STERN DRIVE AND INBOARD DRIVE UNITS 133

Transcription

1 STERN DRIVE AND INBOARD DRIVE UNITS 133 NOTE Lubricate pivot points of dual tie bar, if installed. MERCRUISER STERN DRIVE (ALPHA ONE EXCEPT GENERATION II) The lubrication tasks described in this section should be performed at the intervals indicated in Table 1. These intervals are only guidelines, however. Consider the frequency and extent of boat use when setting actual intervals and perform the tasks more frequently if the boat is used under severe service conditions. An oil reservoir kit is available as an accessory. This allows you to check the oil level in the drive unit from inside the boat when it is in the water. Dispose of old lubricant properly. Disposal methods discussed under Engine Oil and Filter Change in this chapter are applicable. Fluid Check (Without Reservoir Kit) Since the lubricant expands when hot, its level should be checked when the unit is cool. The expanded lubricant may spray out if the oil vent plug is removed when the unit is hot and can cause serious burns. A. Grease fitting B. Steering cabie C. Steering cabie pivot points D. Extension rod 1. With the drive unit in a vertical position (antiventilation plate level), unscrew and remove the oil vent plug from the port side of the drive shaft housing (Figure 35). 2. Carefully check the oil level. It should be even with the bottom edge of the vent hole. If oil A. Grease fitting B. Steering cabie

2 134 CHAPTER SIX level is correct, check the condition of the sealing washer on the plug. Reinstall the vent plug with a new washer, if the old one is damaged or deteriorated. 3. If the oil level is not correct: a. Temporarily reinstall the vent plug to create an air lock inside the unit. The lubricant in the stern drive should be periodically checked for water contamination. To check for water, trim the drive unit to the fully OUT position. Remove thefill/drainplug and take a small sample of the lubricant. If the lubricant is milky brown or if water is evident, a leak is present that must be repaired before the unit is returned to service. On 1987 and later models, a magnetic fill/drain plug is used. Check the magnetic tip of the plug for metallic particles which could indicate internal problems. Thoroughly clean the tip before reinstalling the plug. b. Remove the oil fill/drain plug (Figure 36) and insert lubricant pump (part No ) or equivalent in the fill/drain hole. c. Remove the oil vent plug and inject lubricant from the pump through the oil fill/drain hole until it fiows from the vent hole in an air-free stream. The unit should not require more than 2 ounces of lubricant. If it does, an oil leak is probable and the unit should not be used until it is checked for leakage and any problem corrected. d. Reinstall the oil vent plug and washer. e. Remove the lubricant pump and quickly reinstall the fill/drain plug and washer. f. Wipe any excess lubricant from the drive g. Repeat Step 1 and Step 2 to recheck lubricant level. Fluid Check (With Reservoir Kit) If the lubricant in the reservoir is milky brown or if water is mixed with it, the drive unit has a leak which must be corrected before it is returned to service. Check the lubricant level in the reservoir (Figure 37). If the fiuid level is below the RJLLmark on the reservoir, remove the cover and add sufficient lubricant to bring the level to the mark. Reinstall the cover tightly. The unit should not require more than 2 ounces of lubricant. If it does, an oil leak is probable and the unit should not be used until it is checked for leakage and any problem corrected. Fluid Change (Without Reservoir Kit) I. Trim the drive unit to its full out position. When the oil fill/drain plug is removed in Step 2, let a small quantity of fluid drain on your fingers. If the lubricant is Sealing washer Oil fill/drain piug o

3 STERN DRIVE AND INBOARD DRIVE UNITS 135 milky brown or if water is mixed with it, the drive unit has a leak which must be corrected before it is returned to service. 2. Place a suitable container underneath the drive unit so that the fiuid can drain into it. Remove the oil vent plug (Figure 35) and fill/drain plug (Figure 36). Allow the lubricant to drain completely. 3. When the lubricant has drained, retum the drive unit to a vertical position (antiventilation plate level). 4. Insert lubricant pump (part No ) or equivalent in the fill/drain hole. Inject lubricant from the pump through the oil fill/drain hole until it fiows from the vent hole in an air-free stream. 5. Reinstall the oil vent plug and washer. 6. Remove the lubricant pump and quickly reinstall the fill/drain plug and washer. 7. Wipe any excess lubricant from the drive 8. Repeat Step 1 and Step 2 of Fluid Check in this chapter to check lubricant level. Fluid Change (With Reservoir Kit) 1. Trim the drive unit to its full out position. When the oil fill/drain plug is removed in Step 2, let a small quantity of fiuid drain on your fingers. If the lubricant is milky brown or if water is mixed with it, the drive unit has a leak which must be corrected before it is returned to service. 2. Place a suitable container underneath the drive unit so the fiuid can drain into it. Remove the oil fill/drain plug (Figure 36). Allow the lubricant to drain completely. 3. Remove the reservoir from its bracket (Figure 37). Remove the cover and drain the lubricant into a suitable container. 4. Unscrew and remove the adapter and hose from the drive shaft housing oil vent hole. See Figure When the lubricant has drained, retum the drive unit to a vertical position (antiventilation plate level). 6. Insert lubricant pump (part No ) or equivalent in the fill/drain hole. Inject lubricant from the pump through the oil fill/drain hole until it fiows from the vent hole in an air-free stream. 7. Temporarily plug the oil vent hole to create an airlock in the drive unit. 8. Remove the lubricant pump and quickly reinstall the fill/drain plug and washer. 9. Wipe any excess lubricant from the drive

4 136 CHAPTER SIX A. Adaptor B. Hose C. on vent hole A. Oii reservoir B. Cover

5 STERN DRIVE AND INBOARD DRIVE UNITS Reinstall the adapter and hose to the drive shaft housing oil vent hole. Tighten adapter securely. 11. Reinstall the oil reservoir to its bracket. Fill the reservoir to its FULL mark and reinstall the cover tightly. 12. Loosen the adapter fitting at the drive shaft housing vent hole. Let the lubricant flow until there are no air bubbles in the stream, then retighten the fitting securely. Repeat Step Recheck fluid level in oil reservoir and top up, if required. Do not fill the reservoir above the FULL mark. MERCRUISER STERN DRIVE (ALPHA ONE GENERATION II, BRAVO ONE AND BRAVO TWO) The lubrication tasks described in this section should be performed at the intervals indicated in Table 1. These intervals are only guidelines. -B -A however. Consider the frequency and extent of boat use when setting actual intervals and perform the tasks more frequently if the boat is used under severe service conditions. The lube oil monitor (Figure 39) is standard on 1989-on Bravo One and Bravo Two models and available as an option on Alpha One Generation II models. The lube oil monitor allows the drive unit oil level to be checked from inside the boat. The reservoir is equipped with a lubricant level waming sensor that activates the audio waming system should the drive unit oil level become low. Unlike the extemal reservoir connection used on early Alpha One models (Figure 38), the connection is intemal on Bravo One, Bravo Two and Alpha One Generation II models. A check valve connector permits easy removal and installation of the drive unit. See Figure 40. Fluid Check (Without Reservoir) 1. Bring the stem drive to a vertical position (anti-ventilation plate level). 2. Unscrew and remove the oil level dipstick on the top of the upper gear housing (Figure 41). If the oil level is at the line on the dipstick, reinstall the dipstick with the sealing washer. Tighten the dipstick securely. If the oil level is low, continue at Step 3. NOTE On late Bravo One models, the drive unit fill/drain plug is located in the propeller shaft bearing carrier On models so equipped, the propeller and forward thrust hub must be removed to access the fill/drain plug. A. Oii dipstick B. Seaiing washer 3. On late Bravo One models, remove the propeller and thrust hub, then remove the fill/drain plug located in the propeller shaft bearing carrier (Figure 42). On all other models, remove the fill/drain plug from the gear housing (Figure 43). Insert lubricant pump (part No , or equivalent) into the fill/drain plug hole.