TRANSOM ASSEMBLY. Table of Contents. Section 4A - Service Procedures Requiring Minor Disassembly. Shift Cable... 4A-19

Transcription

1 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY TRANSOM ASSEMBLY Section 4A - Service Procedures Requiring Minor Disssemly Tle of Contents Specifictions A-2 Torque Specifictions A-2 Luricnts/Selers/Adhesives A-2 Specil Tools A-2 Specil Informtion A-3 Trim Limit Switch A-3 Trim Position Sender A-3 Trim Limit Switch nd Trim Position Sender A-4 Removl A-4 Instlltion A-7 Trim Position Sender Adjustment... 4A-12 Trim Limit Switch Adjustment A-13 Giml Bering A-15 Inspection A-15 Removl A-15 Instlltion A-17 Shift Cle A-19 Removl A-19 Inspection A-22 Instlltion A-23 Remote Control Shift Cle Adjustment (Drive Unit Instlled) A-28 Exhust Bellows A-38 Removl A-38 Clening And Inspection A-39 Instlltion A-39 Ger Lue Monitor Kit System Components - Replcement.. 4A-42 Monitor To Thru-Bulkhed Fitting Hose: A-42 Thru-ulkhed To Bell Housing Ger Lue Monitor Hose A-46 Bell Housing To Driveshft Housing Anti-Drile Vlves A-48 Crimp Clmp Tool A-50 4 A APRIL 2001 Pge 4A-1

2 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Specifictions Torque Specifictions Torque Description l-in. l-ft Nm Shift Cle Core Wire Anchor Screws Bellows Hose Clmps 35 4 Hinge Pins Luricnts/Selers/Adhesives Specil Tools Description Prt Numer 3M Brnd Adhesive Q1 Quicksilver 2-4-C Mrine Luricnt with Teflon A12 Description Prt Numer Bering Removl nd Instlltion Tool A7 Bellows Expnder Tool A1 Slide Hmmer Puller A1 Shift Cle Removl nd Instlltion Tool Hinge Pin Tool Sleeve Removl Tool (U-joint Bellows) T Sleeve Instlltion Tool (U-joint Bellows) Pge 4A APRIL 2001

3 SERVICE MANUAL NUMBER 14 Specil Informtion SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY Trim Limit Switch The trim limit switch hs seling system for improved wter resistnce nd durility. The trim limit switch leds re connected internlly to help ensure good electricl integrity Trim Position Sender Trim Limit Switch Port The trim position sender hs seling system for improved wter resistnce nd durility. The trim limit leds re connected internlly to help ensure good electricl integrity Trim Position Sender Strord APRIL 2001 Pge 4A-3

4 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Trim Limit Switch nd Trim Position Sender Removl NOTE: Disconnect oth the trim limit nd trim sender leds efore removing. 1. Remove sterndrive unit. 2. Remove trim limit switch. -Screws, Wshers And Retiners Remove trim position sender. -Screws, Wshers nd Retiners Pge 4A APRIL 2001

5 SERVICE MANUAL NUMBER Remove U-joint ellows sleeve. SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY -Sleeve Removl Tool ( ) Remove oth hinge pins. c -Bell Housing -Giml Ring c -Hinge Pin Tool ( ) Remove ellows from ell housing APRIL 2001 Pge 4A-5

6 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Pull ck on ell housing nd rotte it 90 degrees to gin ccess to the trim wire retiner screw. -Bell Housing Remove trim wire retiner. -Clmp -Belt Screw Remove trim sender nd trim limit wires from giml housing. Pge 4A APRIL 2001

7 SERVICE MANUAL NUMBER 14 Instlltion SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Route the new sender wires through the hole. Bring the two grommet hlves together nd ensure they re seted lightly in the hole nd tht the flt edges tht mte together re verticlly ligned. Mintin light tension on the wires from inside the ot, to hold the grommets in the hole. -Trim Limit Switch Wires -Trim Position Sender Wires Reinstll retiner nd torque screw to 95 l-in. (10.8 Nm). -Clmp -Screw APRIL 2001 Pge 4A-7

8 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Connect U-joint ellows to ell housing s follows:. Position U-joint ellows on ell housing. Ensure tht the ell housing flnge rests in the groove t the end of ellows. c -Bell Housing Flnge -Bellows c -Groove Luricte sleeve O.D. with engine clener (Quicksilver Power Tune works well nd it evportes quickly) nd instll sleeve with tool nd suitle driving rod. c -Sleeve -Instlltion Tool ( ) c -Suitle Driving Rod Pge 4A APRIL 2001

9 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 4. Apply Locquic Primer T to internl ell housing threds nd externl hinge pin threds nd llow to dry. Apply Loctite 8831 or 271 to ell housing threds nd instll hinge pins. Torque hinge pins to 100 l-ft (136 Nm). c -Bell Housing -Giml Ring c -Hinge Pin Tool ( ) Reinstll trim position sender s follows:. Plce sterndrive unit in the full DOWN/IN position.. Turn center rotor to lign index mrk on rotor with index mrk on sender ody Index Mrks APRIL 2001 Pge 4A-9

10 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 c. Instll trim position sender nd secure with ttching hrdwre. -Screws, Wshers And Retiners 6. Tighten trim position sender retining screws. 7. Reinstll trim limit switch s follows:. Plce drive unit in full DOWN/IN position.. Turn center rotor to lign index mrk on rotor with index mrk on sender ody Index Mrks Pge 4A APRIL 2001

11 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY c. Instll trim limit switch nd secure with ttching hrdwre. -Screws, Wshers And Retiners Secure the trim limit switch hrness to the wter hose with the plstic clip shown in figure elow. -Plstic Clip APRIL 2001 Pge 4A-11

12 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Trim Position Sender Adjustment 1. Reconnect trim position sender wires to engine hrness nd trim limit switch leds to trim pump hrness. 2. Reinstll ttery cles. -Positive Bttery Led (-) -Negtive Bttery Led (+) Turn ignition key to the RUN position. DO NOT START ENGINE with the drive unit in the DOWN/IN position. Rotte sender until needle is t ottom mrk on the guge. Retighten screws when djustment is correct Pge 4A APRIL 2001

13 SERVICE MANUAL NUMBER 14 Trim Limit Switch Adjustment SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY WARNING When djusting trim limit switch, use extreme cre tht the engine is not strted nd keep cler of the re ner the propeller. Use cre to prevent plcing hnds in n re where injury could occur ecuse of drive unit movement. CAUTION Trim limit switch MUST BE djusted exctly s outlined. If switch is djusted incorrectly, drive unit could move out eyond the giml ring support flnges nd cuse dmge to sterndrive unit. 1. Adjust trim limit switch s follows:. Loosen screws nd turn trim limit switch clockwise to end of slots. -Screws -Slots Ensure drive unit is in the full DOWN/IN position. c. Using the Trim utton on the control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON APRIL 2001 Pge 4A-13

14 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown (Refer to illustrtion elow.) -Rotte Counterclockwise To Adjust e. Retighten screws when djustment is correct /4 in. Mximum (520 mm) Pge 4A APRIL 2001

15 SERVICE MANUAL NUMBER 14 Giml Bering SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY Inspection Removl IMPORTANT: Giml ering nd crrier re mtched set nd must e replced s n ssemly. Tolernce ring must e replced nytime giml ering is removed. 1. Remove sterndrive unit. 2. Rech through ell housing nd rotte giml ering to check for rough spots. Push nd pull on inner rce to check for side wer. Any excessive movement or roughness is cuse for replcement. CAUTION Do not remove giml ering unless replcement is necessry, s dmge to ering my result during removl. 1. Remove giml ering ssemly using tools s shown. c f d e g Puller Shft ( )* -Nut ( )* c -Wsher ( )* d-pltes (2) ( )* e -Slide Hmmer Puller f -Giml Bering Inner Rce g-giml Bering Crrier * From Bering Removl nd Instlltion Tool A APRIL 2001 Pge 4A-15

16 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Remove tolernce ring. -Giml Bering Crrier -Tolernce Ring Remove grese sel. -Giml Housing -Grese Sel Pge 4A APRIL 2001

17 SERVICE MANUAL NUMBER 14 Instlltion SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Instll new grese sel to position shown in illustrtion elow using suitle mndrel Giml Housing -Grese Sel 2. Instll nd position new tolernce ring, s shown. d c e Crrier -Crrier Grese Hole c -Tolernce Ring d-align Opening In Tolernce Ring With Grese Hole In Crrier e -Notched Edge Of Bering Crrier 3. Ensure tht notched edge of ering crrier fces inwrd in ore when instlling giml ering APRIL 2001 Pge 4A-17

18 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Align giml ering crrier grese hole nd tolernce ring opening with grese cvity hole in giml housing. c -Giml Bering Crrier Grese Hole -Tolernce Ring Opening c -Bering Crrier Notch - Fce Inwrd Instll giml ering with tools, s shown. Tp in with led hmmer until crrier rests on the giml housing. Approximtely 1/8 in. of the ore will show when the ering is ottomed out. e c d -Driver Rod ( )* -Plte ( )* c -Driver Hed ( )* d-mndrel ( )* e -Giml Bering Assemly * From Bering Removl nd Instlltion Tool A7 Pge 4A APRIL 2001

19 SERVICE MANUAL NUMBER 14 Shift Cle SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY Removl 1. Remove sterndrive unit. 2. Disconnect shift cle from shift plte nd remove end guide Anchor Screws (2) -End Guide 3. Remove threded tue. -Jm Nut -Threded Tue Cut sfety wire nd remove set screw from shift slide. c Set Screw -Shift Slide c -Sfety Wire APRIL 2001 Pge 4A-19

20 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Remove inner core wire nd shift slide. -Inner Core Wire -Shift Slide Using shift cle removl nd instlltion tool ( ), completely loosen shift cle retining nut. -Shift Cle Retining Nut IMPORTANT: The shift cle should e replced s n ssemly only. Pge 4A APRIL 2001

21 SERVICE MANUAL NUMBER Loosen nd remove shift cle ellows crimp clmp. SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY c -Crimp Clmp -Shift Cle Bellows c -Shift Cle Remove shift cle wrpping from shift cle on inner trnsom. c -Inner Trnsom -Shift Cle c -Wrpping APRIL 2001 Pge 4A-21

22 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Pull shift cle through shift cle ellows. -Shift Cle -Shift Cle Bellows Inspection 1. Inspect shift cle for cuts, kinks nd chfing. 2. Inspect inner core wire for kinks nd unrveling. 3. Inspect shift cle retiner nut threds for dmge. 4. Inspect for signs of retiner nut seprting from outer csing. Pge 4A APRIL 2001

23 SERVICE MANUAL NUMBER 14 Instlltion SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Insert shift cle through ell housing nd shift cle ellows Shift Cle -Shift Cle Bellows 2. Apply Perfect Sel to shift cle retiner nut threds nd secure shift cle to ell housing, using shift cle removl nd instlltion tool ( ). No more thn 2 threds on retiner nut should e exposed. -Shift Cle -Retiner Nut APRIL 2001 Pge 4A-23

24 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Instll nd compress shift cle ellows crimp clmp. Be sure tht clmp is crimped evenly so tht good sel is mintined etween ellows nd shift cle. (Plns for Crimp Clmp Tool re on p. 4A-26) DO NOT llow ellows to fltten or wter lek my occur. c -Crimp Clmp -Shift Cle Bellows c -Shift Cle Instll shift cle wrpping. c -Shift Cle -Shift Cle Wrpping c -Inner Trnsom Plte Pge 4A APRIL 2001

25 SERVICE MANUAL NUMBER Instll inner core wire through shift slide. SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY Core Wire -Shift Slide 6. Instll inner core wire through shift cle. -Inner Core Wire -Shift Slide APRIL 2001 Pge 4A-25

26 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Instll set screw into shift slide. Tighten until it contcts core wire. Then ck off mximum of 1/8 turn. Sfety wire set screw to shift slide using figure 8 pttern. Twist until tight nd cut off excess length of sfety wire. c Set Screw -Shift Slide c -Sfety Wire 8. Instll threded tue on shift cle nd tighten until it ottoms. Secure jm nut ginst shift cle end. c Threded Tue -Core Wire c -Jm Nut 9. Instll sterndrive unit. Pge 4A APRIL 2001

27 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 10. Push in on drive unit shift cle while simultneously turning propeller shft counterclockwise until shft stops. To ensure tht clutch is fully engged, mintin pressure on propeller shft with suitle device (elstic strp) Inner Core Wire -Propeller Shft NOTE: Clutch enggement will e in forwrd on right hnd rottion units nd reverse for left hnd rottion. 11. Instll shift cle end guide over core wire nd insert core wire through cle nchor. Tighten screws securely. d c d Shift Cle End Guide -Core Wire c -Cle Anchor d-screws (2) 12. While pplying light inwrd pressure, rotte rrel on shift cle threds until distnce etween center of hole in shift cle end guide nd center of rss rrel mesure 6 in. (153 mm). c -End Guide -Brss Brrel c -6 in. (153 mm) Adjust shift cle APRIL 2001 Pge 4A-27

28 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Remote Control Shift Cle Adjustment (Drive Unit Instlled) NOTE: The illustrtions on the following pges show models tht hve shift plte tht is mounted on the exhust elow. The shift mechnism components on the 3.0L model re locted on the top of the vlve cover s shown in the following illustrtion. The procedure for mking the djustments is exctly the sme L Model With Components Mounted On Vlve Cover -Shift Assist Assemly -Remote Control Shift Cle IMPORTANT: Shift cle djustment for right hnd (RH) rottion drive unit is different thn the procedure for djusting left hnd (LH) rottion drive unit. Be sure to refer to the pproprite procedure when performing the following steps. IMPORTANT: Drive unit must e instlled. IMPORTANT: DO NOT run engine. Pge 4A APRIL 2001

29 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Remove remote control shift cle nd shift ssist ssemly (if instlled) With Shift Assist Assemly -Shift Assist Assemly -Remote Control Shift Cle Without Shift Assist Assemly -Remote Control Shift Cle APRIL 2001 Pge 4A-29

30 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Ensure shift lever djustle stud is t ottom of slot. If necessry, loosen stud nd move it to ottom of slot towrd the pivot olt, then retighten stud. -Adjustle Stud -Towrd pivot olt Shift remote control s stted in or following:. Right Hnd (RH) Rottion Drive Unit - forwrd ger, pst detent, into wide-open-throttle position. (RH) Pge 4A APRIL 2001

31 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY. Left Hnd (LH) Rottion Drive Unit - reverse ger, pst detent, into wide-open-throttle position. (LH) 4. Plce drive unit into ger y pushing in on drive unit shift cle, while simultneously rotting propeller shft counterclockwise until shft stops, to ensure full clutch enggement. Mintin light pressure on the drive unit shift cle to hold it t the end of its trvel (this removes ll slck from the cle). IMPORTANT: Do not use excessive force when holding pressure on the drive unit shift cle. Excessive force would e indicted y movement of the v-notch on the shift cutout switch Drive Unit Shift Cle - Push In -Propeller Shft - Rotte Counterclockwise APRIL 2001 Pge 4A-31

32 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Lightly pull on remote control shift cle end guide (to remove slck from remote control nd cle) nd djust rss rrel s necessry to lign ttching points with shift lever clevis pin hole nd stud. Be sure to mintin light pressure on drive unit shift cle. c d End Guide -Brss Brrel c -Shift Lever Clevis Pin Hole d-stud 6. After cle hs een ligned, turn rss rrel 4 turns wy from cle end guide e -End Guide f -Brss Brrel Pge 4A APRIL 2001

33 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 7. Temporrily instll remote control shift cle on stud nd instll clevis pin Remote Control Shift Cle -Clevis Pin 8. Shift remote control s stted in or following:. Right Hnd (RH) Rottion Drive Unit - reverse ger, pst detent, into wide-open-throttle position.. Left Hnd (LH) Rottion Drive Unit - forwrd ger, pst detent, into wide-open-throttle position. (RH) (LH) APRIL 2001 Pge 4A-33

34 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Simultneously rotte propeller shft clockwise until shft stops to ensure full clutch enggement. -Propeller Shft - Rotte Clockwise Perform or s pproprite:. On Models with Erlier Type Switch: check shift cutout switch lever position. Roller must e centered Shift Cutout Switch Roller. On Models with Lter Type Switch: check shift cutout switch plunger position. Pin must e centered. -Shift Cutout Switch Roller Pge 4A APRIL 2001

35 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 11. If roller or plunger pin is not centered:. Ensure djustle stud is t ottom of slot in shift lever.. Check remote control for proper shift cle output [3 in. (76 mm) ± 1/8 in. (3 mm)]. Refer to Instlltion Requirements. c. If nd re correct, ensure drive unit shift cle is not crushed or kinked. (If drive unit shift cle is inding, the shift cutout switch roller or plunger pin will move off center when shifting into nd out of forwrd nd reverse). NOTE: If shift cle ws dmged during instlltion, instll new shift cle ssemly in ccordnce with instructions contined in sterndrive service mnul, then repet shift cle djustment procedure. NOTE: Some controllers, such s the Commnder 3000, hve different djustment procedures. Refer to the pproprite instlltion instructions for the model eing repired After remote control shift cle hs een properly djusted, reinstll cle nd shift ssist ssemly (if pplicle) nd secure with hrdwre s shown. If shift ssist ssemly ttching points will not lign, push in or pull out on end of shift ssist ssemly to instll. Do not ttempt to redjust shift cle. d e f g c With Shift Assist Assemly -Remote Control Shift Cle -Shift Assist Assemly c -Clevis Pin d-cotter Pin (Spred Both Prongs) e -Lrge I.D. Wsher f -Smll I.D. Wsher g-locknut (Tighten Until Bottomed, Then Bck Off 1/2 Turn) APRIL 2001 Pge 4A-35

36 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Without Shift Assist Assemly -Remote Control Shift Cle -Clevis Pin c -Cotter Pin (Existing) d-spring (Existing) e -Wsher (Existing) f -Wsher g-spcer h-wsher (Existing) i -Locknut (Existing) - (Tighten Until Bottomed, Then Bck Off 1/2 Turn) IMPORTANT: If n extr long remote control shift cle is used, or if there re lrge numer of ends in remote control shift cle, or remote control hs indequte output trvel, n dditionl djustment my e necessry. Refer to step 12 or 13 s pplicle. 13. Remote Control with Single Lever Shift/Throttle Control:. RIGHT HAND (RH) propeller rottion drive unit - Shift remote control into reverse ger, wide-open-throttle position while simultneously rotting propeller shft clockwise. Clutch should engge nd cuse propeller shft to lock. If clutch does not engge, loosen djustle stud on shift lever nd move it upwrd in slot until clutch engges with reverse ger. Retighten stud. Shift remote control severl times nd stop in reverse to recheck shift cutout switch position. Roller must e centered.. LEFT HAND (LH) propeller rottion drive unit - Shift remote control into forwrd ger, wide-open-throttle position while simultneously rotting propeller shft clockwise. Clutch should engge nd cuse propeller shft to lock. If clutch does not engge, loosen djustle stud on shift lever nd move it upwrd in slot until clutch engges with forwrd ger. Retighten stud. Shift remote control severl times nd stop in forwrd to recheck shift cutout switch position. Roller must e centered. 14. Two Lever Remote Control with Seprte Shift nd Throttle Levers:. RIGHT HAND (RH) propeller rottion drive unit - While turning propeller shft clockwise, move remote control shift hndle into full reverse position. Clutch should engge efore shift lever comes to stop. If clutch does not engge, loosen Pge 4A APRIL 2001

37 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY djustle stud on shift lever nd move it upwrd in slot until clutch engges with reverse ger. Retighten stud. Shift remote control severl times nd stop in reverse to recheck shift cutout switch position. Roller must e centered.. LEFT HAND (LH) propeller rottion drive unit - While turning propeller shft clockwise, move remote control shift hndle into full forwrd position. Clutch should engge efore shift lever comes to stop. If clutch does not engge, loosen djustle stud on shift lever nd move it upwrd in slot until clutch engges with forwrd ger. Retighten stud. Shift remote control severl times nd stop in forwrd to recheck shift cutout switch position. Roller or pin must e centered. -Adjustle Stud Shift Cutout Switch Roller Shift Cutout Switch Roller APRIL 2001 Pge 4A-37

38 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Exhust Bellows Removl 1. Remove sterndrive unit. 2. Loosen hose clmps nd remove exhust ellows Exhust Bellows -Hose Clmps Pge 4A APRIL 2001

39 SERVICE MANUAL NUMBER 14 Clening And Inspection SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Inspect exhust ellows for internl chrring, crcks, cuts or hrdening. 2. Clen old dhesive from ellows mounting flnge on giml housing nd on ell housing with lcquer thinner. 3. If reusing old ellows, clen old dhesive from mounting surfces of exhust ellows. Instlltion 4. Roughen exhust ellows mting surfces with sndpper nd wipe clen with lcquer thinner. WARNING Bellows dhesive contins toluol nd petroleum distilltes which re hrmful or ftl if swllowed. Avoid prolonged contct with skin or rething of vpors. If swllowed, do not induce vomiting. Cll physicin immeditely. Keep out of rech of children. 1. Apply ellows dhesive to mounting surfces on inside of ellows. Allow to dry until no longer tcky (pproximtely 10 minutes). CAUTION Bellows clmp my corrode if grounding clips re not instlled. 2. Position grounding clips on ellows Mounting Surfce (Apply Bellows Adhesive) -Grounding Clips APRIL 2001 Pge 4A-39

40 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER Instll exhust ellows on giml housing. Position hose clmp s shown. Tighten hose clmp screw to 35 l-in. (8-10 Nm) using screwdriver through ccess holes in giml housing. c -Exhust Bellows -Hose Clmp c -Giml Housing Access Hole Instll exhust ellows on ell housing s follows:. Plce hose clmp over ellows end.. Plce expnder tool ( A1) through ell housing into first ellows convolution Pge 4A APRIL 2001

41 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY c. Pull tool until tool touches the flnge on ell housing (ellows strts to slip onto flnge); then relese tool Expnder Tool ( A1) -Bell Housing Flnge d. Reposition tool into the third ellows convolution. e. Pull ellows onto ell housing flnge. f. Torque hose clmp to 35 l-in. (4 Nm). -Exhust Bellows -Hose Clmp APRIL 2001 Pge 4A-41

42 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Ger Lue Monitor Kit System Components - Replcement Monitor To Thru-Bulkhed Fitting Hose: EARLIER STYLE Check hose periodiclly for condition, including crcks, hrdening, etc.; replce s necessry. 1. To replce hose, remove hose clmps nd clip, then remove hose. 2. Instll new hose of sufficient length to llow reservoir to e removed from topside or ottom-side of rcket. Secure hose with hose clmps. 3. If thru-ulkhed fitting ws tken out to remove giml housing. The following steps must e completed. 4. Instll giml housing fitting through housing. Ensure the hex on fitting lines up with formed cvity in housing, which prevents fitting from rotting. 5. Instll wsher nd secure ssemly with locknut. Torque to 12 l-ft (16.5 Nm). IMPORTANT: To ensure tht fitting is seted securely in cvity there should e 1/2 in. (12.7 mm) of threds protruding through the top of the nut to the end of the giml housing fitting. 6. Instll 90 degree swivel fitting nd position s shown while torquing to 80 l-in. (9 Nm). c d e -Swivel Fitting -Locknut c -Wsher d-o-ring e -Giml Housing Fitting Pge 4A APRIL 2001

43 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 7. Connect oil reservoir hose to 90 degree fitting nd secure with hose clmp. If required, remove screw from wter cover plte nd retin hose with clip. Retorque wter cover plte screw to 95 l-in. (10.8 Nm). d c e -Hose -Hose Clmp c -Hose Clip d-wter Cover Plte e -Screw IMPORTANT: Loction of reservoir rcket is optionl. If rcket is moved, instlltion must not cuse hose (when routed) to interfere with the movement of the power steering ssemly or engine coupler. MINIMUM HEIGHT OF INSTALLATION: ottom of rcket must e no lower thn the top surfce of the fier wshers upon which the engine mounts set. NOTE: If loction does not require tht the connecting hose crosses the inner trnsom plte to port side, the J-clip on wter pickup outlet (top olt) would neither e needed nor instlled. The plstic hose clip cn e used to hold hose in position, if needed, on trnsom nd prevent it from contcting the power steering ssemly or engine coupler, fter they re instlled APRIL 2001 Pge 4A-43

44 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER If rcket is eing mounted port side, ttch sewter outlet nd gsket, with J-clip t top olt, t loction shown. Do not mount where ny component will interfere with power steering ssemly, when instlled. If mounting rcket on strord side, do not use or ttch J-clip. e d g f i c f h Connecting Hose -Hose Clmp (2) c -Plstic Hose Clip d-oil Monitor Bottle e -Brcket (Alternte Loction) f -Fier Wshers g-clip h-90 Hose Br Compression Fitting i -Locknut And Wsher Pge 4A APRIL 2001

45 SERVICE MANUAL NUMBER 14 LATER STYLE SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Connect the ger lue monitor hose to quick relese 90 fitting. 2. Connect fitting to the giml housing. IMPORTANT: Hose must not come in contct with steering system components or the engine coupler, U-joint shft or drive shft. d c Hose -90 Hose Fitting c -Giml Housing Fitting d-ger Lue Monitor NOTE: The quick relese utton on hose fitting must e positioned wy from wter inlet fitting, or lock-off plte, if equipped. Relese utton must not contct wter fitting, or lockoff plte if equipped. CAUTION Avoid sterndrive unit dmge. Quick relese utton on ger lue monitor 90 hose fitting my not lock on giml housing if touching or depressed y wter inlet fitting, or lock-off plte, if equipped. Ensure quick relese utton does not contct lock-off plte, or wter inlet fitting if equipped. Filure to do so could result in loose 90 fitting cusing loss of ger lue nd dmge to drive unit. e f d c d Block-Off Plte Instlltion Shown (Similr For Models With Wter Fitting) -Block-Off Plte (Or Wter Inlet Fitting If Equipped) -Str Wsher nd Screw c -90 Hose Fitting d-quick Relese Button e -ACCEPTABLE Positions f -NOT ACCEPTABLE Position NOTE: The hose must not come into contct with the steering system components or the engine coupler nd drive shft APRIL 2001 Pge 4A-45

46 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Thru-ulkhed To Bell Housing Ger Lue Monitor Hose 1. If the ell housing ger lue monitor hose ws removed. Apply Perfect Sel to threds of hose connector nd instll into ell housing. Torque to 8 l-ft (11 Nm) Pre-ssemle 10 in. (254 mm) long hose to the red end of the through-giml housing fitting nd tighten clmp securely so tht clmp tensioner will e ccessile when fitting is instlled. e c d f -Clmp -O-ring c -10 inch (254 mm) Hose d-giml Housing Fitting e -Cle Tie f -Connector (Assemled In Bell Housing) Pre-ssemle cle tie so it cn e slid up the hose nd positioned over stright fitting. 4. Push 10 inch (254 mm) hose over stright connector lredy ssemled in ell housing. Be sure hose is s fr up on connector s possile. Pge 4A APRIL 2001

47 SERVICE MANUAL NUMBER 14 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 5. Slide cle tie down the hose until it is over the connector. Pull the cle tie tight with needle nose pliers. Then crefully cut tie tking cre not to puncture ny internl prts. -Cle Tie -Hose Apply oil to O-rings on nti-drile vlve nd instll into ell housing mking sure tht the shoulder on vlve is completely flush to the ell housing fce. -Anti-Drile Vlve When instlling new gsket the hole with silicon sel should e positioned round nti-drile vlve. Instll sterndrive unit APRIL 2001 Pge 4A-47

48 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Bell Housing To Driveshft Housing Anti-Drile Vlves Unless dmged during disssemly, or y het, these nti-drile vlves should lst the life of the drive unit. The ell housing nti-drile vlve is replced s n ssemly. REMOVAL 1. The ell housing nti-drile vlve cn e removed with pliers nd discrded, or it cn e removed y plcing hose clmp snugly over re f, nd pulling out, with pliers on hose clmp nd reinstlled if working properly. 2. The driveshft housing nti-drile vlve cn e removed y retrcting the sel cup with pliers or hook nd discrded. Remove the check vlve nd spring nd discrd. f e c d Drive Shft Housing Bell Housing -Sel Cup -Check Bll c -Spring d-check Vlve Assemly e -O-rings (2) f -Are To Secure Hose Clmp For Retrction Pge 4A APRIL 2001

49 SERVICE MANUAL NUMBER 14 REASSEMBLY SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY 1. Driveshft Housing - insert spring, check ll nd sel cup - press or tp, crefully, on sel cup until outer fce is flush with csting surfce, s shown. Do not use selnt. 2. Bell Housing - cot O-rings with Ger Lue; insert check vlve ssemly into pssgewy, plce 3/8 in. deep wll socket over vlve end nd tp into csting until shoulder surfce e is flush with csting surfce. g c e f d Drive Shft Housing Bell Housing -Sel Cup -Check Bll c -Spring d-bell Housing Check Vlve Assemly e -This Surfce Must Be Flush With Csting f -O-rings (2) g-vlve End 3. After units re connected nd drive unit nd ger lue monitor re filled with Ger Lue, check re, nd under ottom sem of mting surfces, for oil lek. Recheck for oil lek fter first use. -Connection Are APRIL 2001 Pge 4A-49

50 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 Crimp Clmp Tool -Bevel Edges -3/4 in. Nut c -Pliers d-sw Nut in Hlf Weld 3/4 in. nut to the jws of pir of pliers (s shown). 2. Sw the nut in hlf without dmging the pliers. 3. Clmp the jws of the pliers in vice so tht the two hlves of the nut re pressed firmly together. 4. Use 1/2 in. drill it to drill the threds out of the nut. Pge 4A APRIL 2001

51 SERVICE MANUAL NUMBER 14 THIS PAGE IS INTENTIONALLY BLANK SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY APRIL 2001 Pge 4A-51

52 service PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 14 THIS PAGE IS INTENTIONALLY BLANK Pge 4A APRIL 2001