TRANSOM ASSEMBLY. Table of Contents. Section 4B - Service Procedures Requiring Major Disassembly

Transcription

1 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY TRANSOM ASSEMBLY Setion 4B - Servie Proedures Requiring Mjor Disssemly Tle of Contents Brvo Trnsom Assemly Speifitions. 4B-2 Torque Speifitions B-2 Lurints/Selers/Adhesives B-2 Speil Tools B-2 Brvo Trnsom Assemly Exploded Views B-4 Inner Trnsom Plte Components.... 4B-4 Bell Housing Components B-5 Giml Ring Components B-6 Giml Housing Components B-8 Bell Housing Removl B-10 Aess Plug Kit Instlltion B-15 Giml Ring, Swivel Shft nd Steering Lever Removl B-17 Giml Ring Serviing B-20 Giml Housing Serviing B-26 U-joint Bellows Replement B-26 Shift Cle Bellows Replement.... 4B-28 Exhust Bellows Replement B-32 Speedometer Hose Replement.... 4B-34 Ger Lue Monitor System Components B-36 Trim Position Sender nd Trim Limit Swith Wire Replement B-39 Giml Ring/Swivel Shft/nd Steering Lever Instlltion B-40 Bell Housing Instlltion B-46 Shift Cle Instlltion B-52 Brvo Aess Plug Drilling Templte.... 4B-56 4 B MARCH 1998 Pge 4B-1

2 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Brvo Trnsom Assemly Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Shift Cle Core Wire Anhor Srews Bellows Hose Clmps 35 4 Hinge Pins Through Bolt Loknut Pivot Bolt U-Bolt Nuts Bellows Clmps Sterndrive Atthing Nut Hose-Br Compression Fitting Fitting Nut Lurints/Selers/Adhesives Speil Tools DESCRIPTION PART NUMBER 3M Brnd Adhesive Liquid Neoprene Resiweld Seler Lotite Quiksilver 2-4-C Mrine Lurint with Teflon A12 DESCRIPTION PART NUMBER Bering Removl nd Instlltion Tool A7 Bellows Expnder Tool A1 Slide Hmmer Puller A1 Tpered Insert Tool Core Wire Loting Shift Cle Anhor Adjustment Tool Sleeve Removl Tool (U-joint Bellows) Sleeve Instlltion Tool (U-joint Bellows) Hinge Pin Puller (High Performne Trnsom Assemly) Pge 4B MARCH 1998

3 SERVICE MANUAL NUMBER 11 THIS PAGE IS INTENTIONALLY BLANK SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY MARCH 1998 Pge 4B-3

4 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Brvo Trnsom Assemly Exploded Views Inner Trnsom Plte Components Trnsom Plte Assemly 2 - Pivot Bolts 3 - T Wshers 4 - Srew Engine Mounting 5 - Wsher 6 - Sper 7 - Wsher - Fier 8 - Lokwsher - Doule Wound 9 - Loknut 10- Wsher 11- Loknut 12- Shift Cle Csing 13- Core Wire Anhor 14- Anhor Srews (2) 15- End Guide 16- Pilot Bushing - Giml Housing 17- Core Wire Torque Speifitions 25 l. ft. (34 N m) 23 l. ft. (30 N m) 37 l. ft. (50 N m) Pge 4B MARCH 1998

5 SERVICE MANUAL NUMBER 11 Bell Housing Components SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY A D A B C A Bell Housing 2 - Stud 3 - Wsher 4 - Loknut 5 - O-ring 6 - Ger Lue Vlve 7 - O-rings 8 - Hinge Pin Wsher 9 - Bellows Clmp 10- U-Joint Bellows 11- Grounding Clip Lurints/Selers/Adhesives 12- Sleeve 13- Bellows Clmp 14- Exhust Bellows 15- Exhust Tue (Some Models) 16- Speedometer Hose 17- Hose Clmp 18- Byonet Fitting 19- Bushing (High Performne Trnsom) 20- Indenttions in Lter Style Bell Housing (Must Be Used With Trim-In Limit Pins) A - 3M Brnd Adhesive B - Lotite C - Quiksilver High Performne Ger Lue A4 D - Quiksilver Perfet Sel Torque Speifitions Tighten Seurely -Approximtely 35 l. in. (4 N m) 50 l. ft. (68 N m) MARCH 1998 Pge 4B-5

6 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Giml Ring Components d B A Giml Ring 2 - Bushing 3 - Bushing 4 - Wsher 5 - Hinge Pin 6 - Srew 7 - Trim Position Sender 8 - Clip 9 - Wsher 10- Srew 11- Clip 12- U-Bolt 13- Plte 14- Loknuts 15- Swivel Shft 16- Steering Lever 17- Wsher (Smller I.D.) 18- Wsher (Lrger I.D.) 19- Clmp Srew 20- Nut 21- Wire Retiner 22- Trim Wire Clmp 23- Srew 24- Hinge Pin (High Performne Trnsom Only) 25- Srews (High Performne Trnsom Only) 26- Stndrd Giml Ring Identifition. (Two Ris) 27- Mgnum nd High Performne Giml Ring Identifition. (Filled Are) Pge 4B MARCH 1998

7 SERVICE MANUAL NUMBER 11 Lurints/Selers/Adhesives SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY A - Resiweld Seler B - Quiksilver 2-4-C Mrine Lurint with Teflon A12 Torque Speifitions l. ft. (67-74 N m) 150 l. ft. (203 N m) l. ft. (61-74 N m) d l. in. (10-11 N m) MARCH 1998 Pge 4B-7

8 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Giml Housing Components A E d B C A B B Giml Housing 2 - Stud 3 - Lower Bushing 4 - Sel 5 - Upper Bushing 6 - Clmp 7 - Ger Lue Hose 8 - Swivel Fitting 9 - Loknut 10- Wsher 11- O-ring 12- Ger Lue Fitting 13- Sel 14- Giml Bering 15- Tolerne Ring 16- Crimp Clmp 17- Shift Cle Bellows 18- Bellows Clmp 19- Wsher 20- Lower Swivel Pin 21- Cotter Pin 22- Stud 23- Gsket 24- Hydruli Mnifold 25- Lokwsher 26- Loknut 27- Exhust Pssge O-ring 28- Wter Hose Insert 29- Wter Hose 30- Wter Fitting Gsket 31- Wter Fitting 32- Lokwsher 33- Srew 34- Giml Housing Sel 35- Wter Bypss Fitting (Some Diesel Models) 36- Pipe Plug (or Speedometer Fitting - Lter Style) 37- Pipe Plug (or Speedometer Fitting - Erlier Style) 38- Wsher Pge 4B MARCH 1998

9 SERVICE MANUAL NUMBER 11 Lurints, Selers, nd Adhesives SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY A - Lotite B - 3M Brnd Adhesive C - Quiksilver U-Joint nd Giml Bering Grese A2 D - Super Glue Otin Lolly E - Perfet Sel Torque Speifitions Tighten Seurely - Approximtely 35 l. in. (4 N m) 12 l. ft. (16 N m) 80 l. in. (9 N m) d 25 l. ft. (34 N m) MARCH 1998 Pge 4B-9

10 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Bell Housing Removl NOTE: If drive shft housing is equipped with Trim-In Limit Pins, the ell housing shown in the following illustrtion must e used. There re two indenttions in the top ft edge of the ell housing. These indenttions help prevent srthing of the top side of the ell housing y the giml ring U-olt, when the trim-in limit pin is positioned in the ft position (Refer to Se. 5B for Trim-In Limit Pin Informtion.) - Indenttions Remove sterndrive unit (refer to Setion 2A). 2. Remove shift le from ell housing.. Disonnet shift le end guide from shift rket nd remove end guide. - End Guide - Anhor Srews - Loosen Models with erlier style shift le - (identified y smll nut whih will not pss over le nhor - ore wire must e pulled from shift le to remove le ssemly from ell housing).. Remove threded tue. - Jm Nut - Loosen - Threded Tue - Turn Out Pge 4B MARCH 1998

11 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY. Remove support tue from ore wire. Do not ut ore wire, unless solutely neessry Support Tue - Remove Crimp - Remove - Disrd (not needed) - Core Wire - Cut Here, If Asolutely Neessry. Remove inner ore wire. - Core Wire - Pull Out d. Remove shift le retining nut. Hold inside nut with wrenh. - Shift Cle Retining Nut - Inside Nut MARCH 1998 Pge 4B-11

12 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Models with lter style shift le - identified y lrger nut whih fits over ore wire nhor; it is unneessry to remove ore wire to remove shift le ssemly Remove shift le retining nut nd wsher. Hold inside nut with wrenh. - Lrger Shift Cle Retining Nut - Inside Nut - Wsher Remove wter hose insert from I.D. of wter hose nd remove wter hose from ell housing. d - Bell Housing - Tpered Insert - Turn Counterlokwise - Tpered Insert Tool ( ) d - Wter Hose Models with Ger Lue Monitor - remove Ger Lue Monitor 90 hose r fitting, nd nut nd wsher from thru-ulkhed fitting, so tht fitting will pull out of giml housing upon removl of ell housing Br Fitting - Nut nd Wsher - Thru-Bulkhed Fitting Pge 4B MARCH 1998

13 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 6. Spry engine lener round edge of ellows sleeve nd remove with U-joint ellows sleeve removl tool P/N Bell Housing - U-Bellows Sleeve Removl Tool ( ) Remove exhust ellows from ell housing. - Exhust Bellows - Hose Clmps - Loosen Remove speedometer tuing lip from ell housing. - Bell Housing - Speedometer Tuing Clip - Remove MARCH 1998 Pge 4B-13

14 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER On Stndrd Trnsom Assemly - Remove hinge pins. - Bell Housing - Hinge Pins - Remove (Port nd Strord) On High Performne Trnsom Assemly - Remove hinge pins using speil tool ( ) nd slide hmmer s follows:. Thred speil tool into hinge pin. - Slide Hmmer - Speil Tool Remove hinge pins Hinge Pin Pge 4B MARCH 1998

15 SERVICE MANUAL NUMBER 11 Aess Plug Kit Instlltion SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY NOTE: If steering lever vity is not essile, it will e neessry to drill ess holes in giml housing. This proedure requires the following: Aess Plug Kit A-1 1-1/8 in. Hole Sw (otin lolly) 1 in. NPT Pipe Tp (otin lolly) IMPORTANT: Do not use the templtes whih ome with ess plug kit. These templtes will not work on this drive unit giml housing Erlier Models - lurite upper swivel shft with lierl mount of 2-4-C Mrine Lurint with Teflon. This will help to prevent metl hips from getting into erings when utting holes, following. - Swivel Shft Grese Fitting (Erly Models only) Use templte t the end of this setion s guide for the orret lotion for utting nd drilling ess holes. Align templte with dimple loted eneth del on the giml housing. - Dimple (Beneth del) - Templte MARCH 1998 Pge 4B-15

16 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 CAUTION Be sure to drill nd ut hole nd tp threds perpendiulr to giml housing surfes in the following steps. 3. Drill pilot holes (port nd strord) using drill tht is the sme size s the pilot rod eing supplied with the hole sw (pproximtely 1/4 in.) (6mm) Cut holes in giml housing (port nd strord) using 1-1/8 in. hole sw nd pilot rod. Remove metl hips with ompressed ir. - Hole Sw Mrk 1 in. pipe tp with piee of tpe, 1-1/8 in. (28mm) from end of tp. Cut threds in ess holes. Stop utting when the edge of the tpe rehes the giml housing. Cot pipe tp with grese to id in piking up metl hips Pge 4B MARCH 1998

17 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY Giml Ring, Swivel Shft nd Steering Lever Removl 1. Loosen srews nd nuts (not neessry to remove). d - Srews (2) - Nuts (2) - Wshers (4) d - Giml Ring Loosen steering lever lmping olt nd nut. Engine nd trnsom ssemly instlled. - Wrenh - Soket Wrenh Engine nd trnsom ssemly removed. - Wrenh - Wrenh MARCH 1998 Pge 4B-17

18 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Remove loknut. Engine And Trnsom Assemly Instlled - Pin Punh Engine And Trnsom Assemly Removed - Loknut - 1-1/16 in. Wrenh Disonnet trim ylinders from giml ring (if not lredy done). Suspend ylinders to void dmge to hoses. d e e f g h - Anhor Pin (1) - Slots (2) - Flt Wsher (Lrge I.D.) (2) d - Snp Rings (2) e - Ruer Bushings (4) f - Flt Wsher (Smll I.D.) (2) g - Loknut (2) h - Plsti Cp (2) Pge 4B MARCH 1998

19 SERVICE MANUAL NUMBER Disonnet ontinuity wire. SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY - Continuity Wire 6. Remove otter pin, lower swivel pin nd wsher Cotter Pin - Lower Swivel Pin - Wsher Remove upper swivel shft from giml ring, lrge I.D. wsher, steering lever, smll I.D. wsher, nd loknut. - Upper Swivel Shft - Giml Ring f e d - Wsher d - Steering Lever e - Smll I.D. Wsher f - Loknut MARCH 1998 Pge 4B-19

20 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 IMPORTANT: If swivel shft is seized, remove shft using slide hmmer puller ( A1) nd puller hed ( ). Bell housing nd ellows must e removed. - Swivel Shft - Puller Hed - Slide Hmmer Giml Ring Serviing 8. Remove giml ring GIMBAL RING IDENTIFICATION The giml ring used on vrious model trnsom ssemlies n e identified s shown in the following illustrtion: - Stndrd Giml Ring Identifition. (Two Ris) - Mgnum nd High Performne Giml Ring Identifition. (Filled Are) Pge 4B MARCH 1998

21 SERVICE MANUAL NUMBER 11 REMOVING BUSHINGS SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY CAUTION Be reful not to dmge ores when removing self-luriting ushings in the following steps. 1. Tp out nd remove giml ring lower swivel pin ushing using suitle mndrel. - Suitle Mndrel Remove giml ring hinge pin ushings (port nd strord) using suitle mndrel. - Suitle Mndrel - Tp Out Hinge Pin Bushings Remove oil sel nd lrge ushing from giml housing using two-jw puller nd slide hmmer ssemly. - Two Jw Puller - Slide Hmmer Assemly MARCH 1998 Pge 4B-21

22 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Remove smll ushing from giml housing using ushing removl tool. (Snp On Tool Compny P/N CG40CB) Bushing Removl Tool (Snp On Tool Compny P/N CG40CB) INSTALL BUSHINGS 1. Instll giml ring hinge pin ushings s follows:. Instll hinge pin into ering nd sel driver (P/N A1) Hinge Pin - Del Driver. Apply Resiweld Seler ( ) to O.D. of hinge pin ushing nd position ushing on ering nd sel driver. - Hinge Pin Bushing - Bering nd Sel Driver Pge 4B MARCH 1998

23 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY. Inspet ore for lenliness nd dmge efore instlling ushing. d. Instll ushing in eh side of giml ring y pressing in ple. - Giml Ring Instll giml ring lower swivel pin ushing s follows:. Apply Resiweld Seler ( ) to O.D. of ushing nd position ushing on ering nd sel driver. - O.D. of Bushing - Bering nd Sel Driver Inspet ore for lenliness nd dmge efore instlling ushing.. Instll ushing in giml ring y pressing or tpping in ple with hmmer. NOTE: Pressing is preferred. - Bushing MARCH 1998 Pge 4B-23

24 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Instll upper swivel shft smll ushing s follows:. Ple ushing on ering nd sel driver. - Bushing - Bering nd Sel Driver Instll ushing y tpping it in ple with hmmer. - Hmmer 4. Instll upper swivel shft lrge ushing s follows:. Ple ushing on ering nd sel driver Bushing - Bering nd Sel Driver Pge 4B MARCH 1998

25 SERVICE MANUAL NUMBER 11. Instll ushing y tpping it in ple with hmmer. SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY - Hmmer Instll upper swivel shft grese sel s follows:. Ple sel on ering nd sel driver with lip fing the smll dimeter end of tool. Apply Lotite to O.D. of sel. - Sel - Bering nd Sel Driver Instll grese sel y tpping it in ple with hmmer. - Hmmer MARCH 1998 Pge 4B-25

26 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Giml Housing Serviing U-joint Bellows Replement 1. Remove U-joint ellows from giml housing. - U-joint Bellows - Hose Clmp 2. If reusing ellows, remove old dhesive from U-joint ellows using lquer thinner U-joint Bellows Clen ellows mounting flnge on giml housing with sndpper nd wipe len with lquer thinner. - Mounting Flnge Pge 4B MARCH 1998

27 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY WARNING Be sure to red nd follow pkge lel diretion when using ellows dhesive. 4. Apply ellows dhesive to inside dimeter of ellows end tht will e tthed to giml housing. (Bellows dhesive IS NOT needed on the other end tht onnets to the ell housing.) Allow to dry (pproximtely 10 minutes), efore instlling. - Inside Dimeter of Bellows End IMPORTANT: TOP mrk on U-joint ellows must e fing upwrd when instlling ellows. IMPORTANT: Ensure tht the ed on the inner mting surfe of ellows is positioned in the groove in giml housing flnge. - Top Mrk - Bed CAUTION Bellows lmp my orrode if ground lip is not instlled Position ground lip on ellows. - Grounding Clip MARCH 1998 Pge 4B-27

28 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Position U-joint ellows with Top mrk fing upwrds nd instll U-joint ellows on giml housing flnge nd position lmp s shown. Torque to l. in. ( N m). - U-joint Bellows - Hose Clmp - Torque to l. in. ( N m) Shift Cle Bellows Replement 1. Remove shift le.. Disonnet shift le from shift plte nd remove end guide Anhor Srews (2) - Loosen - End Guide Model with erlier style shift le - is identified y smll nut whih will not pss over le nhor. Core wire must e pulled from shift le to remove le ssemly from ell housing.. Remove threded tue. - Jm Nut - Loosen - Threded Tue Remove support tue nd disrd from ore wire. Do not ut ore wire, unless solutely neessry. - Support Tue - Core Wire - Cut Here, If Asolutely Neessry Pge 4B MARCH 1998

29 SERVICE MANUAL NUMBER 11. Remove inner ore wire. SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY - Core Wire - Pull Out d. Remove shift le retining nut. Hold inside nut with wrenh. - Shift Cle Retining Nut - Inside Nut Model with lter style shift le - is identified y lrger nut whih fits over ore wire nhor. It is unneessry to remove ore wire to remove shift le ssemly. Remove shift le retining nut nd wsher. Hold inside nut with wrenh. - Shift Cle Retining Nut - Inside Nut - Wsher MARCH 1998 Pge 4B-29

30 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Remove shift le wrpping. - Shift Cle Wrpping Loosen shift le ellows rimp lmp, nd pull shift le, through shift le ellows. - Crimp Clmp - Shift Cle - Shift Cle Bellows Remove shift le ellows from giml housing. - Shift Cle Bellow - Hose Clmp Pge 4B MARCH 1998

31 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 7. Remove old dhesive from shift le ellows mounting surfe using lquer thinner. - Shift Cle Bellows Mounting Surfe Clen shift le ellows mounting flnge on giml housing with sndpper nd wipe len with lquer thinner. - Mounting Flnge WARNING Red nd follow pkge lel diretions efore using ellows dhesive Apply ellows dhesive to shift le ellows mounting surfe. Allow to dry (pproximtely 10 minutes), efore instlling. - Bellows Mounting Surfe Instll shift le ellows on giml housing flnge. Position hose lmp s shown. Torque to l. in. ( N m). - Shift Cle Bellows - Hose Clmp MARCH 1998 Pge 4B-31

32 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Exhust Bellows Replement NOTE: (For Exhust Tue Replement, see Setion 4A) 1. Remove exhust ellows from giml housing. - Exhust Bellows - Hose Clmp If old exhust ellows will e reinstlled, remove old dhesive from exhust ellows mounting surfes, using lquer thinner. - Mounting Surfe Clen exhust ellows mounting flnge with sndpper nd wipe len with lquer thinner. - Mounting Flnge Pge 4B MARCH 1998

33 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY WARNING Be sure to red nd follow pkge lel diretions when using ellows dhesive. 4. Position grounding lips on ellows. Use ellows P/N 18654, only. Do not sustitute erlier model ellows Apply Bellows Adhesive - Grounding Clips - Prt Numer - ll replement ellows should e P/N Do not use erlier model ellows. 5. Apply ellows dhesive to exhust ellows mounting surfe. Allow to dry (pproximtely 10 minutes), efore instlling. - Mounting Surfe Instll exhust ellows on giml housing flnge. Position hose lmp s shown. Torque to l. in. ( N m). - Exhust Bellows - Hose Clmp MARCH 1998 Pge 4B-33

34 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Speedometer Hose Replement 1. Remove hose lmp, if present, nd remove outer speedometer hose from red fitting, y heting (low het-hot wter), nd pulling off Speedometer Hose Lotion 2. Remove hose from dptor fitting y heting (low het-hot wter), nd pulling off. - Hose - Adptor Fitting Remove inner speedometer hose from red fitting y removing hose lmp nd pulling hose off. - Hose Clmp Pge 4B MARCH 1998

35 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 4. Instll inner speedometer hose on red fitting. Seure with hose lmp. Torque to l. in. ( N m). - Hose Clmp Instll outer speedometer hose on red fitting.. Het end of hose with low het (hot wter).. Slip hose with hose lmp, over red fitting. As the hose ools, it will eome tight on red fitting. Tighten hose lmp, seurely. 6. Instll dptor fitting on speedometer hose.. Het end of hose using low het. (Dip in hot wter). Slip hose over dptor fitting. As the hose ools, it will eome tight on dptor fitting. - End of Hose - Adptor Fitting Ger Lue Monitor System Components MONITOR TO THRU-BULKHEAD FITTING HOSE Chek hose periodilly for ondition, inluding rks, hrdening, et.; reple s neessry. 1. To reple hose, remove hose lmps, nd remove hose. 2. Instll new hose of suffiient length to llow Monitor to e removed from topside or ottom side of rket. Seure hose with hose lmps. 3. If thru-ulkhed fitting ws tken out to remove giml housing, loknut (with wsher) must e torqued to 12 l. ft. (16 N m); 90 hose r ompression fitting must e torqued to l. in. (8-10 N m). Position of hose r must e mintined, s shown. IMPORTANT: Lotion of Monitor rket is optionl; if rket is moved, instlltion must not use hose (when routed) to interfere with the movement of the power steering ssemly or engine oupler. MINIMUM HEIGHT OF INSTALLATION: ottom of rket must e no lower thn the top surfe of the fire wshers upon whih the engine mounts set MARCH 1998 Pge 4B-35

36 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 NOTE: If lotion does not require tht the onneting hose rosses the inner trnsom plte to port side, the J-lip on wter pikup outlet (top olt) would neither e needed nor instlled. The plsti hose lip n e used to hold hose in position, if needed, on trnsom, nd prevent it from ontting the power steering ssemly or engine oupler, fter they re instlled. 4. If rket is eing mounted port side, tth sewter outlet nd gsket, with J-lip under top olt, t lotion shown. Do not mount where ny omponent will interfere with power steering ssemly, when instlled. If mounting rket on strord side, do not use or tth J-lip. e g d h h f Monitor Brket - Fier Wshers - J-lip (instll t this lotion, if used) d - Plsti Hose Clip e - Conneting Hose f-90 Hose Br Compression Fitting g - Loknut nd Wsher h - Hose Clmp IMPORTANT: After instlltion of replement hose, hek tht hose will not ontt ny prt of the power steering ssemly or engine oupler. Pge 4B MARCH 1998

37 SERVICE MANUAL NUMBER 11 THRU-BULKHEAD TO BELL HOUSING GEAR LUBE MONITOR HOSE SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY NOTE: Bell housing must e removed from giml ring for this proedure (see Setion 4B-10). 1. Remove hose lmps, nd remove hose. 2. Reple hose nd hose lmps; tighten hose lmps seurely (hose nd lmps re instlled on ell housing hose r nd thru-ulkhed fitting, efore thru-ulkhed fitting is reinstlled). - Hose - Hose Clmps - Thru-Bulkhed Fitting d - O-ring Sel (not shown) d BELL HOUSING TO DRIVESHAFT HOUSING CHECK VALVES Unless dmged during disssemly, or y het, these hek vlves should lst the life of the drive unit. The ell housing hek vlve is repled s n ssemly. Removl 1. The ell housing hek vlve n e removed with pliers, nd disrded, or it n e removed y pling hose lmp snugly over re f, nd pulling out, with pliers on hose lmp, nd reinstlled if working properly MARCH 1998 Pge 4B-37

38 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER The driveshft housing hek vlve n e removed y retrting the sel up with pliers or hook, nd disrded. Remove the hek vlve nd spring, nd disrd. f e - Sel Cup - Chek Bll - Spring d - Chek Vlve Assemly e - O-rings (2) f - Are to Seure Hose Clmp for Retrtion d Ressemly 1. Driveshft Housing - insert spring, hek ll, nd sel up - press or tp, refully, on sel up until outer fe is flush with sting surfe, s shown. Do not use selnt. 2. Bell Housing - ot O-rings with Ger Lue; insert hek vlve ssemly into pssgewy, ple 3/8 in. deep wll soket over vlve end, nd tp into sting until shoulder surfe e is flush with sting surfe. g - Sel Cup - Chek Bll - Spring d - Bell Housing Chek Vlve Assemly e - This Surfe Must Be Flush with Csting f - O-rings (2) g - Vlve End e f d After units re onneted, nd drive unit nd Ger Lue Monitor re filled with Ger Lue, hek re, nd under ottom sem of mting surfes, for oil lek. Rehek for oil lek fter first use. - Chek for Oil Lek Pge 4B MARCH 1998

39 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY Trim Position Sender nd Trim Limit Swith Wire Replement 1. Remove trim limit swith wires nd trim position sender wires. d - Srew - Trim Hrness Clmp - Remove - Trim Limit Swith Wires d - Trim Position Sender Wires 2. Instll trim limit swith wires nd trim position sender wires. DO NOT pinh wires Trim Limit Swith Wires - Trim Position Sender Wires 3. Apply Perfet Sel to threds of srew nd instll trim hrness lmp, nd srew Trim Hrness Clmp - Srew MARCH 1998 Pge 4B-39

40 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Giml Ring/Swivel Shft/nd Steering Lever Instlltion 1. If instlling new upper swivel shft or giml ring, ensure tht upper swivel shft fits ll the wy into giml ring. Shoulder on shft must ottom out ginst ring. If neessry, len up mting surfes with file Giml Ring - Upper Swivel Shft - Flnge Must Bottom Out Aginst Giml Ring 2. Ple lrge I.D. wsher, steering lever, smll I.D. wsher, nd loknut into steering lever vity in giml housing. d Lrge I.D. Wsher - Steering Lever - Smll I.D. Wsher d - Loknut Pge 4B MARCH 1998

41 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 3. Instll upper swivel shft through giml ring nd up into nd through wshers, steering lever nd loknut. Strt loknut on upper swivel shft threds. DO NOT tighten t this time. e d - Upper Swivel Shft - Giml Ring - Wshers d - Steering Lever e - Loknut Instll lower swivel pin, wsher, nd seure with otter pin. Spred ends Swivel Pin - Wsher - Cotter Pin MARCH 1998 Pge 4B-41

42 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Connet ground wire from giml housing to giml ring, fter lening ground wire ring terminl nd srew. Tighten seurely. - Ground Wire Tighten loknut until lerne of in. ( mm) exists etween lower swivel pin wsher nd giml housing mount. Engine And Trnsom Assemly Instlled - Pin Punh Engine And Trnsom Assemly Removed - Loknut - 1-1/16 in. Wrenh Pge 4B MARCH 1998

43 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 7. Strike down on giml ring flnges using rwhide mllet. Rehek lerne nd tighten loknut s neessry. d Feeler Guge in. ( mm) - Wsher - Giml Housing Mount d - Giml Ring d Torque U-olt nuts evenly to l. ft. (67-74 N m). - Srews (2) nd Wshers (2) Nuts (2) (not seen) - Giml Ring MARCH 1998 Pge 4B-43

44 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Tighten steering lever lmping olt nd nut. Torque l. ft. (61-74 N m). Engine And Trnsom Assemly Instlled - Wrenh - Soket Wrenh Engine And Trnsom Assemly Removed - Wrenh - Wrenh Instll steering lever ground wire. Wire must e positioned s shown. Tighten seurely. - Ground Wire - Srews - Tighten Seurely Pge 4B MARCH 1998

45 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY IMPORTANT: If equipped with Trim-In-Limit Bloks, refer to Setion 5B efore instlling trim ylinders on giml ring. NOTE: The ushings on Lter Brvo drive units re mde from different type of mteril. The lter style is hrder. The ushing n lso e identified y smll indenttion on the outside fe of the ushing. Do not mix the erlier style ruer ushings with the lter style. - Erlier Style Bushing - Lter Style Bushing - Indenttion on Lter Style Instll trim ylinders on giml ring. d e e f g h Anhor Pin (1) - Slots (2) - Flt Wsher (Lrge I.D.) (2) d - Snp Rings (2) e - Ruer Bushings (4) f - Flt Wsher (Smll l.d.) (2) g - Loknut (2) h - Plsti Cp (2) 12. Cot threds of plsti plugs (if used) with Perfet Sel nd thred into ess hole until flush with housing. Use 5/8 in. hex wrenh or 5/8 in. hex stok to seure Plsti Plugs Touh up ny re metl spots with primer nd Phntom Blk spry pint MARCH 1998 Pge 4B-45

46 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Bell Housing Instlltion 1. On Stndrd Trnsom Assemly - Instll fier wshers on giml ring. Seure with Resiweld Seler ( ) (Epoxy). Ensure tht wsher pilots on hinge pin ushing. - Fier Wshers - Glue in Ple - Giml Ring - Hinge Pin Bushing NOTE: If drive shft housing is equipped with Trim-In Limit Pins, the ell housing shown in the following illustrtion must e used. There re two indenttions in the top ft edge of the ell housing. These indenttions help prevent srthing of the top side of the ell housing y the giml ring U-olt, when the trim-in limit pin is positioned in the ft position (Refer to Se. 5B for Trim-In Limit Pin Informtion.) Indenttions 2. On Stndrd Trnsom Assemly - Instll ell housing. Clen threds nd pply Lotite to threds of hinge pins (Port nd Strord). Instll hinge pins nd torque to l. ft. ( N m). - Hinge Pin Tool ( ) - Torque Wrenh Pge 4B MARCH 1998

47 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 3. On High Performne Trnsom Assemly - Instll hinge pins using speil tool ( ) nd slide hmmer s follows:. Thred hinge pin onto speil tool. Lurite hinge pins with Quiksilver Speil Lurint Hinge Pin - Speil Tool Slide hinge pin through giml ring nd ell housing. Be sure to lign srew holes in hinge pin with holes in giml ring. - Srew Holes Lightly tp hinge pin into ple using slide hmmer. - Slide Hmmer MARCH 1998 Pge 4B-47

48 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 d. Apply Lotite 242 to threds of srews nd instll. Torque srews to l.in. ( N m). - Srews Instll speedometer hose lip onto ell housing. - Speedometer Hose Clip - Bell Housing WARNING Be sure to red nd follow pkge lel diretions when using ellows dhesive. 5. Instll exhust ellows on ell housing s follows:. Clen exhust ellows mounting flnge on ell housing with sndpper nd wipe len with lquer thinner.. Apply ellows dhesive to mounting surfe on inside of ellows.. Position grounding lip on ellows. d. Ple hose lmp over ellows end. - Mounting Surfe - Grounding Clip - Hose Clmp Pge 4B MARCH 1998

49 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY e. Ple ellows expnder tool ( A1) into first ellows onvolution f. Pull tool until tool touhes the mounting flnge on ell housing (ellows strts to slip onto flnge); then relese tool. - Expnder Tool ( A1) - Bell Housing Flnge - Exhust Bellows d - Hose Clmp d g. Reposition tool into the third ellows onvolution. h. Pull ellows onto ell housing flnge. i. Tighten hose lmp. Torque to l. in. ( N m). Remove tool. - Exhust Bellows - Bell Housing Flnge - Hose Clmp - Tighten Seurely MARCH 1998 Pge 4B-49

50 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Instll U-joint ellows on ell housing s follows:. Position U-joint ellows on ell housing. Ensure tht the ell housing flnge () rests in the seond groove from the end of ellows. - Bell Housing Flnge Lurite sleeve O.D. with wter or engine lener nd instll sleeve instlltion tool nd suitle driving rod. - Sleeve - Sleeve Instlltion Tool ( ) - Suitle Driving Rod Pge 4B MARCH 1998

51 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 7. Instll wter hose on ell housing s follows:. Position hose so tht pproximtely 1/8 in. (3mm) protrudes from edge of opening. - Bell Housing - Wter Hose Apply smll mount of 2-4-C Mrine Lurint with Teflon to hose I.D. nd instll tpered inserts using the tpered insert tool ( ). - Tpered Insert - Tpered Insert Tool (P/N ) MARCH 1998 Pge 4B-51

52 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Shift Cle Instlltion If repling ore wire in shift le refer to setion 4A. 1. Insert shift le end into nd through shift le ellows. - Shift Cle End - Shift Bellows Apply Perfet Sel to shift le retining nut threds. Seure shift le to ell housing. Erlier Style Cle (Core Wire Removed) - Shift Cle Retining Nut - Apply Perfet Sel To Threds Of Nut - Sel LATER STYLE CABLE - Is identified y lrger nut whih fits over ore wire nhor. It is unneessry to remove ore wire to remove/instll shift le ssemly. - Shift Cle Retining Nut - Apply Perfet Sel To Threds Of Nut - Wsher - Sel Pge 4B MARCH 1998

53 SERVICE MANUAL NUMBER Instll shift le wrpping. SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY - Shift Cle Wrpping Chek tht ellows end is not flttened out when rimping in the following step. Wter lekge my result if lmp is not instlled properly. 4. Instll nd ompress shift le ellows rimp lmp, mintining 1/2 in. dimeter round O.D. Be sure tht lmp is rimped evenly so tht good sel is mintined etween ellows nd shift le. Do not llow ellows to fltten. - Crimp Clmp Models With Erlier Shift Cle - Instll inner ore wire. - Inner Core Wire MARCH 1998 Pge 4B-53

54 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER Instll ore wire loting tool (P/N ) on fe of ell housing. - Bell Housing - Core Wire Loting Tool (P/N ) 7. Instll threded tue until it ottoms. Tighten finger tight. Seure jm nut Threded Tue - Jm Nut - Tighten Seurely Erlier shift les with support tues - disrd support tue; do not reinstll Instll le end guide over ore wire, nd insert ore wire through le nhor. Tighten nhor srews evenly. Erlier Models - Core Wire - Anhor or Srews - Torque to 20 l. in. (2.3 N m) - Cle End Guide d Lter Models - Cle End Guide - Core Wire - Anhor Srews - Torque to 20 l. in. (2.3 N m) d - Sight Port - ottom-out ore wire (present on ll lter style nd some erlier style les) d Pge 4B MARCH 1998

55 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY 11. Ple shift le nhor djustment tool (P/N ) on end of shift le s shown. - Shift Cle Anhor Adjustment Tool ( ) - Stud - Pled through Hole in End Guide - Hole - Brrel Pled Here Ensure tht ell housing end of ore wire is positioned tight ginst ore wire loting tool. - Bell Housing - Core Wire Loting Tool - Core Wire Adjust le rrel to lign with hole in tool. Remove tools. - Brrel - Hole in Tool MARCH 1998 Pge 4B-55

56 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 Brvo Aess Plug Drilling Templte IMPORTANT: Crefully ut-out templte - use strightedge to mke urte folds. Align enterline of templte with enterline of dimple or grese fitting (on older models). With templte urtely ligned, TAPE TEMPLATE TO GIMBAL HOUSING, seurely, so tht it nnot move or shift Pge 4B MARCH 1998

57 SERVICE MANUAL NUMBER 11 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY MARCH 1998 Pge 4B-57

58 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 11 THIS PAGE IS INTENTIONALLY BLANK Pge 4B MARCH 1998