What else should I do while I'm replacing the bellows?

dwojciechowicz

Recruit
Joined
Mar 22, 2004
Messages
2
I have an Alpha One outdrive mated to a Mercruiser 260. In a few weeks, I will replacing all of the bellows as well as the water pump. I can figure out how to turn a wrench on just about anything, but I have never worked on and I/O, so I really don't know what else to replace or check for while I am performing the above mentioned maintnance. Could you please let me know of the items that I should look for wear and tear on, replace, etc.? Also, are there any general tips that you can provide to make the job go smooth? Also, any tips on where is the best place to get the needed parts from? Thanks in advance for any help!
 

fireship1

Chief Petty Officer
Joined
Aug 26, 2003
Messages
581
Re: What else should I do while I'm replacing the bellows?

Hello, This is a job I have tackled before and like yourself, I will be doing it again in a few weeks. Buy a transom service kit. It will contain all of the parts that commonly need to be replaced when doing this service. The kit includes: The outdrive gasket set, drive shaft bellows, exhaust bellows, shift cable bellows, gimbal bearing and grease seal and molded water hose for the outdrive's water pickup. The cheapest place you will find these parts is at eBasic power. com. Their prices are first rate and they ship fast. Most of their parts are made by GLM marine, a good after-market supplier. If you are looking to do full maintenance here are some other things to check replace as well: U joints, They should have little to no play and should not have rust. If in doubt remember "new is best!" Shift cable, since you have to pull it out anyway to change the bellows on it. They bind and then your shifting goes to hell. :mad: Now is a GREAT time to change it. Trim limit and senders, The cables that connect them to the engine's wiring falls apart :eek: Then the drive don't trim right. They will be partially pulled out anyway, so that's another thing to consider. Outdrive zincs. They rot to save the drive. Guess what rots after they're gone and rotted away? ;) The water pump impeller and housings in the lower unit, It keeps you cool for the outdrive and the engine. No one wants to loose their cool 10 miles out...do they? :eek: This is another kit you can buy. It will come with impeller, pump housings and all gaskets. Lower unit oil. Pick up two quarts of merc high performance lube, a lower unit pump and new drain and vent plug gaskets. When you drain the oil it should look like oil. Not milk or something that resembles a milkshake. If it does you need to have the outdrive resealed. Pull the prop and grease the shaft. If the prop needs to be pulled in the future you will really like yourself for doing this step! Put some aerosol antifoulant on the outdrive before you put the boat in. Barnacles may be cute, but they are not easy to evict when they move to your outdrive as their new home! You can get all of the parts for all of this service at ebasic power. Oh and above all BUY A MANUAL! Don't attempt to do any of this without one! You can get a generic Clymer or Seloc here at iBoats or at Ebasic's. But if you really want to get all of the best advice, get one from Mercury at their website mercury marine.com. I wish you the best of luck in doing your work. Give us a shout if you need some tips!
 

merc 140 pontoon

Petty Officer 2nd Class
Joined
Aug 23, 2003
Messages
129
Re: What else should I do while I'm replacing the bellows?

Hey dwoj..., where ya from in SE Wisconsin? We spend our boating time on Big Cedar.
 

dwojciechowicz

Recruit
Joined
Mar 22, 2004
Messages
2
Re: What else should I do while I'm replacing the bellows?

Thanks for the help! I'm form Kenosha, and spend most of my time on the big pond. <br /><br />When you say "Outdrive zincs. They rot to save the drive.", I am not quite sure what those are. Everything else, I am well aware of, and I just wanted to make sure that I covered all of the bases.<br /><br />Also, are there any special tools that I need? I have the oil pump, but how about tools for the shift cable, replacing bellows, etc.? <br /><br />Thanks again!
 

Fishermark

Vice Admiral
Joined
Oct 19, 2003
Messages
5,617
Re: What else should I do while I'm replacing the bellows?

There are several zincs on the outdrive - the most obvious one is the "rudder" looking thing on the bottom of your outdrive:<br />
zinc2.jpg
<br /><br />One important tip when removing the shift cable - be sure to remove the plastic spiral wrap (if present) from the cable before trying to pull it out. It can get stuck otherwise and be very difficult to remove.
 

merc 140 pontoon

Petty Officer 2nd Class
Joined
Aug 23, 2003
Messages
129
Re: What else should I do while I'm replacing the bellows?

dwoj...<br /><br />Glad to hear of another local sterndriver.<br /><br />M140P
 

fireship1

Chief Petty Officer
Joined
Aug 26, 2003
Messages
581
Re: What else should I do while I'm replacing the bellows?

Hello, You will need the following tools to do this job. Hinge pin tool, To remove the two large pins behind the trim sender and limit switches on the gimbal ring. Shift cable socket, You might be tempted to use an ordinary deep well socket but it won't work. You will chew up the fitting on the cable before you get it into place. Exhaust bellows expander. Some say you can do without this, I disagree! Trying to get the exhaust bellows back in place without this is a real pain. The tool will pay for itself the first time you use it! Engine alignment tool, You will need this tool if you decide to replace the gimbal bearing. It properly aligns the outdrive's drive shaft to the engine's coupler. Even if you don't replace the bearing, you should check the alignment whenever you pull the drive. Misalignment can trash the u joints, gimbal bearing and the engine coupler. Gimbal bearing driver, This you might be able to do without if you use a large socket and extension as a driver. Even though I would spring for the genuine article. These tools are the basic drive repair tools you will need to get the job done right. Plus a good set of sockets with extensions, screwdrivers, wrenches. Basically a good set of mechanics tools. You can get all the special merc tools at eBasic power.com or Mercstuff.com Good luck! :)
 

merc200

Seaman
Joined
Jan 24, 2004
Messages
67
Re: What else should I do while I'm replacing the bellows?

You really don't need to buy those tools. I made a gimble bearing driver by welding a piece of 3" diameter flat steel with a hole cut in the middle of it onto a 1" shaft. Worked great. I also made a shift cable socket by welding two 9/16" deepwell sockets together. Worked great. As for the hinge pin tool, you really don't need it. I just finished replacing all the bellows on my merc 165 without removing the bell housing. Just takes a little time and patience. Now, if I did it every day, I'd probably buy the hinge pin tool; It would be easier on my knuckles!
 

fireship1

Chief Petty Officer
Joined
Aug 26, 2003
Messages
581
Re: What else should I do while I'm replacing the bellows?

Hello, You might be able to make the tools if you are handy. I will agree to that. But I wouldn't attempt to change all of those bellows without pulling the bell and cleaning the parts properly. You will never be able to access the fittings and clean everything so that the bellows adhesive can bond well. On the other hand if they don't seal well you will have the most expensive man made reef money can buy! :D
 

BinLurkin

Petty Officer 2nd Class
Joined
Mar 12, 2004
Messages
192
Re: What else should I do while I'm replacing the bellows?

That hinge pin tool, looks like a big torx socket to me, is $16.oo out here in California. I'd check that last yoke that carries one of the u-joints too. It's the one that goes into the outdrive. As long as your removing the bearing retainer anyway to do the u-joints. That seal can wear & make a groove in the yoke there right behind the retainer. The seal is $16.oo & the yoke is $60.oo out here. You don't want that seal to fail & let water in there either.
 

djvan

Chief Petty Officer
Joined
May 3, 2003
Messages
411
Re: What else should I do while I'm replacing the bellows?

An allen wrench of the correct size will remove hinge pins. I've done it and my local marina advised me that's what they use.<br /><br />DougV>
 

BinLurkin

Petty Officer 2nd Class
Joined
Mar 12, 2004
Messages
192
Re: What else should I do while I'm replacing the bellows?

Thanks for the tip. Wish I'd have known that yesterday.
 
Top