TRANSOM ASSEMBLY Setion 4B - Servie Proedures Requiring Mjor Disssemly Tle of Contents Trnsom Assemly Speifitions..... 4B-2 Torque Speifitions............. 4B-2 Speil Tools..................... 4B-2 Lurints / Selers / Adhesives.... 4B-3 Speil Informtion.................. 4B-4 Trim Limit Swith................. 4B-4 Trim Position Sender.............. 4B-4 Shift Cle....................... 4B-4 Ger Lue Monitor Kit Aess Plug Lotions................... 4B-5 Alph One Trnsom Assemly Exploded View..................... 4B-7 Bell Housing Components......... 4B-7 Giml Housing Components...... 4B-9 Inner Trnsom Plte Components.. 4B-11 Giml Ring nd Steering Lever Components.................... 4B-13 Component Disssemly............. 4B-15 Bell Housing Removl............. 4B-15 Trim Position Sender nd Trim Limit Swith Wire Removl........ 4B-21 Giml Ring, Swivel Shft nd Steering Lever Removl.......... 4B-21 Giml Housing Serviing............ 4B-28 U-Joint Bellows Removl.......... 4B-28 Shift Cle Bellows Removl....... 4B-29 Bushings And Upper Sel Removl. 4B-30 Component Serviing................ 4B-32 Bell Housing Disssemly......... 4B-32 Bell Housing Ressemly.......... 4B-37 Gsket And O-Ring............... 4B-41 Speedometer Tuing And Wter Hose........................... 4B-42 Ressemly........................ 4B-45 Giml Ring Bushing Instlltion... 4B-45 Oil Sel Instlltion............... 4B-47 Exhust Bellows Instlltion........ 4B-49 Trim Position Sender nd Trim Limit Swith Wire Instlltion........... 4B-50 Giml Ring, Swivel Shft nd Steering Lever Instlltion......... 4B-51 Shift Cle Bellows Instlltion..... 4B-59 Bell Housing Instlltion........... 4B-61 Trim Limit Swith Instlltion....... 4B-69 Trim Position Sender Instlltion.... 4B-70 ALPHA ONE (GENERATION II) ACCESS PLUG.................. 4B-71 DRILLING TEMPLATE......... 4B-71 4 B 90-818177--3 APRIL 2001 Pge 4B-1
SERVICE MANUAL NUMBER 14 Trnsom Assemly Speifitions Torque Speifitions Speil Tools Desription Torque l-in. l-ft Nm Shift Cle Core Wire Anhor Srews 20 2.3 Bellows Hose Clmps 35 4 Giml Ring to Bell Housing Hinge Pins 100 143 Giml Ring Srews 55 74 Steering Srew nd Nut 60 81 Trnsom Assemly Atthing Srews, Nut 22.5 30.5 90Fitting Nut 12 16.5 90Fitting 80 9 Oil Fill/Drin Srew 23 30 Desription Prt Numer Bering Removl nd Instlltion Tool 91-31229A1 Bellows Expnder Tool 91-45497A1 Slide Hmmer Puller 91-34569A1 Shift Cle Removl nd Instlltion Tool 91-12037 Driver, Needle Bering 91-33492T Driver, Needle Bering 91-33491 Driver, Bering 91-33489 Driver Hed 91-32325T Driver Rod 91-37323 Drive Shft Nut Wrenh 91-56775T Alignment Tool Assemly 91-805475A1 Expnder Tool 91-45497A1 Hinge Pin Tool 91-78310 Mndrel 91-30366-1 Nut 11-24156 Plte (2) 91-29310 Puller 91-63616T Puller Hed 91-38919 Puller Shft 91-31229 Wsher 12-34961 Bushing Instlltion Tool 91-806928T Sleeve Instlltion Tool 91-818169T Sleeve Removl Tool 91-818162 Pge 4B-2 90-818177--3 APRIL 2001
Lurints / Selers / Adhesives Desription Prt Numer 3M Brnd Adhesive 92-86166Q1 Quiksilver 2-4-C Mrine Lurint With Teflon 92-825407A12 Quiksilver U-Joint AndGiml Bering Grese 92-828052A2 Perfet Sel 92-34227-1 Anti-Corrosion Grese 92-78376A6 Loqui Primer T 92-809824 Lotite 27131 92-809820 Quiksilver Speil Lurint 101 92-13872A1 90-818177--3 APRIL 2001 Pge 4B-3
SERVICE MANUAL NUMBER 14 Speil Informtion Trim Limit Swith The trim limit swith hs seling system for improved wter resistne nd durility. The trim limit swith leds re onneted internlly to help ensure good eletril integrity. 71415 Trim Position Sender Trim Limit Swith - Port The trim position sender hs seling system for improved wter resistne nd durility. The trim limit leds re onneted internlly to help ensure good eletril integrity. 71414 Shift Cle Trim Position Sender - Strord A Drive Unit Shift Cle Removl nd Instlltion Tool 91-12037 is required for le removl nd instlltion. -Shift Cle Retining Nut 23156 Pge 4B-4 90-818177--3 APRIL 2001
IMPORTANT: The shift le should e repled s n ssemly only. Ger Lue Monitor Kit Aess Plug Lotions This model hs the option to e equipped with remote oil monitor. These plugs only need to e removed during instlltion of tht kit. 70876 -Bell Housing -Hex Hed Plug -Giml Housing -Allen Hed Pipe Plug 70149 90-818177--3 APRIL 2001 Pge 4B-5
SERVICE MANUAL NUMBER 14 Alph One Trnsom Assemly Exploded View Bell Housing Components A B C A B (O.D.) A A B C D A 73316 Pge 4B-6 90-818177--3 APRIL 2001
1 -Bell Housing Assemly 2 -Gsket 3 -Connetor 4 -Pipe Plug 5 -Bushing 6 -Bushing 7 -Gsket (Ruer) 8 -O-Ring 9 -Wsher (Synthne) 10 - Stud 11 - Wsher 12 - Nut 13 - Universl Joint Bellows 14 - Ground Clip 15 - Clmp 16 - Sleeve 17 - Hose 18 - Clmp 19 - Exhust Bellows 20 - Sels 21 - Clmp 22 - Lever Assemly 23 - Wsher 24 - Srew 25 - Shift Shft (Upper) 26 - Coupling Assemly 27 - Tuing 28 - Clip 29 - Clmp 30 - Fitting Assemly 31 - Connetor 32 - Clmp 33 - Hose 34 - Clmp 35 - Connetor 36 - O-Ring 37 - Vlve Assemly 38 - O-rIng Lurints/Selers/Adhesives A - 3M Brnd Adhesive B - Lotite 27131 C - Quiksilver Perfet Sel D - Quiksilver High Performne Ger Lue Torque Speifitions -Tighten Seurely Approximtely 35 l-in. (4 Nm) -50 l-ft (68 Nm) -8 l-ft (11 Nm) 90-818177--3 APRIL 2001 Pge 4B-7
SERVICE MANUAL NUMBER 14 Giml Housing Components B C d D A 74861 Pge 4B-8 90-818177--3 APRIL 2001
1 -Giml Housing 2 -Stud 3 -Lower Bushing 4 -Oil Sel 5 -Upper Bushing 6 -Grese Fitting 7 -Lurip 8 -Grese Sel 9 -Bering Assemly 10 - Tolerne Ring 11 - O-Ring 12 - Stud 13 - Sel 14 - Pipe Plug 15 - Wter Tue 16 - Bushing 17 - Cover 18 - Srew 19 - Lower Swivel Pin 20 - Cotter PIn 21 - Wsher 22 - Bolt 23 - Wsher 24 - Wsher 25 - Nut 26 - Bellows 27 - Clmp 28 - Clmp 29 - Wsher 30 - Nut 31 - Gsket 32 - Connetor 33 - Lok Wsher 34 - Nut 35 - Anodi Plte 36 - Sel 37 - Gsket 38 - Srew 39 - Lok Wsher 40 - Hose 41 - Clmp 42-90 Fitting 43 - Nut 44 - Wsher 45 - O-Ring 46 - Connetor 47 - Continuity Wire 48 - Continuity Wire Connetion 49 - Hose Clmp Lurints/Selers/Adhesives A B - 3M Brnd Adhesive - Quiksilver Perfet Sel C - Lotite 27131 D - Quiksilver U-Joint And Giml Bering Grese Torque Speifitions -80 l-in. (9 Nm) -12 l-ft (16.5 Nm) -Approximtely 35 l-in. (3.96 Nm) d-25 l-ft (34 Nm) 90-818177--3 APRIL 2001 Pge 4B-9
SERVICE MANUAL NUMBER 14 Inner Trnsom Plte Components 74850 1 -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 Torque Speifitions -25 l-ft (34 Nm) -37 l-ft (50 Nm) 11 - Loknut 12 - Shift Cle Outer Csing 13 - End Guide 14 - Core Wire Anhor 15 - Anhor Srews 16 - Core Wire 17 - Shift Slide 18 - Srew - Core Wire Cvity 19 - Giml Housing Eyelet 20 - Cle Wrpping 74865 Pge 4B-10 90-818177--3 APRIL 2001
THIS PAGE IS INTENTIONALLY BLANK 90-818177--3 APRIL 2001 Pge 4B-11
SERVICE MANUAL NUMBER 14 Giml Ring nd Steering Lever Components d (O.D.) A 73318 Pge 4B-12 90-818177--3 APRIL 2001
1 -Giml Ring 2 -Bushing 3 -Grese Fitting 4 -Lurip 5 -Hinge Pin 6 -Trim Limit Swith 7 -Wsher 8 -Srew 9 -Lokwsher 10 - Retiner 11 - Trim Wire Clmp 12 - Srew 13 - Steering Lever 14 - Swivel Shft 15 - Wsher 16 - Wsher 17 - Nut 18 - Srew 19 - Nut 20 - Srew 21 - Wsher 22 - Wsher 23 - Loknut 24 - Clevis Pin 25 - Cotter Pin 26 - Trim Position Sender Lurints/Selers/Adhesives A - Resiweld Seler Torque Speifitions -60 l-ft (81 Nm) d-55 l-ft (74 Nm) e -110 l-ft (148 Nm) f -95 l-in. (10.5 Nm) 90-818177--3 APRIL 2001 Pge 4B-13
SERVICE MANUAL NUMBER 14 THIS PAGE IS INTENTIONALLY BLANK Pge 4B-14 90-818177--3 APRIL 2001
Component Disssemly Bell Housing Removl 1. Remove sterndrive unit. 2. Remove trim position sender. 71220 -Trim Position Sender -Srews (2) nd Wshers (2) -Retiners (2) 3. Remove trim limit swith. 71221 -Trim Limit Swith -Srews (2) nd Wshers (2) -Retiners (2) 90-818177--3 APRIL 2001 Pge 4B-15
SERVICE MANUAL NUMBER 14 4. Disonnet shift le from shift plte nd remove le end guide () y loosening nhor srews (). -Anhor Srews (2) -End Guide 22183 5. Remove threded tue () y loosening loking nut (). 22183 -Jm Nut -Threded Tue 6. Remove lok wire nd set srew from shift slide. 70139 -Set Srew -Shift Slide -Sfety Wire Pge 4B-16 90-818177--3 APRIL 2001
7. Remove inner ore wire nd shift slide. 70138 -Inner Core Wire -Shift Slide 8. Remove nd disrd shift le ellows rimp lmp. 70137 -Crimp Clmp -Shift Cle Bellows -Shift Cle 90-818177--3 APRIL 2001 Pge 4B-17
SERVICE MANUAL NUMBER 14 9. Remove shift le wrpping from shift le on inner trnsom. 22030 -Inner Trnsom -Shift Cle -Wrpping 10. Remove wter tue over nd ruer grommet. Push wter tue through giml housing. d 70149 -Wter Tue Cover -Srews -Wter Tue d-ruer Grommet (Beneth Cover) Pge 4B-18 90-818177--3 APRIL 2001
11. Insert removl tool into U-joint ellows nd tighten nut until sleeve eomes dislodged from ellows. 70178 -Removl Tool (91-818169) -Bell Housing 12. Remove sleeve from universl joint ellows. -Sleeve 13. Loosen exhust ellows lmps nd remove ellows. 70179 22116 -Exhust Bellows -Hose Clmps 90-818177--3 APRIL 2001 Pge 4B-19
SERVICE MANUAL NUMBER 14 14. Remove speedometer tuing lip from ell housing. 70196 -Bell Housing -Speedometer Tuing Clip 15. Remove ontinuity wire from port side of ell housing. 16. Remove hinge pins. -Bell Housing -Hinge Pins - Remove (Port And Strord) -Hinge Pin tool (91-78310) 22113 17. Remove ell housing. Pge 4B-20 90-818177--3 APRIL 2001
Trim Position Sender nd Trim Limit Swith Wire Removl 1. Remove trim limit swith wires nd trim position sender wires. d 70197 -Srew -Trim Hrness Clmp - Remove -Trim Limit Swith Wires d-trim Position Sender Wires Giml Ring, Swivel Shft nd Steering Lever Removl GIMBAL HOUSING ACCESS PLUG This kit, ville for use on MerCruiser Trnsom ssemlies, llows for removl nd instlltion of giml ring without hving to remove engine nd trnsom ssemly. A templte is lso inluded in this kit to lote ess holes. 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 22-88847A-1 1-1/8 in. Hole Sw (otin lolly) 1 in. NPT Pipe Tp #180 (otin lolly) 26409 -Plsti Plugs (2) -Swivel Shft Nut 90-818177--3 APRIL 2001 Pge 4B-21
SERVICE MANUAL NUMBER 14 1. 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) 70862 CAUTION Be sure to drill nd ut hole nd tp threds perpendiulr to giml housing surfes in the following steps. 2. 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.) (6 mm). CAUTION 70152 Eye Protetion must e worn when performing the following proedure. Filure to do so my use personl injury. Pge 4B-22 90-818177--3 APRIL 2001
3. Cut holes in giml housing (port nd strord) using 1-1/8 in. hole sw nd pilot rod. Remove metl hips with ompressed ir. -Drill Pilot Hole 70153 22652 REMOVAL 1. Loosen srews nd nuts (not neessry to remove). d 70150 -Srews (2) -Nuts (2) -Wshers (4) d-giml Ring 90-818177--3 APRIL 2001 Pge 4B-23
SERVICE MANUAL NUMBER 14 2. Loosen steering lever lmping olt nd nut. With Engine And Trnsom Assemly Instlled -Wrenh -Soket Wrenh 70157 22460 With Engine And Trnsom Assemly Removed -Wrenh -Wrenh Pge 4B-24 90-818177--3 APRIL 2001
3. Unthred elsti loknut. 70156 With Engine And Trnsom Assemly Instlled -Pin Punh 22452 With Engine And Trnsom Assemly Removed -Loknut -1-1/16 in. Wrenh 4. Disonnet trim ylinders from giml ring (if not lredy done). Suspend ylinders to void dmge to hoses using re not to rek the ontinuity wires. e d -Plsti Cp -Clip -Flt Wsher d-bushing e -Anhor Pin 70176 90-818177--3 APRIL 2001 Pge 4B-25
SERVICE MANUAL NUMBER 14 5. Disonnet ontinuity wire. -Continuity Wire 22261 6. Remove otter pin, lower swivel pin nd nti-guling wsher. 22461 -Cotter Pin -Lower Swivel Pin -Wsher (nti-guling) 7. Remove upper swivel shft from giml ring, lrge I.D. wsher, steering lever, smll I.D. wsher, nd loknut. Pge 4B-26 90-818177--3 APRIL 2001
IMPORTANT: If swivel shft is seized, remove shft using Slide Hmmer Puller (91-34569A1) nd Puller Hed (91-63616). Bell housing nd ellows must e removed. 70884 g 22463 f e d 22492 -Swivel Shft -Puller Hed -Slide Hmmer Puller d-lrge I.D. Wsher e -Steering Lever f -Smll I.D. Wsher g-loknut 90-818177--3 APRIL 2001 Pge 4B-27
SERVICE MANUAL NUMBER 14 8. Remove upper swivel shft, steering lever nd hrdwre shown. Remove giml ring. d e 23293 -Nut -Wsher (Smll I.D.) -Steering Lever d-wsher (Lrge I.D.) e -Upper Swivel Shft Giml Housing Serviing U-Joint Bellows Removl 1. Remove U-joint ellows from giml housing. 50383 -U-joint Bellows -Hose Clmp Pge 4B-28 90-818177--3 APRIL 2001
2. If reusing ellows, remove old dhesive from inside dimeter of U-joint ellows end using lquer thinner, nd inspet for possile dmge. 50383 -Bellows 3. Clen ellows mounting flnge on giml housing with sndpper nd wipe len with lquer thinner. 70184 -Mounting Flnge Shift Cle Bellows Removl 1. Loosen hose lmp nd remove shift le ellows. 50542 -Shift Cle Bellows -Hose Clmp 90-818177--3 APRIL 2001 Pge 4B-29
SERVICE MANUAL NUMBER 14 2. Clen old dhesive from shift le ellows mounting surfe using lquer thinner, nd inspet for possile dmge. -Shift Cle Bellows -Mounting Surfe -Hose Clmp 22454 3. Clen shift le ellows mounting flnge with wire rush or sndpper nd wipe len with lquer thinner. -Mounting Flnge Bushings And Upper Sel Removl 50542 1. Remove oil sel nd lrge ushing from giml housing using two-jw puller nd slide hmmer ssemly. -Two Jw Puller And Slide Hmmer Assemly 70177 Pge 4B-30 90-818177--3 APRIL 2001
2. Remove smll ushing from giml housing using Bushing Removl Tool. (Snp On Tool Compny P/N CG40CB) 22438 22454 -Bushing Removl Tool (Snp On Tool Compny P/N CG40CB) CAUTION Be reful not to dmge ores when removing self-luriting ushings in the following steps. 3. Remove giml ring lower swivel pin ushing using suitle mndrel. 22451 -Suitle Mndrel - Tp Out Lower Swivel Pin Bushing 90-818177--3 APRIL 2001 Pge 4B-31
SERVICE MANUAL NUMBER 14 Component Serviing Bell Housing Disssemly 1. Pull ell housing wy from giml housing nd remove plsti lips from wter hose. -Wter Hose -Plsti Clips 70202 2. Loosen or ut smll st-strp round speedometer fitting. Remove speedometer fitting from tuing. NOTE: It my e neessry to loosen hose in hot wter to enle removl of speedometer fitting. -Tuing -Speedometer Fitting -St-strp 70200 Pge 4B-32 90-818177--3 APRIL 2001
3. Disonnet speedometer hose t trnsom nd remove fitting nd hose from unit. -Fitting -Giml Housing 70203 4. Remove lmp nd fitting from tuing. NOTE: It my e neessry to loosen hose in hot wter to enle removl of fitting. 70201 -Tuing -Fitting -Clmp 5. Remove wter inlet hose from ell housing. 90-818177--3 APRIL 2001 Pge 4B-33
SERVICE MANUAL NUMBER 14 6. Clen ell housing mounting flnge with wire rush or sndpper. Wipe len with lquer thinner. -Bell Housing -Mounting Flnge -Wter Tue d-hose Clmp d 23361 7. Loosen hose lmp nd remove wter tue from wter hose. -Wter Hose -Wter Tue -Hose Clmp 23294 8. Remove wter hose onnetor from ell housing. 50543 -Bell Housing -Wter Hose Connetor Pge 4B-34 90-818177--3 APRIL 2001
9. Loosen shift le using Shift Cle Removl And Instlltion Tool nd remove shift le. 23156 -Shift Cle -Retining Nut - Use Tool (91-12037) 10. Remove upper shift shft lever nd shift shft. d 70141 -Upper Shift Shft Lever Srew -Upper Shift Shft Lever -Wsher (Beneth Lever) d-upper Shift Shft 90-818177--3 APRIL 2001 Pge 4B-35
SERVICE MANUAL NUMBER 14 11. Remove shift shft upper ushing. 70182 -Upper Bushing -Bushing (Below Sel) 12. Remove shift shft lower ushing. 70182 -Bushing Pge 4B-36 90-818177--3 APRIL 2001
Bell Housing Ressemly All units uilt with seril numers from 0D644651 to 0F094774 will hve the following ushing instlled. The sels were previously instlled into the ell housing upper ore. They now re lredy instlled in the ushing nd n e instlled with one proedure using Bushing Tool 91-805057A2. 23-805041A2 71227 Erlier Model Bushing nd Sels NOTE: It my e neessry to pply het to shift shft lever srew to id in removing. NOTE: The inner dimeter of the lter model ushing is muh lrger thn the shift shft. All units with seril numer 0F094775 nd ove hve the following ushing nd sel rrngement. Use Bushing Instlltion Tool 91-806928 A1 to instll the lter model ushing nd sels. Lter Model Bushing nd Sels 1. Erlier Model Bushing nd Sel: Apply smll mount of Speil Lurint 101 to O.D. of shift shft lower ushing. Instll ushing flush with ottom of the ore in ell housing. (On units with lter model ushing nd sel rrngement, instll the lower ushing in Step 6.) 74116 70181 -Bell Housing -Bushing 90-818177--3 APRIL 2001 Pge 4B-37
SERVICE MANUAL NUMBER 14 2. Lter Model Bushing nd Sel: Use instlltion tool 91-806928T to instll lower ushing flush with the ottom of the ore in the ell housing. 74117 -Relief Cut Out 3. Both Models: Apply Lurint 101 to O.D. of ushing nd instll shift shft upper ushing in ore from ottom using pproprite ushing instlltion tool. Lter Model Bushing nd Sel: Instll the upper ushing nd sels individully. -Upper Bushing -Bushing Instlltion Tool (91-805057A2) 70982 Pge 4B-38 90-818177--3 APRIL 2001
4. Instll upper shift shft lever nd shift shft. Apply Lotite 27131 or Type A to srew threds. Tighten seurely. d -Upper Shift Shft Lever Srew -Upper Shift Shft Lever -Wsher (Beneth Lever) d-upper Shift Shft 70141 5. Apply Perfet Sel to threds of shift le retiner nd instll shift le. Tighten retiner seurely using shift le removl nd instlltion tool (until no more thn two threds of retiner re showing). -Shift Cle -Retining Nut - Use Tool (91-12037) 23156 90-818177--3 APRIL 2001 Pge 4B-39
SERVICE MANUAL NUMBER 14 6. Apply Perfet Sel to threds of wter hose onnetor nd instll in ell housing. On erlier style, tighten seurely. Lter models hve onnetor sted in. 50543 -Bell Housing -Wter Hose Connetor 7. Connet wter hose to wter tue nd position hose lmp s shown. Tighten seurely. -Wter Hose -Wter Tue -Hose Clmp 23294 8. Connet wter hose to onnetor on ell housing. Position hose nd lmp s shown. Tighten seurely. -Wter Hose -Hose Clmp 70170 Pge 4B-40 90-818177--3 APRIL 2001
Gsket And O-Ring 1. Instll U-joint ore ruer gsket nd wter pssge O-ring. NOTE: It my e neessry to pply 3M Adhesive to help hold the ruer gsket in ple. -O-ring -Ruer Gsket 70022 90-818177--3 APRIL 2001 Pge 4B-41
SERVICE MANUAL NUMBER 14 Speedometer Tuing And Wter Hose 1. Reple fitting inside speedometer tuing nd seure in ple with smll st-strp. NOTE: It my e neessry to soften hose in hot wter efore repling fitting. 70200 1997 1/2 And Erlier Model Speedometer Connetor -Tuing -Fitting -St-strp 75502 75581 1998 Model Speedometer Connetor -Topside Portion, Femle End -Bell Housing -St-Strp Pge 4B-42 90-818177--3 APRIL 2001
2. Apply Perfet Sel to threds of rss fitting. Tighten fitting seurely into giml housing. 70204 -Brss Fitting (Apply Perfet Sel) -Giml Housing 3. Reple st-strp on the hose t the onnetor. 4. Instll wter tue through giml housing nd instll ruer grommet over tue. Push grommet into vity. -Wter Tue -Ruer Grommet 50544 5. Instll wter tue over nd tighten srews seurely. 70149 -Wter Tue Cover -Srews 90-818177--3 APRIL 2001 Pge 4B-43
SERVICE MANUAL NUMBER 14 6. Seure tuing to wter hose using st-strps. Do not overtighten or kink tuing. 70202 -Wter Hose -St-strps 7. Reple speedometer tuing lip onto tuing nd reple in hole in ell housing. -Bell Housing -Tuing Clip -Speedometer Tuing 70196 Pge 4B-44 90-818177--3 APRIL 2001
Ressemly Giml Ring Bushing Instlltion 1. Instll giml ring lower swivel pin ushing s follows:. Apply Resiweld Seler (92-65150-1) to O.D. of ushing () nd position ushing on ering nd sel driver (). 22440. Inspet ore for lenliness nd dmge efore instlling ushing.. Instll ushing in giml ring () y pressing or tpping in ple with rss hmmer. (Pressing is preferred). 2. Instll upper swivel shft smll ushing s follows:. Ple ushing on ering nd sel driver. 22453 -Smll Bushing -Sel Driver 70185 90-818177--3 APRIL 2001 Pge 4B-45
SERVICE MANUAL NUMBER 14. Instll ushing y tpping it in ple with rss hmmer. -Brss Hmmer 3. Instll upper swivel shft lrge ushing s follows:. Ple ushing on ering nd sel driver. 22450 70187 -Lrge Bushing -Sel Driver. Instll ushing y tpping it in ple with rss hmmer. -Brss Hmmer 22450 Pge 4B-46 90-818177--3 APRIL 2001
SYNTHANE WASHERS 1. If synthne wshers re worn, remove nd len ny exess dhesive from surfe. Peel king off of wsher nd pply to giml ring. -Giml Ring -Synthne Wsher (Port nd Strord) 22454 Oil Sel Instlltion 1. Instll upper swivel shft oil sel s follows:. Ple oil sel on ering nd sel driver with lip fing the smll dimeter end of tool. Apply Lotite 271 to O.D. of sel. 70673 -Oil Sel -Sel Driver 70186 90-818177--3 APRIL 2001 Pge 4B-47
SERVICE MANUAL NUMBER 14. Instll oil sel y tpping it in ple with rss hmmer. -Brss Hmmer 22450 2. Instll shift le ellows on giml housing. Position hose lmp s shown. Tighten seurely. 50542 -Shift Cle Bellows -Hose Clmp Pge 4B-48 90-818177--3 APRIL 2001
Exhust Bellows Instlltion 1. If old exhust ellows will e reinstlled, remove old dhesive from exhust ellows mounting surfes, using lquer thinner, nd inspet for possile dmge. -Exhust Bellows Mounting Surfe 22450 2. Clen exhust ellows mounting flnge with sndpper nd wipe len with lquer thinner. -Exhust Flnge 70184 WARNING Be sure to red nd follow pkge lel diretions when using ellows dhesive. 90-818177--3 APRIL 2001 Pge 4B-49
SERVICE MANUAL NUMBER 14 3. Position grounding lips on ellows. Use ellows P/N 18654 only. -Apply 3M Brnd Adhesive -Grounding Clips -Bellows Prt Numer 22079 4. Apply ellows dhesive to exhust ellows mounting surfe. Allow to dry (pproximtely 10 minutes), efore instlling. 22450 -Exhust Bellows Mounting Surfe 5. Instll exhust ellows on giml housing flnge. Position hose lmp s shown. Torque to 30-40 l-in. (3.3-4.5 Nm). 70199 -Giml Housing Flnge -Hose Clmp Pge 4B-50 90-818177--3 APRIL 2001
Trim Position Sender nd Trim Limit Swith Wire Instlltion 1. Instll trim limit swith wires nd trim position sender wires. DO NOT pinh wires. 70198 -Trim Limit Swith Wires -Trim Position Sender Wires 2. Apply Perfet Sel to threds of srew nd instll trim hrness lmp nd srew. 70197 -Trim Hrness Clmp -Srew-Torque 90-100 l-in. (10.2-11.3 Nm) 90-818177--3 APRIL 2001 Pge 4B-51
SERVICE MANUAL NUMBER 14 Giml Ring, Swivel Shft nd Steering Lever Instlltion 1. If removed, instll giml ring srews with hrdwre shown. Do not tighten. d 23293 23364 -Giml Ring Srews (2) -Wshers (4) -Nuts (2) d-giml Ring 2. Instll lower swivel pin nd wsher nd seure with otter pin. Spred oth ends. 22461 22445 -Lower Swivel Pin -Wsher -Cotter Pin Pge 4B-52 90-818177--3 APRIL 2001
3. If removed, instll lmping srew nd nut on steering lever. -Srew -Nut 4. Thred new, grooved nut ll the wy onto swivel shft to ut threds. Remove nut. 70189 -Nut -Swivel Shft 23293 5. Ple lrge I.D. wsher, steering lever, smll I.D. wsher, nd loknut into steering lever vity in giml housing. 22463 d -Loknut -Smll I.D. Wsher -Steering Lever d-lrge I.D. Wsher 22492 90-818177--3 APRIL 2001 Pge 4B-53
SERVICE MANUAL NUMBER 14 6. 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. -Upper Swivel Shft -Giml Ring 70885 IMPORTANT: When instlling upper swivel shft through giml ring nd steering lever, e sure tht giml ring is stright nd steering lever is pointed stright forwrd. 7. Instll swivel shft through giml rings nd up through steering lever. Strt nut on swivel shft. 23362 -Swivel Shft -Nut -Steering Lever (Wsher On Top And Bottom) Pge 4B-54 90-818177--3 APRIL 2001
8. 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 rest ginst ring. If neessry, len up mting surfes with file. 70886 -Giml Ring -Upper Swivel Shft 90-818177--3 APRIL 2001 Pge 4B-55
SERVICE MANUAL NUMBER 14 9. Tighten nut until lerne of.002 -.010 in. (0.05-0.25 mm) exists etween lower swivel pin wsher nd giml housing mount. Engine And Trnsom Assemly Instlled -Pin Punh -Nut 70156 50541 Engine And Trnsom Assemly Removed -Nut -Wrenh (1-1/16in.) Pge 4B-56 90-818177--3 APRIL 2001
d -Feeler Guge -.001 -.010 in. (0.05-0.25 mm) -Wsher -Giml Housing Mount d-giml Ring d 22445 10. Strike down on giml ring flnges using rwhide mllet. Rehek lerne nd tighten swivel shft nut s neessry. 11. Torque giml ring srews to 55 l-ft (74 Nm). 70150 -Srews (2) And Wshers (2) Nuts (2) (Not Seen) -Giml Ring 90-818177--3 APRIL 2001 Pge 4B-57
SERVICE MANUAL NUMBER 14 12. Tighten steering lever lmping srew nd nut. Torque to 60 l-ft (81 Nm). 70157 Engine And Trnsom Assemly Instlled -Wrenh -Soket Wrenh Engine And Trnsom Assemly Removed -Wrenh -Wrenh 50541 13. Instll steering lever ground wire. Wire must e positioned extly s shown. -Ground Wire -Srews 22028 Pge 4B-58 90-818177--3 APRIL 2001
14. Connet ontinuity wire from giml housing to giml ring. -Continuity Wire 15. Instll trim ylinders on giml ring. 22261 e d 70176 -Plsti Cp -Clip -Flt Wsher d-bushing e -Anhor Pin 90-818177--3 APRIL 2001 Pge 4B-59
SERVICE MANUAL NUMBER 14 16. Mrk 1 in. (25 mm) pipe tp with piee of tpe 1-1/8 in. (28 mm) from end of tp. Cut threds in ess holes. Cot pipe tp with grese to id in piking up metl hips. 70155 22757 17. Cot threds of plsti plugs (from kit) with Perfet Sel efore instlling into ess hole. Instll plug so tht it is flush with giml housing. 18. Touh up ny re metl spots with primer nd Phntom Blk spry pint. Shift Cle Bellows Instlltion 1. Clen shift le ellows mounting flnge with wire rush or sndpper nd wipe len with lquer thinner. 50542 -Mounting Flnge 2. Apply dhesive to shift le ellows mounting surfe, using proper dhesive. -Shift Cle Bellows -Mounting Surfe 22454 Pge 4B-60 90-818177--3 APRIL 2001
3. Instll the shift le ellows nd tighten ellows lmp. -Shift Cle Bellows -Hose Clmp 50542 90-818177--3 APRIL 2001 Pge 4B-61
SERVICE MANUAL NUMBER 14 Bell Housing Instlltion 1. Prepre U-joint ellows for instlltion s follows:. Clen giml housing mounting flnge with sndpper nd wipe len with lquer thinner.. Apply ellows dhesive to mounting surfe on inside of ellows.. Position grounding lip nd hose lmp over ellows end. 2. Lurite the end of the shift le with Quiksilver 2-4-C Mrine Lurint with Teflon. 3. Crefully insert the le through the smll opening in the ellows nd through the giml housing. 4. Then insert the le into the engine omprtment. Route the le s shown in the following illustrtions. 74903 3.0L Model V6 nd V8 Models WARNING 74901 Be sure to red nd follow pkge lel diretions when using ellows dhesive. Pge 4B-62 90-818177--3 APRIL 2001
5. Instll ell housing etween giml ring. Push on ell housing nd guide U-joint ellows onto giml housing mounting flnge. 23363 -Bell Housing -U-joint Bellows -Hose Clmp 6. Apply Loqui Primer T to internl ell housing threds nd externl hinge pin threds nd llow to dry. Apply Lotite 271 to ell housing threds nd instll hinge pins. Torque hinge pins to 100 l-ft (136 Nm). d 23292 -Bell Housing -Giml Ring -Hinge Pin Tool (91-78310) d-torque Wrenh 7. Instll U-joint ellows on ell housing s follows: 90-818177--3 APRIL 2001 Pge 4B-63
SERVICE MANUAL NUMBER 14. Position U-joint ellows on ell housing. Ensure tht the ell housing flnge rests in the groove t the end of ellows. 75268 -Bell Housing Flnge. Lurite sleeve O.D. with engine lener (Quiksilver Power Tune works well nd it evportes quikly) nd instll sleeve with tool nd suitle driving rod. 70207 -Sleeve -Sleeve Instlltion Tool (91-818162) -Suitle Driving Rod 8. Instll exhust ellows on ell housing (one end ws previously instlled on giml housing) s follows:. Clen ell housing mounting flnge with sndpper nd wipe len with lquer thinner.. Apply ellows dhesive to mounting surfe on inside of ellows.. Position grounding lip on ellows. Pge 4B-64 90-818177--3 APRIL 2001
d. Ple hose lmp over ellows end. 22079 -Exhust Bellows -Mounting Surfe -Ground Clip e. Ple expnder tool (91-45497A1) into first ellows onvolution. 22161 -Expnder Tool f. Pull tool until tool touhes the mounting flnge on ell housing (ellows strts to slip onto flnge); then, relese tool. 75270 -Expnder Tool (91-45497A1) -Bell Housing Flnge g. Reposition tool into the third ellows onvolution. 90-818177--3 APRIL 2001 Pge 4B-65
SERVICE MANUAL NUMBER 14 h. Pull ellows onto ell housing flnge. i. Position hose lmp s shown nd tighten seurely. Remove tool. -Exhust Bellows -Hose Clmp 75269 IMPORTANT: Ensure shift le ellows rimp lmp is not flttened out when ompressing in the following step. Crimp lmp must e ompressed evenly round ellows nd shift le to prevent wter lekge. 9. Insert shift le through shift le ellows. NOTE: After inserting shift le through shift ellows e sure tht ellows is in relxed position [2 1/2 in (63 mm) from ell housing] efore rimping lmp. 10. Compress rimp lmp. 70137 -Shift Cle -Shift Cle Bellows -Crimp Clmp Pge 4B-66 90-818177--3 APRIL 2001
11. Instll shift le wrpping on shift le from inner trnsom. Position pproximtely 2 inhes from giml housing. 22030 -Shift Cle Wrpping 12. Instll ore wire through shift slide. -Shift Slide -Core Wire 23262 13. Instll inner ore wire through shift le. Be sure nd position shift lever roller etween slot on shift slide. d 23262 -Inner Core Wire -Shift Cle -Shift Slide d-shift Lever 90-818177--3 APRIL 2001 Pge 4B-67
SERVICE MANUAL NUMBER 14 14. Instll set srew into shift slide. Tighten until ontt with ore wire. Then k off 1/8 turn mx. Sfety wire set srew to shift slide using figure 8 pttern. Twist until tight nd ut off exess length of sfety wire. Bend til of wire in-etween srew nd t. 70139 -Set Srew -Shift Slide -Sfety Wire 15. Instll threded tue on shift le nd tighten until it ottoms out, finger tight only. Seure jm nut ginst shift le end. 22183 -Threded Tue -Core Wire -Jm Nut 16. Instll sterndrive unit. Pge 4B-68 90-818177--3 APRIL 2001
17. Push in on drive unit shift le ore wire while simultneously turning propeller shft ounterlokwise until shft stops. To ensure tht luth is fully engged mintin pressure on propeller shft with suitle devie (elsti strp). 22183 -Inner Core Wire -Propeller Shft 23170 NOTE: Cluth enggement will e in forwrd on stndrd rottion units nd reverse for ounter rottion. 18. Instll shift le end guide over ore wire nd insert ore wire through le nhor. Tighten srews seurely. d d 22183 -Shift Cle End Guide -Core Wire -Cle Anhor d-srews (2) 19. While pplying light pressure, mesure distne etween enter of hole in shift le end guide nd enter of rss rrel. Mesurement should e 6 in. (153 mm). -End Guide -Brss Brrel -6 in. (153 mm) 20. Connet shift le to shift plte nd djust. 50484 90-818177--3 APRIL 2001 Pge 4B-69
SERVICE MANUAL NUMBER 14 Trim Limit Swith Instlltion 1. Align index mrks on swith. 70860 -Index Mrks 2. Instll trim limit swith. 71221 -Trim Limit Swith -Retiners (2) -Srews (2) And Wshers (2) 3. Adjust trim limit swith. (See Setion 4A) Pge 4B-70 90-818177--3 APRIL 2001
Trim Position Sender Instlltion 1. Align index mrks. 70860 -Index Mrks 2. Instll trim position sender. 71220 -Trim Position Sender -Srews (2) And Wshers (2) -Retiners (2) 3. Adjust trim position sender. (See Setion 4A) 90-818177--3 APRIL 2001 Pge 4B-71
SERVICE MANUAL NUMBER 14 70862 ALPHA ONE (GENERATION II) ACCESS PLUG DRILLING TEMPLATE IMPORTANT: CAREFULLY CUT OUT TEMPLATE -USE STRAIGHT EDGE TO MAKE ACCURATE FOLDS. ALIGN CENTERLINE WITH CENTER LINE OF DIMPLE. WITH TEMPLATE ACCURATELY ALIGNED, TAPE TEMPLATE TO GIMBAL HOUSING SECURELY SO THAT IT CANNOT MOVE OR SHIFT. Pge 4B-72 90-818177--3 APRIL 2001
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