Notice

Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus Common Sense operation, are major accident prevention measures.

DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION
Hazards or unsafe practices which could result in minor personal injury or product or property damage.

Notice to Users of This Manual

This service manual has been written and published by the Service Department of Mercury Marine to aid our dealers mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they have been trained in the recommended servicing procedures of these products which includes the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. It should be kept in mind, while working on the product, that the electrical system and ignition system are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started.

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It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products described in this manual.

Engine Mechanical Components

Many of the engine mechanical components are designed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle operation and, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications which are required to provide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard automotive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor engine performance and/or durability, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replacement parts, will void the warranty on those parts which are damaged as a result of the use of other than recommended replacement parts.

Replacement Parts
WARNING
Electrical, ignition and fuel system components on MerCruiser Engines and Sterndrives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed.

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90-818177-3 APRIL 2001

Models Covered in This Manual

Transom Assembly
Model MC Alpha One Generation II Serial Number OD492742 and Above

MC ALPHA ONE GENERATION II - STANDARD ROTATION

Model 1.47:1 1.50:1 1.62:1 1.65:1 1.81:1 1.84:1 1.94:1 1.98:1 2.0:1 2.40:1 Serial Number 0F680000 and Above 0D469859 thru OF503723 0F691000 and Above 0D469884 thru OF501799 0F691500 and Above 0D469885 thru OF503021 0F713549 and Above 0D469898 thru OF502356 0L100009 and Above 0D469898 and Above

MC ALPHA ONE GENERATION II - COUNTER ROTATION

Model 1.47:1 1.50:1 1.62:1 1.65:1 1.81:1 1.84:1 1.94:1 1.98:1 2.0:1 Serial Number 0F728823 and Above 0D350945 thru OF320162 0F729013 and Above 0D341151 thru OF305180 0F729151 and Above 0D342272 thru OF386000 0F729751 and Above 0D350952 thru OF624917 0L100009 and Above

NOTICE Refer to Appropriate Engine Service Manual for Engine Repair

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Service Manual Outline

Important Information

Section 1 - Important Information A - General Information B - Maintenance C - Troubleshooting Section 2 - Removal, Installation and Adjustment A - All Models Section 3 - Sterndrive Unit A - Drive Shaft Housing B - Standard Rotation Gear Housing C - Counter Rotation Gear Housing Section 4 - Transom Assembly A - Minor Disassembly B - Major Disassembly Section 5 - Power Trim A - Trim Pump B - Trim Cylinders C - Dual Power Trim System D - Auto Trim II Section 6 - Steering Systems A - Power Steering B - Manual Steering Section 7 - Corrosion Protection A - All Models

1 2 3 4 5 6 7 8

Removal, Installation and Adjustment

Sterndrive Unit

Transom Assembly

Power Trim

Steering Systems

Corrosion Protection

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90-818177-3 APRIL 2001

Table of Contents

IMPORTANT INFORMATION
Section 1A - General Information
How To Use This Manual . . . . . . . . . . . . . Page Numbering . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . Special Product Information . . . . . . . . Directional References . . . . . . . . . . . . . . . Propeller Rotation . . . . . . . . . . . . . . . . . . . Serial Number Locations and Engine Designation Decal . . . . . . . . . . . Sterndrive Unit Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 1A-2 1A-3 1A-3 1A-3 1A-4 1A-4 1A-5 Decal Application . . . . . . . . . . . . . . . . . . . . Decal Removal . . . . . . . . . . . . . . . . . . . Instructions for Wet Application . . . Painting Procedures . . . . . . . . . . . . . . . . . Cleaning & Painting Aluminum Propellers & Gear Housings . . . . . . . 1A-5 1A-5 1A-5 1A-7 1A-7

Section 1B - Maintenance
Trim Pump Specifications . . . . . . . . . . . . Valve Pressure Specifications . . . . . . Maintenance Schedules . . . . . . . . . . . . . . Maintenance Intervals . . . . . . . . . . . . . Gas Sterndrive . . . . . . . . . . . . . . . . . . . . . . Routine Maintenance * . . . . . . . . . . . . Scheduled Maintenance * . . . . . . . . . . Quicksilver Maintenance Products . . . . . Lubricating Shift Cable Pivot Points . . . . Lubricating Propeller Shaft . . . . . . . . . . . Lubricating Steering System . . . . . . . . . . Power Steering Models . . . . . . . . . . . . Manual Steering Models . . . . . . . . . . . Lubricating Tie Bar Pivot Points . . . . . . . Models With Control Valve Mounted On Starboard Transom Assembly . . Models With Control Valve Mounted On Port Transom Assembly . . . . . . . Lubricating Transom and Gimbal Assembly ,Hinge Pins and Gimbal Bearing 1B-7 Checking and Adding Sterndrive Oil . . . Models Without Drive Unit Gear Lube Monitor . . . . . . . . . . . . . . . . . . . . Models With Gear Lube Monitor . . . . 5A-2 5A-2 1B-2 1B-2 1B-2 1B-2 1B-3 1B-4 1B-4 1B-4 1B-5 1B-5 1B-5 1B-6 1B-6 1B-6 .... 1B-8 1B-8 1B-9 Checking Lubricant for Water . . . . . . . Changing Lubricant . . . . . . . . . . . . . . . General Maintenance . . . . . . . . . . . . . . . . Maintaining Power Package Exterior Surfaces . . . . . . . . . . . . . . . . Steering Head and Remote Control Maintenance . . . . . . . . . . . . . Checking Quicksilver MerCathode System . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining Anodic Trim Tab or Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Optional Quicksilver Anti-Corrosion Anode Kit . . . . . . . . . . Boat Bottom Care . . . . . . . . . . . . . . . . Antifouling Paint . . . . . . . . . . . . . . . . . . Maintaining Ground Circuit Continuity . . . . . . . . . . . . . . . . . . . . . . . Power Package Layup (Out of Season Storage) . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive . . . . . . . . . . . . . . . . . . . . . . . Power Package Recommissioning . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive . . . . . . . . . . . . . . . . . . . . . . . 1B-10 1B-12 1B-14 1B-14 1B-14 1B-14 1B-14 1B-14 1B-15 1B-15 1B-15 1B-16 1B-16 1B-16 1B-18 1B-18 1B-18

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Section 1C - Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . Sterndrive Unit Troubleshooting . . . . . . . Sterndrive Unit Will Not Slide Into Bell Housing . . . . . . . . . . . . . . . . . . . . . Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Moves Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Does Not Move . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Shifts Hard . . . . . . . . . . . . . Drive Unit In Gear, Will Not Shift Out Of Gear . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Noise . . . . . . . . . . . . . . Drive Shaft Housing Noise . . . . . . . . . Drive Shaft Housing Noise (Continued) . . . . . . . . . . . . . . . . . . . . . Drive Shaft Housing Noise (Continued) . . . . . . . . . . . . . . . . . . . . . Performance Troubleshooting . . . . . . . . . Low WOT Engine Rpm . . . . . . . . . . . . High WOT Engine Rpm . . . . . . . . . . . Propeller Ventilating/Cavitating . . . . . Poor Boat Performance And/Or Poor Maneuverability-Bow Too Low Poor Boat Performance And/Or Poor Maneuverability-Bow Too High Power Steering . . . . . . . . . . . . . . . . . . . . . Hard Steering - Helm And Cable . . . . Hard Steering (Engine Running) - Power Steering System . . . . . . . . . . Power Steering System External Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . Compact Hydraulic Steering . . . . . . . . . . Important Information . . . . . . . . . . . . . Helm Becomes Jammed During Filling . . . . . . . . . . . . . . . . . . . . System Difficult To Fill . . . . . . . . . . . . . Steering Hard To Turn . . . . . . . . . . . . . Helm Unit Bumpy - Requires Too Many Turns . . . . . . . . . . . . . . . . . . Power Trim Electrical System . . . . . . . . . Power Trim Pump Motor Will Not Run In The OUT/UP Or IN/DOWN Direction . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Motor Will Not Run In The OUT/UP Or IN/DOWN Direction . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Motor Runs In The OUT/UP Direction, But Not In The IN/DOWN Direction . . . . . . . . . . Power Trim Pump Motor Runs In The OUT/UP Direction, But Not In The IN/DOWN Direction . . . . . . . . . . 1C-3 1C-3 1C-3 1C-3 1C-3 1C-4 1C-4 1C-4 1C-5 1C-6 1C-7 1C-8 1C-8 1C-8 1C-8 1C-8 1C-9 1C-9 1C-9 1C-10 1C-10 1C-11 1C-11 1C-11 1C-11 1C-11 1C-11 1C-12 1C-12 1C-13 1C-13 1C-14 Power Trim Pump Motor Runs In The IN/DOWN Direction, But Not In The OUT/UP Direction-Both Trim And Trailer Switches Inoperative- . . . . . . . . . . . . . . . . . . . . . Power Trim Pump Motor Runs In The IN/DOWN Direction, But Not In The OUT/UP Direction-Both Trim And Trailer Switches Inoperative . . . . . . . . . . . . . . . . . . . . . . Trim Control OUT/UP Trim Switch Inoperative . . . . . . . . . . . . . . . . . . . . . . Trim Control Trailer Switch Inoperative . . . . . . . . . . . . . . . . . . . . . . Trim System Functions While Unattended . . . . . . . . . . . . . . . . . . . . . Power Trim System Wiring Diagram . . . Power Trim Hydraulic System . . . . . . . . . Drive Unit Cannot Be Trimmed OUT/UP Or Trims Slowly Or With Jerky Movements . . . . . . . . . . . . Drive Unit Will Not Stay In Trimmed OUT/UP Position . . . . . . . . . . . . . . . . . Sterndrive Unit Trails OUT/UP On Deceleration Or When Shifting Into Reverse . . . . . . . . . . . . . . . . . . . . . . . . Oil Foams Out Of Pump Fill/Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Unit Cannot Be Lowered From UP Position Or Lowers With Jerky Movements . . . . . Sterndrive Unit Will Not Stay In Full UP Position For Extended Periods . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Will Not Stay In The Trimmed OUT/UP Position When Underway . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Unit Trails OUT/UP On Deceleration Or When Shifting Into Reverse . . . . . . . . . . . . . . . . . . . . Oil Foams Out Of Pump Fill/Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . Trim Motor Runs But Does Not Pump Oil . . . . . . . . . . . . . . . . . . . . . . . . Trim Pump Runs Slowly In Both Directions . . . . . . . . . . . . . . . . . . . . . . . Trim Pump Runs Slowly With A Laboring Sound . . . . . . . . . . . . . . . . . .

1C-14

1C-14 1C-15 1C-15 1C-15 1C-16 1C-17 1C-17 1C-17 1C-17 1C-18 1C-18 1C-18 1C-19 1C-19 1C-19 1C-19 1C-19 1C-19

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90-818177-3 APRIL 2001

Section 1C - Troubleshooting (continued)

Power Trim Hydraulic Schematic . . . . . . Auto Trim II Electrical System . . . . . . . . . Pump Motor Will Not Run UP Or DOWN In Either Manual Or Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Motor Will Not Stop Running Down In Auto Mode . . . . . . . . . . . . . . Pump Motor Will Not Run Up Or Down In Auto Mode . . . . . . . . . . . . . . Trim System Completely Inoperative In Manual Mode . . . . . . . . . . . . . . . . . Pump Motor Will Run UP, But Not Down In Both Manual And Auto Modes . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Motor Runs Down, But Not UP In Both The Manual And Auto Modes . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Motor Will Run Down, But Not UP In Auto Mode . . . . . . . . . . . . . Pump Motor Will Run UP, But Not DOWN In Auto Mode . . . . . . . . . . . . . Trim DOWN/IN Switch Inoperative In Manual Trim Control . . . . . . . . . . . . Trim UP/OUT Switch Inoperative In Manual Trim Control . . . . . . . . . . . . Trailer Switch In Manual, Trim Control Inoperative . . . . . . . . . . . . . . . Boat Is On Plane Well Before Drive Unit Begins To Trim Out . . . . . Boat Is Not On Plane Before Drive Unit Begins To Trim Out . . . . . 1C-20 1C-21 1C-21 1C-22 1C-22 1C-23 1C-23 1C-23 1C-24 1C-24 1C-24 1C-25 1C-25 1C-25 1C-25 Auto Trim II System Wiring Diagram . . . 1C-26 Corrosion Protection . . . . . . . . . . . . . . . . . 1C-26 Corrosion On Underwater Parts, Without MerCathode Or Impressed Current Protection . . . . . . . . . . . . . . . . . . . . . . . 1C-27 Corrosion On Underwater Parts, With MerCathode Or Impressed Current Protection . . . . . . . . . . . . . . . . 1C-28 Corrosion On Underwater Parts, With MerCathode Or Impressed Current Protection . . . . . . . . . . . . . . . . 1C-30 Testing Procedure for Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . 1C-31 MerCathode Controller . . . . . . . . . . . . 1C-32 Shift System Troubleshooting . . . . . . . . . 1C-33 Troubleshooting Shift Problems . . . . . 1C-34 Checking for Excessive Play . . . . . . . 1C-36 Isolating Excessive Play . . . . . . . . . . . 1C-40 Checking Remote Control Shift Cable Output . . . . . . . . . . . . . . . . . . . . 1C-42 Checking Cutout Switch Timing (Models With Roller Type Switch) . . 1C-43 Checking Cutout Switch Timing (Models With Plunger Type Switch) . 1C-45 Checking Operation . . . . . . . . . . . . . . . 1C-47

REMOVAL, INSTALLATION AND ADJUSTMENT

Section 2A - All Models
Sterndrive Unit Removal . . . . . . . . . . . . . Sterndrive Unit Installation . . . . . . . . . . . . Remote Control Shift Cable Adjustment (Drive Unit Installed) . . . . . . Troubleshooting Shift Problems . . . . . Propeller Installation . . . . . . . . . . . . . . Transom Assembly Removal . . . . . . . . . Power Steering Models . . . . . . . . . . . . Manual Steering Models . . . . . . . . . . . Transom Assembly Installation . . . . . . . . Power Steering Models . . . . . . . . . . . . Manual Steering Models . . . . . . . . . . . 2A-2 2A-6 2A-13 2A-22 2A-23 2A-25 2A-25 2A-26 2A-31 2A-36 2A-38

90-818177-3 APRIL 2001

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STERNDRIVE UNIT
Section 3A - Drive Shaft Housing
Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Upper Drive Shaft Bearing Preload . . U-joint Bearing Preload . . . . . . . . . . . . Gear Shimming Specifications . . . . . . Lubricants/Sealers/Adhesives . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Drive Shaft Housing Exploded Parts View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-joint and Driven Gear Components . . . . . . . . . . . . . . . . . . . . Drive Shaft Components . . . . . . . . . . . Special Information . . . . . . . . . . . . . . . . . . Top Cover Bearing Cup . . . . . . . . . . . . Universal Joint Bearing Set . . . . . . . . Drive Shaft Housing/Gear Housing . . . . Separation . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Housing and Component Disassembly . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Gear Ratio Identification . . Drive Shaft Housing Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 3A-2 3A-2 3A-2 3A-2 3A-3 3A-3 3A-4 3A-4 3A-6 3A-7 3A-7 3A-7 3A-7 3A-7 3A-9 3A-9 3A-15 U-joint Assembly - Inspection and Disassembly . . . . . . . . . . . . . . . . . . . . Oil Seal Carrier Subassembly . . . . . . Pinion Gear Subassembly . . . . . . . . . U-joint Subassembly . . . . . . . . . . . . . . U-joint Assembly . . . . . . . . . . . . . . . . . Top Cover Subassembly . . . . . . . . . . . Upper Driven Gear Subassembly . . . Drive Shaft Housing Reassembly . . . . . . Drive Shaft Housing Inspection . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Assembly and Checking Driven Gear Location . . . . . . . . . . . . . . . . . . . Adjusting Gear Location . . . . . . . . . . . Seal Installation . . . . . . . . . . . . . . . . . . Checking and Adjusting Drive Gear Location . . . . . . . . . . . . . . . . . . . Final Reassembly . . . . . . . . . . . . . . . . . . . Joining Drive Shaft Housing/Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 3A-17 3A-18 3A-21 3A-24 3A-26 3A-29 3A-33 3A-33 3A-33 3A-35 3A-38 3A-39 3A-43 3A-45 3A-47

Section 3B - Gear Housing Standard Rotation

Standard Rotation Gear Housing Specifications . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Shimming Specifications . . . . . . . . . . . Lubricants / Sealers / Adhesives . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Special Tools (continued) . . . . . . . . . . Standard Rotation Gear Housing Exploded Parts View . . . . . . . . . . . . . . . . Drive Shaft Components . . . . . . . . . . . Propeller Shaft Components . . . . . . . Special Information . . . . . . . . . . . . . . . . . . Shift Spool Assembly . . . . . . . . . . . . . Forward Gear Bearing Bore . . . . . . . . Pre-Disassembly Inspection . . . . . . . . . . Propeller . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . Drive Shaft Housing/Gear Housing . . . . Separation . . . . . . . . . . . . . . . . . . . . . . . Gear Housing and Component Disassembly . . . . . . . . . . . . . . . . . . . . . . . Water Pump Subassembly . . . . . . . . . Oil Seal Carrier Subassembly . . . . . . Bearing Carrier Subassembly . . . . . . Drive Shaft Assembly . . . . . . . . . . . . . Propeller Shaft Assembly and Forward Gear Bearing Cup . . . . . . . . Forward Gear Assembly . . . . . . . . . . . 3B-2 3B-2 3B-2 3B-2 3B-3 3B-4 3B-6 3B-6 3B-8 3B-10 3B-10 3B-11 3B-12 3B-12 3B-12 3B-13 3B-13 3B-15 3B-15 3B-18 3B-21 3B-34 3B-37 3B-41 Shift Spool Assembly . . . . . . . . . . . . . Propeller Shaft Assembly . . . . . . . . . . Shift Shaft Assembly . . . . . . . . . . . . . . Pinion Bearing . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly . . . . . . . . . . . Gear Housing Inspection . . . . . . . . . . Pinion Bearing . . . . . . . . . . . . . . . . . . . Forward Gear Bearing Cup . . . . . . . . Shift Shaft Assembly . . . . . . . . . . . . . . Propeller Shaft Assembly . . . . . . . . . . Drive Shaft and Pinion Gear . . . . . . . Drive Shaft - Bearing Preload Tool . . Pinion Gear Location . . . . . . . . . . . . . . Bearing Carrier Assembly . . . . . . . . . . Forward Gear Backlash . . . . . . . . . . . Reverse Gear Backlash . . . . . . . . . . . Forward and/or Reverse Gear Backlash Adjustment . . . . . . . . . . . . . Drive Shaft - Bearing Preload Tool . . Bearing Carrier Assembly . . . . . . . . . . . . Final Installation . . . . . . . . . . . . . . . . . . Oil Seal Carrier Assembly . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Pump Assembly . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Joining Drive Shaft Housing/Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-44 3B-45 3B-47 3B-50 3B-51 3B-51 3B-51 3B-52 3B-53 3B-55 3B-57 3B-60 3B-61 3B-62 3B-65 3B-67 3B-69 3B-69 3B-70 3B-70 3B-74 3B-74 3B-75 3B-75 3B-78

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90-818177-3 APRIL 2001

Section 3C - Gear Housing (Counter Rotation)

Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Shimming Specifications . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Special Tools (continued) . . . . . . . . . . Counter-Rotation Gear Housing Exploded Parts View . . . . . . . . . . . . . . . . Drive Shaft Components . . . . . . . . . . . Propeller Shaft Components . . . . . . . Special Information . . . . . . . . . . . . . . . . . . Shift Spool Assembly . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . Forward Gear Bearing Bore . . . . . . . . Bearing Carrier . . . . . . . . . . . . . . . . . . . Thrust Collar . . . . . . . . . . . . . . . . . . . . . Reverse Gear Bearing Adaptor . . . . . Forward Gear Bearing Adaptor . . . . . Pre-Disassembly Inspection . . . . . . . . . . Propeller . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . Drive Shaft Housing/Gear Housing . . . . Separation . . . . . . . . . . . . . . . . . . . . . . . Gear Housing and Component Disassembly . . . . . . . . . . . . . . . . . . . . . . . Water Pump Assembly . . . . . . . . . . . . Oil Seal Carrier Assembly . . . . . . . . . Bearing Carrier Assembly . . . . . . . . . . Forward Gear Bearing and Adaptor . Bearing Carrier Disassembly And Inspection . . . . . . . . . . . . . . . . . . . . . . . Bearing Carrier Reassembly . . . . . . . Forward Gear Bearing Adaptor Assembly . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Assembly . . . . . . . . . . . . . 3C-2 3C-2 3C-2 3C-2 3C-2 3C-4 3C-6 3C-6 3C-8 3C-10 3C-10 3C-10 3C-11 3C-11 3C-12 3C-12 3C-13 3C-14 3C-14 3C-14 3C-15 3C-15 3C-17 3C-17 3C-20 3C-23 3C-27 3C-35 3C-37 3C-39 3C-42 Propeller Shaft Assembly . . . . . . . . . . Reverse Gear Assembly . . . . . . . . . . . Shift Spool Assembly . . . . . . . . . . . . . Reverse Gear Bearing Adaptor Assembly . . . . . . . . . . . . . . . . . . . . . . . Shift Shaft Assembly . . . . . . . . . . . . . . Pinion Bearing . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly . . . . . . . . . . . Gear Housing Inspection . . . . . . . . . . Pinion Bearing Installation . . . . . . . . . Shift Shaft Assembly Installation . . . . Reverse Gear Bearing Adaptor Assembly Installation . . . . . . . . . . . . . Gear Location/Backlashes Checking and Adjustment . . . . . . . . . . . . . . . . . . . . . Reverse Gear . . . . . . . . . . . . . . . . . . . . Drive Shaft and Pinion Gear . . . . . . . Drive Shaft - Bearing Preload Tool . . Pinion Gear Location . . . . . . . . . . . . . . Reverse Gear Backlash . . . . . . . . . . . Forward Gear Backlash . . . . . . . . . . . Drive Shaft - Bearing Preload Tool . . Propeller Shaft Assembly . . . . . . . . . . . . . Component Reassembly . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft and Pinion Gear . . . . . . . . . . Final Installation . . . . . . . . . . . . . . . . . . Bearing Carrier Assembly . . . . . . . . . . . . Final Installation . . . . . . . . . . . . . . . . . . Oil Seal Carrier Assembly . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Water Pump Assembly . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Joining Drive Shaft Housing/Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47 3C-52 3C-54 3C-56 3C-58 3C-60 3C-62 3C-62 3C-62 3C-63 3C-65 3C-69 3C-69 3C-71 3C-74 3C-76 3C-78 3C-80 3C-88 3C-88 3C-88 3C-91 3C-95 3C-95 3C-98 3C-98 3C-110 3C-110 3C-111 3C-111 3C-114

TRANSOM ASSEMBLY
Section 4A - Service Procedures Requiring Minor Disassembly
Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Special Information . . . . . . . . . . . . . . . . . . Trim Limit Switch . . . . . . . . . . . . . . . . . Trim Position Sender . . . . . . . . . . . . . . Trim Limit Switch and Trim Position Sender . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Trim Position Sender Adjustment . . . Trim Limit Switch Adjustment . . . . . . . Gimbal Bearing . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 4A-2 4A-2 4A-2 4A-2 4A-3 4A-3 4A-3 4A-4 4A-4 4A-7 4A-12 4A-13 4A-15 4A-15 4A-15 4A-17 Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . 4A-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4A-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4A-22 Installation . . . . . . . . . . . . . . . . . . . . . . . 4A-23 Remote Control Shift Cable Adjustment (Drive Unit Installed) . . . . . . . . . . . . . . 4A-28 Exhaust Bellows . . . . . . . . . . . . . . . . . . . . 4A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . 4A-38 Cleaning And Inspection . . . . . . . . . . . 4A-39 Installation . . . . . . . . . . . . . . . . . . . . . . . 4A-39 Gear Lube Monitor Kit System Components - Replacement . . 4A-42 Monitor To Thru-Bulkhead Fitting Hose: . . . . . . . . . . . . . . . . . . . . . 4A-42 Thru-bulkhead To Bell Housing Gear Lube Monitor Hose . . . . . . . . . . 4A-46 Bell Housing To Driveshaft Housing Anti-Dribble Valves . . . . . . . 4A-48 Crimp Clamp Tool . . . . . . . . . . . . . . . . . . . 4A-50

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Section 4B - Service Procedures Requiring Major Disassembly

Transom Assembly Specifications . . . . . Torque Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Lubricants / Sealers / Adhesives . . . . Special Information . . . . . . . . . . . . . . . . . . Trim Limit Switch . . . . . . . . . . . . . . . . . Trim Position Sender . . . . . . . . . . . . . . Shift Cable . . . . . . . . . . . . . . . . . . . . . . . Gear Lube Monitor Kit Access Plug Locations . . . . . . . . . . . . . . . . . . . Alpha One Transom Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . Bell Housing Components . . . . . . . . . Gimbal Housing Components . . . . . . Inner Transom Plate Components . . Gimbal Ring and Steering Lever Components . . . . . . . . . . . . . . . . . . . . Component Disassembly . . . . . . . . . . . . . Bell Housing Removal . . . . . . . . . . . . . Trim Position Sender and Trim Limit Switch Wire Removal . . . . . . . . Gimbal Ring, Swivel Shaft and Steering Lever Removal . . . . . . . . . . Gimbal Housing Servicing . . . . . . . . . . . . U-Joint Bellows Removal . . . . . . . . . . 4B-2 4B-2 4B-2 4B-3 4B-4 4B-4 4B-4 4B-4 4B-5 4B-7 4B-7 4B-9 4B-11 4B-13 4B-15 4B-15 4B-21 4B-21 4B-28 4B-28 Shift Cable Bellows Removal . . . . . . . Bushings And Upper Seal Removal . Component Servicing . . . . . . . . . . . . . . . . Bell Housing Disassembly . . . . . . . . . Bell Housing Reassembly . . . . . . . . . . Gasket And O-Ring . . . . . . . . . . . . . . . Speedometer Tubing And Water Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . Gimbal Ring Bushing Installation . . . Oil Seal Installation . . . . . . . . . . . . . . . Exhaust Bellows Installation . . . . . . . . Trim Position Sender and Trim Limit Switch Wire Installation . . . . . . . . . . . Gimbal Ring, Swivel Shaft and Steering Lever Installation . . . . . . . . . Shift Cable Bellows Installation . . . . . Bell Housing Installation . . . . . . . . . . . Trim Limit Switch Installation . . . . . . . Trim Position Sender Installation . . . . ALPHA ONE (GENERATION II) ACCESS PLUG . . . . . . . . . . . . . . . . . . DRILLING TEMPLATE . . . . . . . . . 4B-29 4B-30 4B-32 4B-32 4B-37 4B-41 4B-42 4B-45 4B-45 4B-47 4B-49 4B-50 4B-51 4B-59 4B-61 4B-69 4B-70 4B-71 4B-71

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90-818177-3 APRIL 2001

POWER TRIM
Section 5A - Olidyne Trim Pump
Trim Pump Specifications . . . . . . . . . . . . Valve Pressure Specifications . . . . . . Electrical Specification . . . . . . . . . . . . Torque Specification . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Lubricants/Adhesives/Sealers . . . . . . Trim Pump Exploded View . . . . . . . . . . . . Oildyne Trim Pump . . . . . . . . . . . . . . . Maintaining Power Trim Pump Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Bleeding Power Trim System . . . . . . Bleeding OUT/UP Trim Circuit . . . . . . Bleeding IN/DOWN Trim Circuit . . . . Testing Power Trim Pump . . . . . . . . . . . . Test Gauge . . . . . . . . . . . . . . . . . . . . . . Internal Restriction Test . . . . . . . . . . . OUT/UP Pressure Test . . . . . . . . . . . . IN/DOWN Pressure Test . . . . . . . . . . . Trim Pump Hydraulic System . . . . . . . Trim Cylinder Internal Leak Test . . . . . . . Trim Cylinder Shock Piston Test . . . . Motor and Electrical Bench Tests . . . . . . 110 Amp Fuse Test (Pump in Boat) . 110 Amp Fuse Test (Pump Out of Boat) . . . . . . . . . . . . . . . 20 Amp Fuse Test . . . . . . . . . . . . . . . . Trim Pump Motor Test (In Boat) . . . . Trim Pump Motor Test (Out of Boat) . . . . . . . . . . . . . . . . . . . . Solenoid Test (Pump In Boat) . . . . . . Solenoid Test (Pump Out of Boat) . . . 5A-2 5A-2 5A-2 5A-2 5A-2 5A-2 5A-4 5A-4 5A-6 5A-7 5A-7 5A-8 5A-9 5A-9 5A-10 5A-10 5A-12 5A-13 5A-14 5A-15 5A-16 5A-16 5A-17 5A-17 5A-18 5A-20 5A-22 5A-24 Trim Pump Removal . . . . . . . . . . . . . . . . . Hydraulic Repair . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Filter Replacement . . . . . . . . . . . . . . . . UP Pressure Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . DOWN Pressure Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . Thermal Relief Valve Replacement . . Pump Replacement . . . . . . . . . . . . . . . Adapter Replacement . . . . . . . . . . . . . Adapter Repair . . . . . . . . . . . . . . . . . . . Pump Shaft Oil Seal Replacement . . Motor Repair . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Armature Tests . . . . . . . . . . . . . . . . . . . . . . Continuity Test . . . . . . . . . . . . . . . . . . . Test for Shorts . . . . . . . . . . . . . . . . . . . Cleaning Commutator . . . . . . . . . . . . . Field Tests . . . . . . . . . . . . . . . . . . . . . . . . . Test for Open Circuit . . . . . . . . . . . . . . Test for Short in Field . . . . . . . . . . . . . Thermal Switch Continuity Test . . . . . Brush Replacement . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . Trim Pump Installation . . . . . . . . . . . . . . . Trim Pump Wiring Diagrams . . . . . . . . . . Model With Three-Button Trim/Trailer Panel . . . . . . . . . . . . . . . . Model With Trim In Handle and Trailer Switch Separate . . . . . . . . . . . 5A-25 5A-27 5A-27 5A-29 5A-30 5A-32 5A-34 5A-34 5A-36 5A-38 5A-41 5A-43 5A-43 5A-46 5A-46 5A-47 5A-47 5A-47 5A-47 5A-48 5A-49 5A-50 5A-53 5A-59 5A-60 5A-60 5A-61

Section 5B - Trim Cylinders

Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . Trim Cylinder Repair . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 5B-2 5B-2 5B-2 5B-2 5B-3 5B-3 5B-5 5B-9 5B-15

Section 5C - Dual Power Trim System

Important Information . . . . . . . . . . . . . . . . Testing Dual Power Trim System . . . . . . Relay Test . . . . . . . . . . . . . . . . . . . . . . . Diode Module Test . . . . . . . . . . . . . . . . Trailer Switch Test . . . . . . . . . . . . . . . . Starboard Trim Switch Test . . . . . . . . Port Trim Switch Test . . . . . . . . . . . . . . Dual Power Trim System Component Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . Relay Replacement . . . . . . . . . . . . . . . 5C-2 5C-2 5C-3 5C-3 5C-4 5C-4 5C-4 5C-5 5C-5 5C-5 Diode Module Replacement . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Trim Control Panel Switch(es) Replacement . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagrams . . . . . . . . . . . . . . . . . . . . Dual Trim Harnesses . . . . . . . . . . . . . . Electrical Box Wiring . . . . . . . . . . . . . . 5C-7 5C-7 5C-7 5C-8 5C-8 5C-9 5C-10 5C-10 5C-11

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Section 5D - Auto Trim II

Auto Trim II System . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . Auto Trim II Operation . . . . . . . . . . . . . . . Auto Mode Operation . . . . . . . . . . . . . Manual Mode Operation . . . . . . . . . . Electrical System Overload Protection . 5D-2 5D-2 5D-2 5D-3 5D-4 5D-6 Auto Trim Limit Adjustment . . . . . . . . . . . Adjusting Sterndrive Unit Trim Angle Control Module Adjustment . . . . . . . . . . . Trim Position Indicator Adjustment . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 5D-6 5D-7 5D-9 5D-10 5D-11

STEERING SYSTEMS
Section 6A - Power Steering
Trim Pump Specifications . . . . . . . . . . . . Valve Pressure Specifications . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Lubricants/Adhesives/Sealers . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . Earlier Style Control Valve . . . . . . . . . Later Style Control Valve . . . . . . . . . . Earlier Model Power Steering System . . Right Turn . . . . . . . . . . . . . . . . . . . . . . . Earlier Model Power Steering System . . Left Turn . . . . . . . . . . . . . . . . . . . . . . . . Earlier Model Power Steering System . . Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . Later Model Power Steering System . . . Right Turn . . . . . . . . . . . . . . . . . . . . . . . Later Model Power Steering System . . . Left Turn . . . . . . . . . . . . . . . . . . . . . . . . Later Model Power Steering System . . . Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Helm and Cable . . . . . . . . . . . . . Steering Cable Specifications . . . . . . Filling and Air Bleeding Power Steering System . . . . . . . . . . . . . . . . . . . . Balancing Power Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Cable Selection, Removal and Installation . . . . . . . . . . . . . . . . . . . . . 5A-2 5A-2 6A-2 6A-2 6A-2 6A-3 6A-3 6A-3 6A-4 6A-4 6A-5 6A-5 6A-6 6A-6 6A-7 6A-7 6A-8 6A-8 6A-9 6A-9 6A-10 6A-11 6A-12 6A-13 6A-17 Selection . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Lugging Test . Power Steering System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Pressure Test . . . . . . . . . . . . . . Booster Cylinder Test . . . . . . . . . . . . . Power Steering Component Repair . . . . Power Steering Unit . . . . . . . . . . . . . . . Cable Guide Tube (Early Style Only) Control Valve (Early Style Only) . . . . Booster Cylinder (Early Style Only) . Power Steering Pump . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Flow Control Valve Servicing . . . . . . . Pump Shaft Oil Seal Replacement . . Disassembly . . . . . . . . . . . . . . . . . . . . . Cleaning And Inspection . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Multiple Sterndrive Steering Tie Bar Arrangements . . . . . . . . . . . . . . . . . . . Determining Tie Bar Length . . . . . . . . Selection . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-17 6A-18 6A-18 6A-20 6A-21 6A-23 6A-25 6A-27 6A-29 6A-29 6A-33 6A-37 6A-50 6A-55 6A-55 6A-55 6A-56 6A-58 6A-61 6A-61 6A-67 6A-67 6A-68 6A-69

Section 6B - Manual Steering

Specifications . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . Steering Cable Selection, Removal and Installation . . . . . . . . . . . . . . . . . . . . . Selection . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-2 6B-2 6B-2 6B-2 6B-2 6B-4 6B-4 Manual Steering Swivel Ring Component Repair . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . 6B-6 6B-6 6B-7 6B-7 6B-9

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CORROSION PROTECTION
Section 7A - All Models
Specifications . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives . . . . . . Continuity Circuit . . . . . . . . . . . . . . . . . . . . Anodic Block . . . . . . . . . . . . . . . . . . . . . . . Trim Cylinder Anodes . . . . . . . . . . . . . . . . Anodic Trim Tab or Plate . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . Integral MerCathode System . . . . . . . . . . Removing Electrode Assembly . . . . . Installing Electrode Assembly . . . . . . . . . Connect Electrical Leads to Controller Assembly . . . . . . . . . . . . . . 7A-2 7A-2 7A-2 7A-2 7A-5 7A-9 7A-10 7A-10 7A-12 7A-12 7A-13 7A-17 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . MerCathode Monitor . . . . . . . . . . . . . . MerCathode Controller . . . . . . . . . . . . Quicksilver Isolator . . . . . . . . . . . . . . . . . . Corrosion Protection Testing and Troubleshooting . . . . . . . . . . . . . . . . . . . . Test Equipment Set-Up . . . . . . . . . . . . Low Readings . . . . . . . . . . . . . . . . . . . . Low Readings (continued) . . . . . . . . . High Reading . . . . . . . . . . . . . . . . . . . . Normal Reading But Corrosion is Evident . . . . . . . . . . . . . . . . . . . . . . . . . 7A-18 7A-18 7A-19 7A-20 7A-20 7A-23 7A-24 7A-25 7A-26 7A-26

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