sign of this in the upper assembly nor the lower. Note, we haven't been able to pull out the pinion gear nor the outer propeller axle to see bearing behind rear prop gear. Desired trim and backlash looks good on gears, but we haven't run it much since sound started. Possible problems noticed:
1 Lower bearing carrier is worn down and chipped by rear seal (see images)
2 Missing material on lower unit by gear case (see image)

Anyone have any theories or similar problems? Thnx
 
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