Water in bellows on Alpha One Gen 2

[Smokey988]

I have a Gen 2 that has water in the u-joint bellow. A few months back I ended up with water in the sterndrive and had changed a few of the seals thinking I had solved the problem. When I originally took the drive off the boat I found water in the u-joint bellow but figured it was a leaky bell housing gasket that was letting water in. Last week while winterizing the boat I drained the gear lube and again it has started going milky. When I removed the sterndrive from the bellhousing I once again found water in u-joint bellow.

I went over the bellow very well to check for cracks and tears and even put a flashlight in to see if light was coming out anywhere. Nothing. The bellows were changed 2.5 years ago.

I did notice that the shift shaft where is goes thru the seal at the bellhousing is scored/pitted. Would this allow water into the u-joint bellow?

 

[Bt Doctur]

how are you installing the large rubber ring

 

[Smokey988]

The area is clean and it was just installed dry. Place it in bellhousing and install sterndrive.

 

[Scott06]

The area is clean and it was just installed dry. Place it in bellhousing and install sterndrive.

This plus the shift shaft let's water in, so does a leaking bellow or a Ton of water inside the boat.
You have to glue big oring in place before placing the drive . Should also pressure test the drive to find oil seal leak

 

[Smokey988]

This plus the shift shaft let's water in, so does a leaking bellow or a Ton of water inside the boat.
You have to glue big oring in place before placing the drive . Should also pressure test the drive to find oil seal leak

The o-ring around the water port was glued. The round gasket by gimbal bearing was dry. Should the large round gasket by gimbal bearing be glued as well?

 

[Bt Doctur]

Yes, if slightly dislodged when installing the drive, water can enter the bellow

 

[Rick Stephens]

Should also pressure test the drive to find oil seal leak

This needs repeating. Any time you have an issue with water intrusion, you should pressure test the drive and find your leak. Of note though, if there is a lot of water in the u-joint bellows, that water will always enter the drive through the input shaft seal. That seal, since it is where oil is on one side and air on the other, is only intended to keep oil in. Water will always get past it going the other way since it isn't designed to keep it out. Only way to know for sure is to pressure test. Build your own tester, there is suggestions on how in the Adults Only section. Test your drive. Either that or spend the $$ for a shop to do the same thing.

 

[Smokey988]

This needs repeating. Any time you have an issue with water intrusion, you should pressure test the drive and find your leak. Of note though, if there is a lot of water in the u-joint bellows, that water will always enter the drive through the input shaft seal. That seal, since it is where oil is on one side and air on the other, is only intended to keep oil in. Water will always get past it going the other way since it isn't designed to keep it out. Only way to know for sure is to pressure test. Build your own tester, there is suggestions on how in the Adults Only section. Test your drive. Either that or spend the $$ for a shop to do the same thing.

The drive was pressure tested and is fine. The water is definately getting in the thru the top seal which is not designed to keep anytging out. Now I need to figure out why water is getting in the bellows. I am assuming it can only be either the upper shift shaft seal or the actual bellow is damaged. The bellow looks in real good condition and the bilge has never been full enough to let the water in the bellow so I am leaning towards the upper shift shaft seals.
Can the wire be removed from the bellow just to inspect the bellow and put back in afterwards?

 

[Scott06]

The o-ring around the water port was glued. The round gasket by gimbal bearing was dry. Should the large round gasket by gimbal bearing be glued as well?

The big not oring but rectangular ring needs to be glued in otherwise it won't stay when you put drive on. Water port oring stays on with a dab of grease. Might be completely no up through your shift shaft. Would make sure all the milk comes out of the drive

 

[Smokey988]

I think I will go ahead and change the bellows even though I can't find a hole. Since the boat is new to me and the service records I received from previous owner show a bearing failure in 2017 and I have actually found a few pieces of metal and bearing pins in the u-joint bellows. Probably safer just changing them.

While at it do I replace the shifter cable as well? The boat is 2007 with 220 hours on it.

 

[hoot]

A cracked bellows can be hard to see especially if it is compressed. Turn the wheel for a right turn and look at the left side of the bellows as it is now stretched. Then do the left turn and look at the right side. Tilt the drive up and check the bottom of the bellows. Now, depending on how much water and how long it was in the bellows, the u joints may need replacing. If not, you might be posting next summer "what is that grinding noise when i turn"

 

[Smokey988]

A cracked bellows can be hard to see especially if it is compressed. Turn the wheel for a right turn and look at the left side of the bellows as it is now stretched. Then do the left turn and look at the right side. Tilt the drive up and check the bottom of the bellows. Now, depending on how much water and how long it was in the bellows, the u joints may need replacing. If not, you might be posting next summer "what is that grinding noise when i turn"

I have checked the u-joint bellow thoroughly inside and out and can't find a hole or crack so I am leaning towards the upper shift shaft seals that were in rough shape that caused water to enter the bellows but with the discovery of metal shavings and bearing needles in the bellow from a previous bearing failure I am just going to replace the bellows and sleep easier not worrying about them.

I will look over the u-joints good to confirm they are good before re-assembling.