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Mercury BRAVO Service Manual

Sterndrives
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Table of Contents

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Download this manual See also: Owner's Manual, Installation Manual
SERVICE
MANUAL
Number 28
BRAVO STERNDRIVES
2000, Mercury Marine
Printed in U.S.A.
90-863160 MAY 2000

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Summary of Contents for Mercury BRAVO

  • Page 1 SERVICE MANUAL Number 28 BRAVO STERNDRIVES 2000, Mercury Marine Printed in U.S.A. 90-863160 MAY 2000...
  • Page 3 Mercury Marine, that they have been trained in the recommended servicing procedures of these products which in- cludes the use of mechanics’ common hand tools and the special Mercury Marine or recom- mended tools from other suppliers.

  • Page 4: Replacement Parts

    It is important to note, during any maintenance procedure replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings.
  • Page 5 A - All Models Section 3 - Sterndrive Unit Sterndrive Unit A - Drive Shaft Housing B - Gear Housing - Bravo One C - Gear Housing - Bravo Two D - Gear Housing - Bravo Three Transom Assembly Section 4 - Transom Assembly...
  • Page 6 Table of Contents IMPORTANT INFORMATION Section 1A - General Information How To Use This Manual ....1A-2 Propeller Rotation ..... 1A-4 Page Numbering .
  • Page 7 ......3A-44 Bravo X, XZ, XR and Diesel Reassembly ..... .
  • Page 8 Section 3B - Gear Housing - Bravo One Specifications ......3B-2 Bearing Carrier Disassembly ..
  • Page 9 Section 3D - Gear Housing - Bravo Three Table of Contents ..... 3D-1 Propeller Shaft ..... . .

  • Page 10: Power Trim

    ....4B-51 Gimbal Housing Servicing ... . . 4B-26 Bravo Access Plug Drilling Template ..4B-55 U-joint Bellows Replacement ..

  • Page 11: Steering Systems

    5B-3 Reassembly ..... . 5B-14 Bravo Trim System Components ..5B-4 Installation ......
  • Page 12 7A-6 and Troubleshooting ....7A-15 Bravo One Sterndrive Units ..7A-6 Test Equipment Set-Up ... . .
  • Page 13 GENERAL INFORMATION SERVICE MANUAL NUMBER 28 IMPORTANT INFORMATION Section 1A - General Information Table of Contents How To Use This Manual ....1A-2 Page Numbering ....1A-2 How to Read a Parts Manual .

  • Page 14: How To Use This Manual

    IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28 How To Use This Manual This manual is divided into sections that represent major components and systems. Some sections are further divided into parts that more fully describe the component. Sections and parts are listed at front of this manual. Page Numbering Two number groups appear at the bottom of each page.
  • Page 15 CABLE TIE REF. NO. : Number shown next to part on exploded view PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM part number will be given in description column. QTY. : The quantity that must be ordered.

  • Page 16: Directional References

    IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28 Introduction This comprehensive overhaul and repair manual is designed as a service guide for the MerCruiser models previously listed. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products.
  • Page 17 GENERAL INFORMATION SERVICE MANUAL NUMBER 28 Sterndrive Unit 10-Hour Break-In Period (New or With Replacement Gears) 1. Avoid full throttle starts. 2. DO NOT operate at any one constant speed for extended periods of time. 3. DO NOT exceed 75% of full throttle during the first 5 hours. During the next 5 hours, operate at intermittent full throttle.
  • Page 18 IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 1A-6 90-863160 MAY 2000...
  • Page 19 MAINTENANCE SERVICE MANUAL NUMBER 28 IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents Lubricants / Sealants / Adhesives ..1B-2 Changing Sterndrive Oil ....1B-10 Maintenance Schedules .
  • Page 20 MAINTENANCE SERVICE MANUAL NUMBER 28 Lubricants / Sealants / Adhesives Description Part Number Quicksilver 4-Cycle 25W-40 Marine Engine Oil 92-802837A1 SAE 20W, 30W Or 40W Engine Oil Obtain Locally Quicksilver High Performance Gear Lube 92-802854A1 Extended Life Ethylene Glycol Antifreeze Obtain Locally Quicksilver Special Lubricant 101 92-13872A1...

  • Page 21: Maintenance Schedules

    However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed. In some cases, this may allow for more tasks to be performed in a single visit to the servicing dealer, rather than multiple visits.
  • Page 22 Check engine alignment. Lubricate U-joints splines. Lubricate gimbal bearing and engine coupler. Check continuity circuit for loose or damaged connec- tions. Test MerCathodeR unit output on Bravo Models. Retorque engine mounts. Check spark plugs, wires, distributor cap and ignition timing. Check and adjust idle speed.
  • Page 23 We recommend the use of Quicksilver Maintenance Products where specified. Fluid Capacities NOTICE Unit Of Measurement: U.S. Quarts (Liters) All capacities are approximate fluid measures. Model Bravo One Bravo Two Bravo Three Sterndrive Unit Oil Capacity 88 (2603) 104 (3076)
  • Page 24 76910 72239 77047 77046 Bravo One / Bravo Two Sterndrives Bravo Three Sterndrive/ Bravo XZ & XR Propeller Shaft Steering System WARNING Transom end of steering cable MUST BE fully retracted into cable housing when lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur.
  • Page 25 MAINTENANCE SERVICE MANUAL NUMBER 28 Tie Bar Pivot Points MODELS WITH CONTROL VALVE MOUNTED ON STARBOARD TRANSOM ASSEMBLY 22079 22079 Starboard Engine Port Engine Pivot Point MODELS WITH CONTROL VALVE MOUNTED ON PORT TRANSOM ASSEMBLY 22079 22079 Starboard Engine Port Engine Pivot Point Transom Gimbal Housing Assembly Swivel Shaft and Gimbal Bearing 50072...
  • Page 26 MAINTENANCE SERVICE MANUAL NUMBER 28 Checking and Adding Sterndrive Oil IMPORTANT: Position sterndrive unit in DOWN/IN position so that anti-ventilation plate is level. CAUTION If more than 2 fl. oz. (59 ml) of oil is required to fill sterndrive unit, an oil leak may exist.
  • Page 27 1. Bravo I: Trim sterndrive unit to full DOWN/IN position. 70023 Oil Fill/Drain Plug Sealing Washer 2. Bravo II and III: Trim sterndrive unit to full UP/OUT position. 22103 22101 Oil Fill/Drain Plug Sealing Washer 3. Remove fill/drain plug to sample lubricant. If water runs out sterndrive unit is leaking and must be resealed.
  • Page 28 1. Bravo I: Trim sterndrive unit to full DOWN/IN position. 70023 Oil Fill/Drain Plug Sealing Washer 2. Bravo II and III: Trim sterndrive unit to full UP/OUT position. 22103 22101 Oil Fill/Drain Plug Sealing Washer 3.
  • Page 29 MAINTENANCE SERVICE MANUAL NUMBER 28 7. Check condition of hose and hose connections. Replace as necessary. 71990 Gear Lube Monitor 8. Remove sterndrive unit vent plug and fill/drain plug. Allow lubricant to drain completely. 9. If sterndrive unit is draining in full DOWN/IN position, trim to full UP/OUT position after draining drain any remaining oil from internal driveshaft housing ledges.

  • Page 30: General Maintenance

    MAINTENANCE SERVICE MANUAL NUMBER 28 General Maintenance Maintaining Power Package Exterior Surfaces Entire power package should be sprayed at recommended intervals with Quicksilver Corrosion Guard. Follow instructions on can for proper application. Entire power package should be cleaned and external surfaces that have become bare should be repainted with Quicksilver Primer and Spray Paint at recommended intervals.

  • Page 31: Power Package Layup

    • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 1-1/2 in. (40 mm) UNPAINTED area on transom of the boat around these items.

  • Page 32: Power Package Recommissioning

    MAINTENANCE SERVICE MANUAL NUMBER 28 9. After paint has dried, spray entire sterndrive with Quicksilver Corrosion Guard. Refer to SECTION 1B. CAUTION Store sterndrive unit in the full trim DOWN/IN position. U-joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to ser- vice.
  • Page 33 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 IMPORTANT INFORMATION Section 1C - Troubleshooting Table of Contents Table of Contents ..... 1C-1 Propeller Ventilating/Cavitating .

  • Page 34: Troubleshooting

    TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Troubleshooting This section is a guide for performance and product troubleshooting. Referrals to specific sections of this manual are made where special tests or repair procedure are to be performed. Because of the relationship between Power Package components (engine and sterndrive), it will be necessary in some cases to simultaneously refer to the appropriate Engine Service Manual for further troubleshooting information.
  • Page 35 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Does Not Move NOTE:For additional information on troubleshooting, refer to SECTION 2A and see “Troubleshooting Shift Problems.” Cause Special Instructions Control box not properly assembled. Properly reassemble control box.
  • Page 36 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Gear Housing Noise Cause Special Instructions Disassemble, clean and inspect and Metal particles in drive unit lubricant. replace necessary components. (Refer to SECTION 3B, 3C or 3D) Inspect mounting hardware. Install Propeller incorrectly installed. propeller correctly. Inspect and replace if necessary.
  • Page 37 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Drive Shaft Housing Noise (Continued) Cause Special Instructions Remove U-joint coupling end yoke and insert into gimbal bearing and engine Worn U-joint shaft splines and/or coupling. Rotate shaft back and forth. engine coupler splines. If play is excessive, replace U-joint coupling end yoke and/or engine coupler, as necessary.
  • Page 38 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Drive Shaft Housing Noise (Continued) Cause Special Instructions Boat transom too thin. Thickness: 2 Add thickness to transom. in. (51mm) minimum, 2-1/4 in. (57mm) maximum. Boat transom thickness uneven. This could affect engine to transom Repair boat as necessary.
  • Page 39 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Shift System Does Not React Cause Special Instructions With engine running, check for vacuum leaks. Squirt oil on fitting and hose connections and on the shift Vacuum leaks. cylinder-to-end plate joint. If oil is sucked in at any point, a vacuum leak exists.
  • Page 40 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Performance Troubleshooting Low WOT Engine RPM Cause Special Instructions Improper drive unit trim angle. Properly adjust drive unit trim angle. Damaged propeller. Repair or replace. Water test boat using a lower pitch Improper propeller pitch. propeller.
  • Page 41 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Poor Boat Performance And/Or Poor Maneuverability-Bow Too Low Cause Special Instructions Improper drive unit trim angle. Properly adjust drive unit trim angle. Redistribute boat load to stern. If bow overweight is caused by permanently Boat is bow heavy. installed fuel tank(s), contact the boat manufacturer.
  • Page 42 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Steering Hard Steering - Helm And Cable Cause Special Instructions Damaged steering cable. Replace cable. (Refer to SECTION 2) Steering cable too short (sharp bends) Select and install proper length cable. or too long (loops and long bends). (Refer to SECTION 2A) Steering cable corroded or not Lubricate or replace the cable.
  • Page 43 Whenever a troubleshooting solution calls for removal from vessel and/or dismantling of steering system components, such work must be carried out by a qualified marine mechanic. The following is offered as a guide only and neither Mercury MerCruiser nor the helm manufacturer are responsible for any consequences resulting from incorrect repairs.
  • Page 44 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Trim Electrical System NOTE:Refer to “Power Trim System Wiring Diagram.” Power Trim Pump Motor Will Not Run In The OUT/UP Or IN/DOWN Direction SOLENOIDS DO NOT CLICK Cause Special Instructions Bad electrical connection at the 110 amp fuse or at the battery or the harness came Check all electrical connection points unplugged from the pump...
  • Page 45 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Trim Pump Motor Will Not Run In The OUT/UP Or IN/DOWN Direction BOTH SOLENOIDS CLICK Cause Special Instructions Check for battery voltage at terminals while trimming Faulty solenoids or loose or corroded OUT/UP. If no voltage is connections.
  • Page 46 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Trim Pump Motor Runs In The OUT/UP Direction, But Not In The IN/DOWN Direction IN/DOWN SOLENOID CLICKS Cause Special Instructions Check connections and 5. Clean Loose or dirty solenoid connections. and/or tighten as necessary. Check for battery voltage at terminal Faulty solenoid.
  • Page 47 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Trim Control OUT/UP Trim Switch Inoperative TRAILER SWITCH OPERATES Cause Special Instructions Trim limit switch lead bullet connectors Clean and/or tighten connections 14, loose or corroded. as necessary. Disconnect trim limit switch leads from trim harness. Connect a continuity meter between leads and 17.

  • Page 48: Power Trim System Wiring Diagram

    TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Trim System Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT...
  • Page 49 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Trim Hydraulic System NOTE:Refer to “Power Trim Hydraulic Schematic.” Drive Unit Cannot Be Trimmed OUT/UP Or Trims Slowly Or With Jerky Movements Cause Special Instructions Check for cause of low oil level and Power trim pump oil level low. correct.
  • Page 50 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Oil Foams Out Of Pump Fill/Vent Screw Cause Special Instructions Flush system with clean oil refill pump Contaminated oil. and bleed trim system. Check for cause of low oil level and Oil level low. correct. Add oil to pump and bleed system.
  • Page 51 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Sterndrive Will Not Stay In The Trimmed OUT/UP Position When Underway Cause Special Instructions Check for cause of entry. Fill and bleed Air in trim system. system. Leaky poppet valve. Install repair kit for poppet valve 1. Sterndrive Unit Trails OUT/UP On Deceleration Or When Shifting Into Reverse UNIT THUMPS WHEN SHIFTING Cause...
  • Page 52 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Trim Motor Runs But Does Not Pump Oil Cause Special Instructions Broken coupler between the pump and the Replace the coupler. motor. Plugged pick-up screens. Replace pick-up screens. Trim Pump Runs Slowly In Both Directions Cause Special Instructions Check the condition of the oil It may be...
  • Page 53 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Power Trim Hydraulic Schematic 73552 Shuttle Pump Adaptor UP/OUT Pressure Relief Valve Thermal Relief Valve Trim Cylinder IN/DOWN Pressure Relief Valve UP/OUT Hose IN/DOWN Hose Poppet Valves 90-863160 MAY 2000 Page 1C-21...
  • Page 54 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Auto Trim II Electrical System NOTE:Refer to “Auto Trim II System Wiring Diagram.” Pump Motor Will Not Run UP Or DOWN In Either Manual Or Auto Mode SOLENOIDS CLICK Cause Special Instructions Pump positive battery cable Check cable 14.
  • Page 55 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 SOLENOIDS DO NOT CLICK Cause Special Instructions Pump negative battery cable loose, Check cable for damage or a loose or corroded or damaged. corroded connection. Mode switch wiring harness connector Secure connection 47. is loose at pump. Connect a jumper wire between terminals and 7.
  • Page 56 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Pump Motor Will Not Stop Running Down In Auto Mode TRIM UP/OUT SWITCH AND TRAILER SWITCH INOPERATIVE IN MANUAL MODE NOTE:An internal timer in the control module stops the pump motor 50 seconds after this problem condition occurs.
  • Page 57 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Trim System Completely Inoperative In Manual Mode AUTO MODE FUNCTIONS PROPERLY Cause Special Instructions Check for voltage at terminal with Faulty mode switch. mode switch in MANUAL mode. If no voltage is indicated, replace switch. Check leads for loose or Open circuit in wiring harness.
  • Page 58 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Pump Motor Will Run DOWN, But Not UP In Auto Mode MANUAL MODE FUNCTIONS PROPERLY Cause Special Instructions Open circuit in control module sense Check lead for loose or corroded lead. connections or damage. Faulty control module. Replace.
  • Page 59 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Trim UP/OUT Switch Inoperative In Manual Trim Control TRIM DOWN/IN SWITCH FUNCTIONS, AUTO MODE FUNCTIONS PROPERLY Cause Special Instructions Trim 20 amp fuse “43” blown (if Determine cause for blown fuse and equipped). correct before replacing fuse. Check voltage at terminal 44.
  • Page 60 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Auto Trim II System Wiring Diagram 22178 Page 1C-28 90-863160 MAY 2000...
  • Page 61 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Corrosion Protection NOTE:Refer to “MerCathode Controller Wiring Diagram.” Corrosion On Underwater Parts, Without MerCathode Or Impressed Current Protection Cause Special Instructions Replace anode(s) when 50% Sacrificial anode(s) consumed. consumed. Add MerCathode (impressed current Stainless steel propeller installed. protection) or additional sacrificial anodes.
  • Page 62 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Corrosion On Underwater Parts, With MerCathode Or Impressed Current Protection DRIVE CORRODING Cause Special Instructions Poor connection between reference electrode (BRN) lead or anode Clean and/or tighten connection. (ORN) lead and MerCathode Repair wiring. controller. Disconnect reference electrode lead (BRN) from the controller “R”...
  • Page 63 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 DRIVE CORRODING - CONTINUED Cause Special Instructions Connect positive (+) lead of volt meter (set on 0-20 volt scale) to positive (+) terminal on the controller and negative (-) volt meter lead to negative (-) No power to MerCathode controller.
  • Page 64 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Corrosion On Underwater Parts, With MerCathode Or Impressed Current Protection DRIVE OVER-PROTECTED Cause Special Instructions Disconnect reference electrode lead (BRN) from “R” terminal on controller. Connect the lead to the positive (+) terminal of a digital multimeter (set on 0-2000 millivolt scale).
  • Page 65 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 Testing Procedure for Corrosion Protection 1. Unplug shore power (if equipped). 2. Measure hull potential with silver/silver chloride reference electrode and digital volt/ohm meter. READINGS Potential Diagnosis Drive is corroding. Below 850 millivolts (Refer to “Drive Corroding”) Saltwater Between 850 - 1100 Drive is protected...
  • Page 66 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 MerCathode Controller 73596 Controller 20 Amp Fuse Electrode Page 1C-34 90-863160 MAY 2000...
  • Page 67 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK 90-863160 MAY 2000 Page 1C-35...
  • Page 68 TROUBLESHOOTING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 1C-36 90-863160 MAY 2000...
  • Page 69 ....2A-4 Shift Cable Installation Bravo Three Notice: and Adjustment ....
  • Page 70 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Torque Specifications NOTE: Securely tighten all fasteners not listed below. Fastener Location lb-in. lb-ft Exhaust Pipe to Gimbal Housing Screws Block Off Plate to Gimbal Housing Screws Propeller Nut Tighten Nut Until It Drive Unit Shift Cable Locknut Contacts Flat Washer, Then Loosen 1 Turn...
  • Page 71 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Transom Thickness and Surface IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts. Transom thickness and surface must conform to the following: Transom Specifications Thickness Between 2 - 2-1/4 in. (51 - 57 mm) Parallelism Inner and outer surfaces must be parallel within 1/8 in.
  • Page 72 IN at higher speeds. Increased trim IN range may cause handling problems on some boats which could result in personal injury. IMPORTANT: On Bravo One, Two and Three Models, the Trim-In Limit Insert, must be properly positioned before installing the trim cylinder anchor pin in the following steps.
  • Page 73 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 1. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model. 75157 Bravo One and Two (Positioned Forward) 75158 Bravo Three (Positioned Aft) Trim-In Limit Insert IMPORTANT: The position of the Trim-In Limit Insert on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested.
  • Page 74 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Sterndrive Unit Removal 1. Shift remote control into neutral. 2. Place the drive unit to the full UP/OUT position. CAUTION Avoid speedometer hose fitting damage. Disconnect the speedometer hose fitting from the drive shaft housing before removing the sterndrive unit. 3.
  • Page 75 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 5. Remove the locknuts holding the sterndrive onto the bell housing, then remove the sterndrive unit. 22031 Locknuts (6) And Flat Washers (5) Ground Plate (Flat Washer Not Used Here) 22025 Shift Linkage Jaws Shift Cable End 6.
  • Page 76 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Transom Assembly Removal 1. Remove engine (Refer to appropriate engine service manual). 2. Completely disconnect the power steering assembly. a. Disconnect the rear clevis pin from the steering lever. b. Disconnect forward clevis pin from steering cable end. c.
  • Page 77 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 3. Disconnect trim limit switch wires. 4. Remove power trim pump hydraulic hoses and disconnect trim limit switch wires. Cap hoses and plug pump fitting holes. 76631 Sta-Strap Trim Limit Switch Wires Hydraulic Hoses 5.
  • Page 78 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 6. Remove the continuity wire from the steering lever. 22028 Steering Lever Screw Continuity Wire 7. Disconnect the speedometer hoses. 70015 Speedometer Fitting 8. Remove seawater intake hose. 76636 Seawater Intake Hose Seawater Pickup Outlet Bolts and Star Washers Gear Lube Monitor Hose...
  • Page 79 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 11. On Diesel Models with Water Bypass Fitting - Remove fitting. 72045 Water Bypass Fitting 12. Remove transom locknuts and washers. 73902 Locknuts and Washers (8) 13. Separate the inner transom plate from the gimbal housing assembly. 90-863160 MAY 2000 Page 2A-11...
  • Page 80 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Transom Assembly Installation CAUTION Avoid continuity wire failure. Position the steering lever ground wire as shown or the wire may fatigue and break. 22028 Steering Lever Transom Plate Continuity Wire 1. Install the transom assembly. Tighten locknuts evenly, starting from the center and working outward.
  • Page 81 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 IMPORTANT: Hose must not come in contact with steering system components or the engine coupler and drive shaft. Connect gear lube monitor hose. 3. Install water inlet fitting with gasket. Torque bolts and star washers to 45 lb-in. (5 Nm). 76640 Hose To Gear Lube Monitor Hose Clamp...
  • Page 82 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 5. On D7.3L Diesel Models with Water Bypass Fitting - Apply Perfect Seal to threads and install fitting. Tighten securely and position as shown. 76656 Water Bypass Fitting 6. Connect water hoses to appropriate fittings. Tighten hose clamps securely. 76641 Seawater Hose To Engine Seawater Pump Seawater Pickup Hose...
  • Page 83 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 IMPORTANT: Exhaust pipe or block-off plate and gimbal housing mating surface, must be clean and free of nicks and scratches and O-ring must be properly seated in groove, or water may leak into boat. 76639 Mating Surface O-Ring...
  • Page 84 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 8. Through the prop exhaust models: Install exhaust pipe. Torque bolts to 23 lb-ft (31 Nm). 22028 Typical V6 and V8 Gasoline Engines Exhaust Pipe Bolts (4) 76657 71945 Typical Diesel Engine Exhaust Pipe Bolts (4) Page 2A-16...
  • Page 85 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 9. Through the transom exhaust models: Install exhaust block-off plate, if removed. Torque bolts to 23 lb-ft (31 Nm). 76638 Block-Off Plate Bolts IMPORTANT: Make hydraulic hose connections as quick as possible to prevent oil from leaking out of the system.
  • Page 86 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 12. Connect the power steering assembly to the transom. a. Lubricate bushings with Special Lubricant 101. 71901 Bushings b. Slide the power steering cylinder bushings between the transom mounting brackets. Tighten the two pivot bolts by hand. At the same time, move the steering assembly slightly to ensure proper pin engagement into the pivot bushings.
  • Page 87 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 16. Connect the cable end to the clevis with the forward clevis pin. Secure the pin in the clevis with a cotter pin. Spread the cotter pin ends. 71901 Rear Clevis Pin Clevis Cotter Pin Steering Cable End...
  • Page 88 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 19. Attach both hydraulic hose fittings. a. Torque both fittings to 23 lb-ft (31 Nm). Route hoses as appropriate to avoid contact with the steering system components. 73860 Models With One Hose Routed Behind Power Steering Control Valve Rear Pressure Hose Front Return Hose 74248...
  • Page 89 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 21. Connect the MerCathode wires at the MerCathode controller. 22232 ORN Lead - From Electrode on Transom Assembly RED/PUR Lead - Connect (Other End) To Positive (+) Battery Terminal BLK Lead - From Engine Harness BRN Lead - From Electrode On Transom Assembly 22.

  • Page 90: Sterndrive Unit Installation

    REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Sterndrive Unit Installation 1. Install and align the engine. Refer to the appropriate engine service manual. NOTE: If the engine was removed and the shift cable was disconnected, reinstall and adjust the shift cable before proceeding. 2.
  • Page 91 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 IMPORTANT: The edge of the U-joint bellows acts as a seal between the bell housing and the drive shaft housing. Ensure that the surface is not damaged. 24725 Drive Shaft Bellows Edge 5.
  • Page 92 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 7. Pull out the shift linkage as far as possible. The jaws will open. Lubricate the underside of the lower lip of the shift linkage assembly with Quicksilver Special Lubricant 101. 22025 Shift Linkage Assembly Jaws Open Underside of Lower Lip...
  • Page 93 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 NOTE: If the shift cable does not line up to properly enter the shift linkage jaws, use your hand to guide the cable into place while installing the sterndrive unit. 22025 Shift Linkage Jaws Shift Cable 9.
  • Page 94 If you are not sure of it’s original position, contact the boat manufacturer for their recommendation. Refer to “Special Information” at the front of this section before reinstalling the Trim-In Limit Insert. 11. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model. 75157...
  • Page 95 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 13. Place a large I.D. flat washer and bushing on each end of the anchor pin. Be sure to install the bushings with the small diameter end facing outward. 22029 Anchor Pin Large I.D.
  • Page 96 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 18. Attach the speedometer hose fitting to the sterndrive unit. a. Raise the sterndrive unit to gain access to the area between the gimbal housing and the sterndrive unit. Locate the opening in the forward end of the anti-ventilation plate. b.
  • Page 97 NOTE: Using Adjustment Tool (91-12427), shift cables can be adjusted with or without the sterndrive installed. IMPORTANT: Front propeller on Bravo Three sterndrive unit is always LH rotation and rear propeller is always RH rotation. Shift cable end guide must move in direction “A”, when control lever is placed in FORWARD gear position.
  • Page 98 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 3. Install sterndrive unit shift cable. 71658 Washers (2) Locknut-Tighten Until Contact, Then Loosen 1 Turn Cotter Pin-Insert from Top and Spread Both Ends 4. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place over the barrel retainer with a piece of tape.
  • Page 99 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 6. Adjust control cable as follows: a. Temporarily install control cable end guide into shift lever and insert anchor pin. b. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud.
  • Page 100 RH ROTATION BRAVO ONE AND TWO, AND ALL BRAVO THREE MODELS: Rear slot in tool should fit over shift lever stud. LH ROTATION BRAVO ONE AND TWO MODELS: Forward slot in tool should fit over shift lever stud. If slot does not fit over stud, loosen shift lever stud and slide stud up or down, until slot in tool fits over stud.

  • Page 101: Troubleshooting Shift Problems

    REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 Troubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting, if hard shifting or chucking/racheting is encountered when shifting into forward gear. 1. When installing the control box in the side panel of the boat, make sure that the cables have enough clearance to operate.
  • Page 102 REMOVAL, INSTALLATION AND ADJUSTMENTS SERVICE MANUAL NUMBER 28 5. Be sure the cable is not permanently kinked. 6. Make sure there is proper clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either forward or reverse.
  • Page 103 ......3A-44 Bravo X, XZ, XR and Diesel Reassembly ..... .
  • Page 104 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Specifications Torque Specifications Fastener Location lb-in. lb-ft Shift Cam Assembly Locknuts U-joint Bearing Retainer Nut Shift Cam Assembly to Shifter Shaft Screw Shift Linkage to Shifter Shaft, Screw Top Cover Screws Back Cover Screws Drive Shaft Housing to Gear Housing Nuts and Screw Anodic Plate Screw...
  • Page 105 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Bearing Preloads Description lb-in. U-joint Bearings (New) U-joint Bearings (Used)* * Bearings are used if spun once under load. Lubricants / Sealants / Adhesives Description Part Number Quicksilver 2-4-C Marine Lubricant with Teflon 92-825407A1 3M Brand Adhesive 92-86166-Q1...
  • Page 106 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Housing Exploded View Complete Housing 76799 Page 3A-4 90-863160 MAY 2000...
  • Page 107 O-ring 34 - Screw (3) 17 - Shifter Shaft Bushing-Upper 35 - Steel Bearing Adapter (Bravo X, XZ, XR and Diesel Bravo) 18 - Shifter Shaft Bushing-Lower - 3M Brand Adhesive - Quicksilver Needle Bearing Assembly Lubricant - Loctite 271...
  • Page 108 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Exploded Parts View (Clutch) 76668 Keepers Garter Springs Collar Clutch Upper Gear Assembly Lower Gear Assembly Thrust Bearings Shaft - Quicksilver High Performance Gear Lube Page 3A-6 90-863160 MAY 2000...
  • Page 109 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Exploded Parts View (Shifter) 73363 Socket Screws Locknuts Shifter Shaft Link Bar Screws 10 - Latch Upper Shift Cam 11 - Shift Lever Yoke 12 - Flat Washer Spacers 13 - Cotter Pin Lower Shift Cam - Quicksilver High Performance Gear Lube - Quicksilver Special Lubricant 101...
  • Page 110 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Standard Bravo U-joint Assembly 73364 Locknut 11 - Beveled Washer Washer 12 - Oil Seal Pinion Gear 13 - Oil Seal Carrier Bearing (Smaller OD) 14 - Ring Nut Bearing (Smaller ID) 15 -...
  • Page 111 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Bravo X, XZ, XR and Diesel Bravo U-joint Assembly 76856 Locknut 10 - Oil Seal Washer 11 - O-Ring Pinion Gear 12 - Retainer Nut Bearing Cup (Smaller OD) 13 - Yoke Bearing (Smaller ID)
  • Page 112 The gear ratio then would have to be determined by counting the teeth on the drive gear and the driven gear in the drive shaft housing and using the following charts for reference. Bravo One U-JOINT IDENTIFICATION RATIO U-JOINT SHAFT MARKING 1.65:1...
  • Page 113 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 NUMBER OF TEETH PER GEAR - DRIVE SHAFT HOUSING RATIO DRIVE DRIVEN 2.20:1 2.00:1 1.81:1 1.65:1 1.50:1 Bravo Three U-JOINT IDENTIFICATION RATIO U-JOINT SHAFT MARKING 2.43:1 2.20:1 2.00:1 1.81:1 1.65:1 1.50:1 1.36:1 NUMBER OF TEETH PER GEAR - DRIVE SHAFT HOUSING...
  • Page 114 RATIO U-JOINT SHAFT MARKING 1.50:1 NUMBER OF TEETH PER GEAR - DRIVE SHAFT HOUSING RATIO DRIVE DRIVEN 1.50:1 Diesel Bravo One X U-JOINT IDENTIFICATION RATIO U-JOINT SHAFT MARKING 1.65:1 1.50:1 1.36:1 NUMBER OF TEETH PER GEAR - DRIVE SHAFT HOUSING...
  • Page 115 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 NUMBER OF TEETH PER GEAR - DRIVE SHAFT HOUSING RATIO DRIVE DRIVEN 2.20:1 2.00:1 1.81:1 1.65:1 1.50:1 Diesel Bravo Three X U-JOINT IDENTIFICATION RATIO U-JOINT SHAFT MARKING 2.43:1 2.20:1 2.00:1 1.81:1 1.65:1 1.50:1 1.36:1...
  • Page 116 22103 Fill/Drain Screw (Bravo Two) Fill/Drain Screw (Bravo One) 3. Remove vent plug. 50072 Vent Screw 4. Bravo One, Bravo XZ, Bravo XR, and Diesel Bravo One X: a. Remove rubber plug. 22093 Rubber Plug Page 3A-14 90-863160 MAY 2000...
  • Page 117 Remove gear case from drive shaft housing. 76801 6 Nuts and Washers (3 Each Side) Bolt (Located In Anodic Cavity) 5. Bravo Two and Diesel Bravo Two X: a. Remove gear case from drive shaft housing. 76802 6 Nuts and Washers (3 Each Side)
  • Page 118 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 6. Bravo Three and Diesel Bravo Three X: a. Remove gear case from drive shaft housing. 76803 Nuts and Washers (3 Each Side) Bolt (Located In Anodic Plate Cavity) Page 3A-16 90-863160 MAY 2000...
  • Page 119 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Housing Disassembly 1. Shift drive unit to the neutral detent position. 2. Remove rear cover by removing screws. Do not replace vent screw until reassembly. 76805 Screws Rear Cover Vent Hole 3.
  • Page 120 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 5. Remove bolts and lift top cover. 76835 Bolts (4) Cover 6. Install shift handle tool in shifter shaft and lift shaft straight out. 76836 Shift Handle Tool (91-17302) Shifter Shaft Page 3A-18 90-863160 MAY 2000...
  • Page 121 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 7. Remove shift linkage assembly. a. Rotate link bar 1/4 turn clockwise. b. Pull linkage assembly out. If linkage binds; move assembly from side to side while pulling. 76837 Shift Linkage 8. Remove yoke and cam assembly. 76838 Yoke and Cam Assembly 90-863160 MAY 2000...
  • Page 122 9. Loosen retainer nut and remove pinion and U-joint assembly using U-joint retainer wrench. 76840 76839 Standard Bravo Retainer Nut U-joint Retainer Nut Wrench (91-17256) 77077 Bravo XZ, XR & Diesel Bravo Retainer Nut U-joint Retainer Nut Wrench (91-862219) Page 3A-20 90-863160 MAY 2000...
  • Page 123 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 10. Remove upper thrust race (shim) and thrust bearing. NOTE: In steps 10 and 12, be sure to note proper order and position of thrust races, thrust bearings and clutch assembly for later reassembly. 76841 Upper Thrust Race Thrust Bearing...
  • Page 124 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 12. Remove lower thrust race (shim) and thrust bearing. 50341 76841 Lower Thrust Race Thrust Bearing Shifter Repair 1. Remove latch from link bar. 22100 Latch Link Bar 2. Remove link bar from shift lever. Discard cotter pin. 22099 Link Bar Cotter Pin...
  • Page 125 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 3. Remove ball detent canister and compression spring. 22100 Ball Detent Canister Compression Spring 4. Disassemble yoke and cam assembly. 22101 Shift Cam Bolts 75221 22101 Spacers Yoke Contact Surface Shift Cam Locknuts 90-863160 MAY 2000 Page 3A-23...
  • Page 126 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 5. Remove shifter shaft upper O-ring. 76843 O-ring 6. Remove shifter shaft upper bushings using tool. 22459 22223 Bushing Removal Tool (91-17273) Bushing Page 3A-24 90-863160 MAY 2000...
  • Page 127 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 7. Remove shifter shaft lower bushing and oil seal using tool. 22459 22223 Shift Shaft Lower Bushing Oil Seal Bushing Removal Tool (91-17273) Shifter Inspection NOTE: Use exploded parts views as reference. 1. Shift link bar and shift lever for: •...
  • Page 128 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Shifter Reassembly 1. Install shifter shaft lower bushing and oil seal as follows: a. Install lower bushing part way into bore as shown. 22223 22459 Lower Bushing b. Place oil seal onto bearing and seal driver with lip of seal facing upward. Apply Loc- tite 271 to outside diameter of seal before installation.
  • Page 129 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 d. Pull oil seal and bushing into place by turning screw clockwise until tool bottoms out on casting. (Top and Bottom). 22223 22459 e. Loosen screw and remove tool. 2. Install shift shaft upper bushings as follows: a.
  • Page 130 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 4. Torque locknuts to 80 lb-in. (9 Nm). 22101 Shift Cam Bolts Contact Surface 22101 Spacers Yoke Contact Surface 75221 Shifter Assembly Locknuts Shift Cam Page 3A-28 90-863160 MAY 2000...
  • Page 131 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 5. Apply small amount of Special Lubricant 101 to compression spring and ball detent can- ister and install into rear cover. 22100 Compression Spring Detent Canister 6. Install link bar to shift lever. Install cotter pin and spread ends. 22099 Link Bar Shift Lever...
  • Page 132 Disassembly 1. Remove nut and washer from U-joint shaft and remove drive gear and bearings as an assembly. Remove remaining components. 76861 Standard Bravo Shown Drive Gear and Bearing Assembly Washer CAUTION DO NOT damage spacer when removing first bearing from pinion gear, spacer must be used in reassembly.
  • Page 133 3. If seal is defective, remove U-joint seal using a punch and hammer or press out with suit- able mandrel. NOTE: The U-joint seal is located in the seal carrier on standard Bravo drives and in the bearing retainer nut on Bravo X, XZ, XR, and Diesel Bravo.
  • Page 134 Drive off universal joint bearing snap rings, using a punch and hammer. 22179 Snap Ring b. Standard Bravo: Using adaptor and U-joint press, press one bearing in until oppo- site bearing is pressed out into adaptor. Remove loose bearing. 22180...
  • Page 135 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Art for Bravo XZ, Bravo XR, and Diesel Bravo U-joint service was not available at time of printing. 90-863160 MAY 2000 Page 3A-33...
  • Page 136 U-joint snap rings might accidentally be knocked off of the u-joint during installa- tion. Wear safety glasses to avoid eye injury. a. Standard Bravo U-Joint:Place U-joint bearing cups in yoke and start them on bear- ing cross members. Install by using adaptor and pressing bearing through yoke and onto cross members.
  • Page 137 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 b. Install bearing cup retaining snap rings. 22182 Hammer Snap Ring c. Install each pair of bearings in this manner. 90-863160 MAY 2000 Page 3A-35...
  • Page 138 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Art for Bravo XZ, Bravo XR, and Diesel Bravo U-joint service was not available at time of printing. Page 3A-36 90-863160 MAY 2000...
  • Page 139 NOTE: The U-joint seal is located in the seal carrier on standard Bravo drives and in the bearing retainer nut on Bravo X, XZ, XR, and Diesel Bravo.
  • Page 140 Larger Outside Diameter Bearing (Fifth) Standard Bravo - Spacer .250 in. (6.35 mm) Thick Bravo X, XZ, XR & Diesel Bravo - Spacer .210 in. (5.36 mm) Thick IMPORTANT: Spacer between bearing cups must free to move. Do not over press, as damage to both bearings could occur.
  • Page 141 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 e. Press larger outside diameter bearing onto gear. Press bearing to the point where bearing rollers initially make contact with tapered bearing cup. 22393 Bearing – Larger Outside Diameter. Larger Outside Diameter Bearing Cup Spacer –...
  • Page 142 O-ring (Position Between Oil Seal Carrier And Sealing Ring) Sealing Ring (Taper Facing U-joints) 76845 Bravo X, XZ, XR & Diesel Bravo Retainer Nut (Threaded End Toward Pinion Gear) Oil Seal (Lip Of Seal Facing Pinion Gear) O-ring (Position On Retainer Nut) Thrust Washer (Taper Facing U-joints) 7.
  • Page 143 U-joint shaft using a soft hammer. Readjust, starting at beginning of this step. 70212 Standard Bravo Shown Torque Wrench (lb-in. – Dial Indicator) Drive Shaft Housing (U-joint Shaft Hanging Straight Down) 90-863160 MAY 2000...
  • Page 144 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Gear Disassembly, Inspection and Reassembly • Refer to “Special Information” on page 19 if gear assembly components are being replaced. Disassembly 1. Remove keepers by pressing down on gear and turning clockwise to release keepers and collar.
  • Page 145 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 3. Remove thrust bearing and garter spring. 76862 Thrust Bearing Garter Spring 4. Twist clutch counterclockwise while pulling up to separate clutch from shaft. 22106 Clutch 5. Remove lower garter spring and thrust bearing. 76848 Garter Spring Thrust Bearing...
  • Page 146 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Inspection 1. Clean all parts in nontoxic solvent; then dry with compressed air. Be careful not to spin bearings. Inspect gears for pitting, chipped or broken teeth, and excessive or uneven wear. Replace gear if any of these conditions exist. 2.
  • Page 147 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 2. Install thrust bearing and garter spring with silver side of bearing toward garter spring. Lubricate parts with gear lube. 76848 Thrust Bearing (Silver Side Toward Garter Spring) Garter Spring 3. Lower clutch over shaft while allowing it to turn clockwise. 22106 Clutch 4.
  • Page 148 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 5. Place top gear and then thrust collar over shaft. 76847 Thrust Collar Top Gear Stand (91-17301A1) 6. Press gear and thrust collar down so that groove in shaft is completely exposed. Install keepers.
  • Page 149 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Housing and Top Cover - Bearings and Bearing Sleeves Inspection 1. Inspect needle bearing races in top cover and in drive shaft housing for pitting, grooves, discoloration or embedded particles. If any of these conditions exist, replace race. 2.
  • Page 150 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 3. Install driver guide as shown. 22082 Driver Guide (92-90244A1) Top Cover 4. Remove sleeve by rotating bolt clockwise. Bearing Sleeve Removal (Drive Shaft Housing) 1. Place puller jaws around sleeve. 22219 Drive Shaft Housing Pull Jaws (2 Halves) (91-90244A1) Sleeve 2.
  • Page 151 Driver Guide (91-90244) 4. Remove sleeve by rotating bolt clockwise. Roller Bearing Removal 1. Standard Bravo: To remove roller bearing from drive shaft housing, use a suitable man- drel and drive bearing down into oil cavity. 22260 Bearing And Mandrel...
  • Page 152 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 2. Bravo X, XZ, XR & Diesel Bravo: Remove roller bearing using a slide hammer puller, Snap-On adaptor and puller head as shown. 76863 Slide Hammer Puller (91-34569A1) Snap-On Adaptor (CG-40-4) Puller Head (CG-40-A10) 3.
  • Page 153 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Steel Bearing Adaptor Removal IMPORTANT: It is not necessary to remove the steel bearing adaptor for normal drive- shaft housing disassembly; however, in the event of gear or bearing failure the steel bearing adaptor can be removed to aid in removal of metal chips and contamination from oil passages.
  • Page 154 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Steel Bearing Adaptor Installation 1. Install oil passage plug. 77043 Drive Shaft Housing Oil Passage Plug 2. Clean threads of steel bearing adaptor and apply Loctite 277. 3. Install steel bearing adaptor in drive shaft housing using bearing adaptor socket. Torque to 175 lb-ft.
  • Page 155 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Bearing Sleeve Installation 1. Install driver head onto puller guide. Secure driver head to puller guide with screw. Place bearing sleeve against edge of driver head as shown. 22084 Driver Head (91-862530) Puller Guide (91-90774) Screw (91-90775) Bearing Sleeve 2.
  • Page 156 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Roller Bearing Installation 1. Install driver head onto puller guide. Secure driver head to puller guide with screw. Lubri- cate inside diameter of roller bearing and place roller bearing on driver head, as shown. 75967 Driver Head (91-862530) Puller Guide (91-90774)
  • Page 157 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Housing Reassembly • Two (2) numbers are stamped in the shifter cavity on the back of the drive shaft hous- ing. The top number designates the thickness of the top thrust bearing race, and the bottom number designates the thickness of the bottom thrust bearing race.
  • Page 158 22437 76850 Standard Bravo Bravo X, XZ, XR, & Diesel Bravo Thrust Bearing Race 2. Apply a mixture of 60% Hi Performance Gear Lube and 40% Special Lubricant 101 to bottom face of bottom gear. Stick thrust bearing to gear. Install clutch assembly.
  • Page 159 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 3. Apply a mixture of 60% Hi Performance Gear Lube and 40% Special Lubricant 101 to the top face top gear and the thrust bearing. Place thrust bearing on gear. Position cor- rect thrust bearing race on top of thrust bearing. 50304 Thrust Bearing Thrust Race...
  • Page 160 5. Install U-joint assembly into drive shaft housing. Apply Special Lubricant 101 to threads of retainer nut and install. Torque retainer nut to 200 lb-ft (271 Nm). NOTE: On Bravo X, XZ, XR & Diesel Bravo, the retainer nut must be started using retainer nut spanner wrench.
  • Page 161 36 (914) 150 (203) 12" 26363 Typical Bravo Retainer Nut Tool Shown Torque Wrench Length TORQUING BRAVO U-JOINT BEARING RETAINER NUT Use the following procedure to allow torquing retainer nut with a torque wrench. a. On beam-type torque wrenches, measure from square drive to fulcrum (pivot) point of handle.
  • Page 162 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 7. Install shift cam assembly into shifter cavity in drive shaft housing with the shift cam nuts facing the bottom of the drive shaft housing. 76838 Shift Cam Assembly Shift Cam Assembly Boss 8.
  • Page 163 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 b. Turn linkage assembly 1/4 turn counterclockwise and position as shown. 76852 Linkage Assembly 9. Install shift handle tool in shifter shaft and push shaft down. Remove tool. 50306 Shift Handle Tool (91-17302) Shifter Shaft 90-863160 MAY 2000 Page 3A-61...
  • Page 164 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 10. Install shift handle tool through shift linkage and into shifter shaft. Move shifter shaft back and forth as necessary to align lower hole in shift cam assembly with threaded hole in shifter shaft. Apply Loctite 271 to first 2 or 3 threads of screw, install shift cam cap screw and torque to 100-120 lb-in.
  • Page 165 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 12. Move shift linkage to the neutral detent position as shown. Apply liberal amount of Spe- cial Lubricant 101 to I.D. of screw recess. 61 1 76852 Screw Recess 90-863160 MAY 2000 Page 3A-63...
  • Page 166 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 13. Replace O-rings in drive shaft housing. Apply 3-M Adhesive to O-rings before installa- tion. 50356 Shift Linkage O-ring Water Passage O-ring 22100 50306 Shifter Shaft O-ring Back Cover O-ring 22088 Top Cover O-ring Page 3A-64 90-863160 MAY 2000...
  • Page 167 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 14. Install top cover. Torque screws to 20 lb-ft (27 Nm). 76835 50304 Top Cover Screws 15. Install rear cover and screws. Torque screws to 20 lb-ft (27 Nm). NOTE: To avoid damage to cover, evenly tighten screws until cover is flush against drive shaft housing before torquing screws.
  • Page 168 SERVICE MANUAL NUMBER 28 Install Gear Housing To Drive Shaft Housing 1. Bravo One, Bravo XZ, Bravo XR, and Diesel Bravo One X: a. Install gear housing to drive shaft housing. Torque nuts and bolt to 35 lb-ft (47 Nm).
  • Page 169 Install anodic plate. Torque bolt to 20 lb-ft (27 Nm). 76801 1/2 in. Bolt 3. Bravo Three and Diesel Bravo Three X: a. Install the bolt in the anode cavity. Torque bolt to 35 lb-ft (47 Nm). 76804 Bolt b.
  • Page 170 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 c. Install anode. Torque bolt to 20 lb-ft (27 Nm). Install rubber plug. 76832 Bolt 4. Fill drive unit with gear lube. (Refer to Section 1B.) Page 3A-68 90-863160 MAY 2000...
  • Page 171 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK 90-863160 MAY 2000 Page 3A-69...
  • Page 172 DRIVE SHAFT HOUSING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 3A-70 90-863160 MAY 2000...
  • Page 173 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 STERNDRIVE UNIT Section 3B - Bravo One Gear Housing Table of Contents Specifications ......
  • Page 174 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Specifications Torque Specifications Fastener Location lb-in. lb-ft Driveshaft Pinion Screw Bearing Carrier Retainer Nut Torque to Proper Preload Drive Shaft Housing to Gear Housing Nuts and Bolt Anodic Plate Screw Oil Fill/Drain Plug...
  • Page 175 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Tools Description Part Number Dial Indicator Set 91-58222A1 Backlash Indicator Rod 91-53459 Dial Indicator Adaptor Kit 91-83155 Slide Hammer Puller 91-34569A1 Torque Wrench (lb-in.) 91-66274 Drive Shaft Pinion Gear Shimming Tool 91-42840T...
  • Page 176 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bravo One Gear Housing Exploded View Drive Shaft Components 76865 Page 3B-4 90-863160 MAY 2000...
  • Page 177 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Retainer 11 - Tapered Bearing (Larger Dia.) Coupler 12 - Tapered Bearing (Smaller Dia.) O-Ring 13 - Seal, Water Passage Spacer 14 - Seal, Speedometer Water Passage Shim(s) 15 - Lock Nut...
  • Page 178 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bravo One and Diesel Bravo One X Propeller Shaft Components 12 11 76826 Page 3B-6 90-863160 MAY 2000...
  • Page 179 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing 14 - Load Ring Shims 15 - Washer Bearing Cup 16 - O-Ring Tapered Bearing 17 - Seals Driven Gear 18 - Bearing Carrier Needle Bearing 19 - Washer Pinion Gear...
  • Page 180 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bravo XZ and Bravo XR Propeller Shaft Components 77109 Page 3B-8 90-863160 MAY 2000...
  • Page 181 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing 15 - Washer Shims 16 - O-Ring Bearing Cup 17 - Seals Tapered Bearing 18 - Bearing Carrier Driven Gear 19 - Washer Needle Bearing 20 - Drain Screw Pinion Gear...
  • Page 182 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Pre-Disassembly Inspection 1. Check propeller shaft for side to side movement, as follows: a. Position dial indicator on propeller shaft. b. Push propeller shaft to one side and zero the dial indicator.
  • Page 183 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Housing and Gear Housing Separation 1. Remove, empty and clean gear lube monitor. 2. Drain sterndrive unit. 76827 Fill/Drain Screw 3. Remove vent plug. 76866 Vent Plug 4. Remove rubber plug.
  • Page 184 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 5. Remove anodic plate. 22258 1/2 in. Bolt 6. Remove gear housing from drive shaft housing. 76879 Nuts And Washers (6) Bolt (1) CAUTION Clamp plate (91-43559) must be installed on gear housing when gear housing is separated from drive shaft housing.
  • Page 185 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing Disassembly 1. Remove propeller. 75492 Forward Thrust Hub Flo-Torque Drive Hub Propeller Drive Sleeve Adaptor Tab Washer 2. Bend tabs of tab washer away from bearing carrier retainer nut. 50136...
  • Page 186 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 3. Remove bearing carrier retainer nut, using bearing carrier retainer wrench. 22112 Bearing Carrier Retainer Wrench (91-61069) 4. Remove bearing carrier using bearing carrier puller. 22104 Bearing Carrier Puller (91-90338A1) 5. Remove propeller shaft.
  • Page 187 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 6. Remove washer, load ring and O-ring. 76829 Washer Load Ring O-ring 7. Temporarily reinstall bearing carrier retainer nut in gear housing to protect housing threads. 76870 Bearing Carrier Retainer Nut 8. Remove pinion gear, screw and washer. Hold drive shaft using drive shaft adaptor tool.
  • Page 188 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 9. Remove clamp plate (installed in Step 2.), then remove O-ring, spacer, shim(s) and tab washer. Retain shims for reassembly. 22262 Clamp Plate O-Ring Spacer Shim(s) Tab Washer 10. Remove drive shaft and pinion gear.
  • Page 189 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 11. Remove driven gear and bearing. 22283 Driven Gear Bearing Cup 12. Remove drive shaft bearing cup and shims using slide hammer puller. 22261 Drive Shaft Bearing Cup Shims 90-863160 MAY 2000...
  • Page 190 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 13. Unless you plan to remove the pinion bearing, remove needle bearings from drive shaft needle bearing race. (See Pinion Bearing Removal) 22083 Needle Bearings Drive Shaft Needle Bearing Race 14. Remove water passage O-ring and oil passage quad ring.
  • Page 191 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft And Pinion Bearing Inspection and Cleaning 1. The condition of the drive shaft tapered bearing cups is an indication of the condition of the tapered roller bearings on the drive shaft. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or has embedded metal particles.
  • Page 192 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Press drive shaft pinion bearing inner race from drive shaft, using universal puller plate. 76881 Drive Shaft Pinion Bearing Inner Race Universal Puller Plate Pinion Bearing Removal IMPORTANT: All needle bearings MUST BE in place inside bearing casing while driv- ing pinion bearing from gear case or bearing casing will bend or break and become difficult to remove.
  • Page 193 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Pinion Bearing Installation 1. Install needles in casing. Use Quicksilver Needle Bearing Assembly Lubricant to help keep needles in place. 2. Position bearing assembly over bearing installation tool with number on bearing casing facing up.
  • Page 194 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Reassembly 1. Lubricate inside diameter of tapered roller bearing with gear lube. Press small tapered roller bearing onto drive shaft using universal puller plate. Ensure that smaller outside diameter faces pinion end of shaft.
  • Page 195 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bearing Carrier Inspection 1. The condition of the propeller shaft tapered roller bearing cup is an indication of the condition of tapered roller bearing on propeller shaft. Replace bearing and cup if cup is pitted, grooved, scored, worn, uneven, discolored from overheating or has embedded metal particles.

  • Page 196: Bearing Carrier Reassembly

    BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bearing Carrier Reassembly 1. Coat outside diameter of oil seal with Loctite 271. Install outer oil seal with lip facing outward using cup and seal driver. 22459 22087 Oil Seal - Lip Outward Cup And Seal Driver (91-89865) 2.
  • Page 197 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Propeller Shaft Inspection 1. Check propeller shaft for bent condition. Use either of the following methods: a. LATHE and DIAL INDICATOR METHOD: (1.) Position propeller shaft centers in lathe. (2.) Mount dial indicator at front edge of propeller shaft.
  • Page 198 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Propeller Shaft Bearing Installation 1. Apply gear lube to inside diameter of new bearing. Install bearing to shaft using universal puller plate and a suitable mandrel (old bearing race) which supports bearing on inner race.
  • Page 199 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Driven Gear Bearing Removal 1. Remove bearing from driven gear using universal puller plate. Inspect both the driven gear and the pinion gear for pitting, chipped or broken teeth and excessive or uneven wear.
  • Page 200 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Driven Gear Bearing Cup Removal and Inspection 1. Remove bearing cup and shims using slide hammer puller. Replace tapered roller bearing and cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or has metal particles embedded in the cup.
  • Page 201 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Speedometer Water Passage Pickup Inspection and Cleaning 1. Inspect opening (pitot tube), on leading edge of gear housing, for obstruction. Clean opening with a short piece of wire. If obstruction can not be removed with wire, carefully reopen tube using a 5/64 in.
  • Page 202 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Water Passage Seal Replacement 1. Pry seal out with a suitable tool. 22085 Seal 2. Lightly coat outside diameter of seal with 3-M adhesive and install in speedometer water passage bore. Ensure that top edge of seal is flush with gear housing surface.
  • Page 203 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing Reassembly And Shimming 1. Lubricate all bearings with gear lube before installing. Components must be lubricated to obtain accurate bearing preload readings. 2. Install water passage O-ring and oil passage quad ring. Hold in place using 3-M adhesive.
  • Page 204 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Install driven gear assembly. 22083 Driven Gear Assembly 5. Install original thickness shim(s) and drive shaft lower bearing cup using bearing cup driver. Use original shims or if misplaced, start with .050 in. (1.27 mm) thickness.
  • Page 205 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 6. Install drive shaft and pinion gear. 22258 Drive Shaft Pinion Gear 7. Install pinion washer and screw. Apply Loctite 271 to threads of screw. 76877 Washer Screw 90-863160 MAY 2000 Page 3B-33...
  • Page 206 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 8. Temporarily install bearing carrier retaining nut to prevent damage to threads. 9. Torque pinion screw to 45 lb-ft (61 Nm). 22260 Drive Shaft Adaptor Tool (91-61077T) Breaker Bar And Socket Torque Wrench And Socket Bearing Carrier Retainer 10.
  • Page 207 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 12. Determine shim thickness required for drive shaft bearing preload using the following procedure or use original thickness shims. a. Measure distance between top of gear housing and tab washer using a 0-1 in. depth micrometer.
  • Page 208 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 13. Install shims, spacer and O-ring. 22259 Shims Spacer O-ring 14. Install clamp plate on gear housing with nuts (2) and washers (4). Torque to 35 lb-ft (47 Nm). 22262 Clamp Plate (91-43559T) 15.
  • Page 209 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 16. If preload is incorrect, adjust by adding or subtracting shims from upper tapered roller bearing cup. Reinstall clamp plate and recheck preload [3-5 lb-in. (0.3-0.6 Nm)]. Record final preload. 17. Check pinion height.
  • Page 210 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 18. Using a dial-type lb-in. torque wrench, recheck the rolling preload by rotating drive shaft with a slow steady motion (3-5 lb-in. [0.3-0.6 N⋅m]). 50410 Torque Wrench Drive Shaft Adaptor 19. Install the original load ring, thrust ring, O-ring and propeller shaft into the gear housing.
  • Page 211 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 20. Install bearing carrier and tab washer. Align inner tab of tab washer with V-notch in bearing retainer. 23257 Bearing Carrier Tab Washer Inner Tab Outer Tab 21. Install and tighten bearing carrier retaining nut using retainer wrench until resistance to propeller shaft rotation can be felt (to preload bearings).
  • Page 212 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 22. Driven gear shimming: a. Install dial indicator adaptor kit, backlash indicator rod and dial indicator set, as shown. Ensure that dial rod is aligned with “I” on indicator rod. 22439 Dial Indicator Adaptor (91-83155)
  • Page 213 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 IMPORTANT: Bearing carrier and threads on retainer must be lubricated to prevent corrosion and cracking in gear housing. Use Quicksilver Special Lubricant 101 on retainer threads; coat outside diameter on carrier mating surfaces with perfect seal.
  • Page 214 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 28. To determine overall gear case preload, add propeller shaft bearing preload (previously recorded) to drive shaft bearing preload as outlined in the example below. IMPORTANT: The overall preload includes both the drive shaft preload and the gear case preload.
  • Page 215 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 b. Using a lb-in. torque wrench, check overall gear housing bearing preload by rotating propeller shaft in direction of normal rotation with a slow steady motion. 75924 Torque Wrench Propeller Nut (Under Socket) c.
  • Page 216 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 31. Install gear housing to drive shaft housing. Torque fasteners to 35 lb-ft (47 Nm). 76879 Nuts And Washers (3 Each Side) Bolt (Located In Anodic Plate Cavity) 32. Install anodic plate. Torque bolt to 20 lb-ft (27 Nm).
  • Page 217 Bravo XZ and XR Heavy Duty Propeller Shaft Gear Housing Disassembly/Reassembly For disassembly and reassembly of Bravo XZ and XR gear housings refer to instructions for standard Bravo One gear housing. Procedures and specifications are identical except for installation of bearing carrier, bearing carrier retainer nut and propeller hub.
  • Page 218 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Position bearing carrier installation tool onto prop shaft as shown below. 3. Slide bearing carrier over installer tool and insert tab washer in gear housing. Position inner tab in V-notch. 77110...
  • Page 219 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 Installing Propeller Hub Assembly NOTE: Propeller Hub Assembly P/N 840389A1 will fit both long A45, A55 and short A46, A56 bore hub propellers. 1. Apply a small amount of Special Lubricant 101 or 2-4-C Marine Lubricant with Teflon to propeller hub assembly.
  • Page 220 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 3B-48 90-863160 MAY 2000...
  • Page 221 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 STERNDRIVE UNIT Section 3C - Bravo Two Gear Housing Table of Contents Specifications ..... . .
  • Page 222 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Specifications Torque Specifications Fastener Location lb-in. lb-ft Drive Shaft Pinion Nut Drive Shaft Housing to Gear Housing Nuts and Bolt Anodic Plate Screw Oil Fill/Drain Plug Propeller Nut Bearing Preloads Description lb-in.
  • Page 223 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Tools Description Part Number Universal Puller Plate 91-37241 Bearing / Seal Driver 91-813653 Bearing Driver 91-89867T Threaded Rod 91-31229 Bearing Cup Driver 91-67443T Driver Rod 91-37323 Bearing Removal Tool 91-63638T Drive Shaft Adaptor Tool...
  • Page 224 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Bravo Two Gear Housing Exploded View Drive Shaft and Propeller Shaft Components 34 36 75971 Page 3C-4 90-863160 MAY 2000...
  • Page 225 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing 25 - Shim Assembly Stud 26 - Tapered Roller Bearing O-Ring 27 - Propeller Shaft Seal 28 - Tapered Roller Bearing Roller Bearing 29 - Drive Gear Fill/Drain Screw 30 -...
  • Page 226 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Pre-Disassembly Inspection 1. Bend tabs straight on tab washer. Remove nut, washer, spline washer, propeller and thrust hub. 22074 Tab Washer Spline Washer Propeller Thrust Hub 2. Check propeller shaft for side to side movement, as follows: a.
  • Page 227 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Housing and Gear Housing Separation 1. Remove, empty and clean gear lube monitor. 2. Tilt drive unit to a 45° angle. Remove fill/drain screw and drive shaft housing vent screw.
  • Page 228 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing Disassembly 1. Remove bolt and anodic plate. 76801 Bolt CAUTION Clamp plate (91-43559) must be installed on gear housing when gear housing is separated from drive shaft housing. 2. Install clamp plate, nuts and 4 washers on gear housing. Tighten securely.
  • Page 229 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Remove bearing carrier retainer nut using bearing carrier retainer wrench (P/N 91-17257). 22112 Bearing Carrier Retainer Wrench 5. Remove bearing carrier using slide hammer puller. 19842 Slide Hammer Puller, 91-34569A1 Puller Jaws, 91-46086A1 6.
  • Page 230 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 7. Remove items shown. 24211 O-Ring Thrust Ring Load Ring 8. Temporarily reinstall retainer nut in gear housing to protect housing threads. 22217 Retainer Nut Page 3C-10 90-863160 MAY 2000...
  • Page 231 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 9. Remove pinion gear nut and washer. Hold drive shaft using drive shaft adaptor tool. 75921 Drive Shaft Adaptor Tool (91-61077T) Breaker Bar And Socket Pinion Gear Bearing Carrier Retainer 10. Remove clamp plate (installed in Step 2), then remove O-ring, spacer, shim(s) and tab washer.
  • Page 232 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 11. Remove drive shaft and pinion gear. 76871 Drive Shaft Pinion Gear 12. Remove driven gear and bearing. 22283 Driven Gear And Bearing 13. Remove drive shaft bearing cup and shims. Retain shims for reassembly.
  • Page 233 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 14. Unless you plan to remove the pinion bearing, remove needle bearings from drive shaft needle bearing race. (See Pinion Bearing Removal) 22083 Needle Bearings Drive Shaft Needle Bearing Race 15. Remove water passage O-ring and oil passage quad ring.
  • Page 234 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft and Pinion Bearing Inspection and Cleaning 1. The condition of the drive shaft tapered bearing cups is an indication of the condition of the tapered roller bearings on the drive shaft. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or has embedded metal particles.
  • Page 235 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Disassembly NOTE: Bearing assembly must be replaced if removed from drive shaft. Tapered roller bear- ings are damaged when removing. 1. Press tapered roller bearing from shaft using universal puller plate to support bearing on bearing inner race.
  • Page 236 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Pinion Bearing Removal IMPORTANT: All needle bearings MUST BE in place inside bearing casing while driv- ing pinion bearing from gear case or bearing casing will bend or break and become difficult to remove.
  • Page 237 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Pinion Bearing Installation 1. Install needles in casing. Use Needle Bearing Assembly Lubricant to help keep needles in place. Position bearing assembly over bearing installation tool with number on bearing casing facing up. Coat casing outside diameter with gear lube.
  • Page 238 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Reassembly 1. Lubricate inside diameter of tapered roller bearing with gear lube. Press small tapered roller bearing onto drive shaft using universal puller plate. Ensure that smaller outside diameter faces pinion end of shaft.
  • Page 239 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 3. Press drive shaft pinion bearing inner-race onto drive shaft until race is fully seated, using universal puller plate. 24210 Drive Shaft Pinion Bearing Inner-Race Universal Puller Plate (91-37241) Bearing Carrier Inspection 1.
  • Page 240 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Disassembly 1. Perform Method “a or b,” following: a. Method A – If Replacing Propeller Shaft Needle Bearing (1.) Press needle bearing and oil seals from carrier. NOTE: Needle bearing MUST BE replaced, if removed.
  • Page 241 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Remove bearing cup using slide hammer puller (P/N 91-34569A1). 50025 Slide Hammer Puller Bearing Cup Reassembly 1. Install bearing cup using cup and seal driver. 50023 Cup and Seal Driver - 91-63626...
  • Page 242 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Install needle bearing using bearing driver and driver rod. 50025 Driver Rod - *91-37323 Driver - 91-55918 Needle Bearing * Contained in Bearing Removal and Installation Tool Kit, 91-31229A7. 3. Coat outside diameter of oil seal with Loctite 271. Install inner oil seal with lip facing inward using cup and seal driver (P/N 91-55916).
  • Page 243 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Coat outside diameter of oil seal with Loctite 271. Install outer oil seal with lip facing outward using cup and seal driver (P/N 91-55916). 50025 Cup And Seal Driver Outer Oil Seal 5.
  • Page 244 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Propeller Shaft Bearing Removal 1. Press bearing from shaft using universal puller plate. 22110 Propeller Shaft Universal Puller Plate Tapered Roller Bearing Propeller Shaft Bearing Installation 1. Apply Gear Lube to inside diameter of new bearing. Install bearing to shaft using universal puller plate and a suitable mandrel (old bearing race) which supports bearing on inner race.
  • Page 245 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Driven Gear Bearing Inspection 1. Remove bearing from driven gear. Inspect both the driven gear and the pinion gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace both gears if any of these conditions exist.
  • Page 246 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Driven Gear Bearing Installation 1. Apply Gear Lube to inside diameter of new bearing. Place a suitable mandrel (old bearing race) against new bearing race. Place another mandrel on face of gear and press gear and bearing together.
  • Page 247 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Driven Gear Bearing Cup Installation 1. Install driven gear bearing cup with original thickness shim(s) using bearing driver. Ensure that cup is not canted. Coat cup outside diameter with gear lube. 19917...
  • Page 248 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Inspect water passage seal for nicks, cuts or distortion. Replace if necessary. 22085 Speedometer Water Passage Seal Water Passage Seal Replacement 1. Pry rubber seal out with a suitable tool. 22085 Rubber Seal 2.
  • Page 249 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing Reassembly and Shimming 1. Lubricate all gears and bearings with gear lube before installing. Components must be lubricated to obtain accurate bearing preload readings. 2. Install water passage O-ring and oil passage quad ring. Hold in place using 3-M Adhesive.
  • Page 250 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Install driven gear assembly. 22083 Driven Gear Assembly 5. Install original thickness shim(s) and drive shaft lower bearing cup using cup driver and old drive shaft. Use original shims or if lost or misplaced, start with .050 in. (1.27 mm).
  • Page 251 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 6. Install drive shaft and pinion gear. 22258 Drive Shaft Pinion Gear 7. Install washer and new pinion nut. Apply Loctite 271 to threads of nut. 71543 Washer Pinion Nut 90-863160 MAY 2000...
  • Page 252 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 8. Temporarily install bearing carrier retainer nut to avoid damage to threads. 9. Torque pinion nut to 100 lb-ft (136 Nm). Drive Shaft Adaptor Tool (91-61077T) Breaker Bar And Socket Torque Wrench And Socket Bearing Carrier Retainer Nut 10.
  • Page 253 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 12. Determine shim thickness required for drive shaft bearing preload using the following procedure or use original thickness shims. a. Measure distance between top of gear housing and tab washer using a 0-1 in. depth micrometer.
  • Page 254 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 13. Install shims, spacer and O-ring. 22259 Shims Spacer O-Ring 14. Install clamp plate on gear housing with nuts and 4 washers. Torque to 35 lb-ft (47 Nm). 22262 Clamp Plate (P/N 91-43559T) 15.
  • Page 255 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 16. If preload is incorrect, adjust by adding or subtracting shims from upper tapered roller bearing cup. Reinstall clamp plate and recheck preload (3-5 lb-in. [0.3-0.6 Nm]). Record final preload. 17. Check pinion height.
  • Page 256 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 18. Using a dial-type lb-in. torque wrench, recheck the rolling preload by rotating drive shaft with a slow steady motion (3-5 lb-in. [0.3-0.6 Nm]). 50410 Torque Wrench Drive Shaft Adaptor 19. Install the original load ring, thrust ring and O-ring into the gear housing.
  • Page 257 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 21. Install and tighten bearing carrier retaining nut using retainer wrench until resistance to propeller shaft rotation can be felt (to preload bearings). 22112 Bearing Carrier Retainer Wrench (91-17257) 22. Driven gear shimming: a.
  • Page 258 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 23. Remove bearing carrier and items shown. Reinstall items shown using NEW load ring. IMPORTANT: Always use a new load ring when reassembling. 76884 O-Ring Thrust Ring Load Ring IMPORTANT: Bearing carrier and threads on retainer must be lubricated to prevent corrosion and cracking in gear housing.
  • Page 259 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 25. Install bearing carrier and tab washer in gear housing. 26. Lubricate threads on bearing carrier retaining nut with Quicksilver Special Lubricant 101. Install and tighten bearing carrier retainer nut until resistance to propeller shaft rotation can be felt (to preload bearings).
  • Page 260 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 28. Tighten the retainer to the proper preload using the following procedure. a. Tighten retainer in small increments using retainer nut wrench. 22112 Bearing Carrier Retainer Wrench (P/N 91-17257) b. Using an lb-in. torque wrench , check overall gear housing bearing preload by rotat- ing propeller shaft in direction of normal rotation with a slow steady motion.
  • Page 261 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 29. Bend one tab into retaining nut as shown after propeller shaft preload has been set correctly. Bend remaining tabs down into gear housing. Cushion housing to avoid chipping or scratching paint.
  • Page 262 BRAVO TWO GEAR HOUSING SERVICE MANUAL NUMBER 28 31. Install gear housing to drive shaft housing. Torque fasteners to 35 lb-ft (47 Nm). Nuts And Washers (3 Each Side) Bolt (1) 32. Reinstall drive unit. Refer to SECTION 2A - Removal, Installation and Adjustments.
  • Page 263 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 STERNDRIVE UNIT Section 3D - Bravo Three Gear Housing Table of Contents Specifications ..... . .
  • Page 264 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Specifications Torque Specifications NOTE: Securely tighten all fasteners not listed below. DESCRIPTION lb-in. lb-ft Oil Fill/Drain Screw Drive Shaft Pinion Gear (Bolt) Bearing Carrier (Left-Hand Thread) Outer Propeller Shaft Bearing Retainer Nut (Left-Hand Thread) Drive Shaft Housing to Gear Housing 47.5...
  • Page 265 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Torque Conversion Chart For Bearing Carrier Torque Wrench Reading in lb-ft (Nm) to Achieve 150 Torque Wrench Length in Inches (mm) lb-ft (203 Nm) 15 (381) 122 (165) 16 (406) 123 (167)
  • Page 266 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Torquing Outer Prop Shaft Bearing Retainer and Bearing Carrier Use the following procedure to allow torquing outer prop shaft bearing retainer and bearing carrier with a torque wrench. 1. On beam-type torque wrenches, measure from square drive to fulcrum (pivot) point of handle.
  • Page 267 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Tools Description Part No. Dial Indicator Set 91-58222A1 Slide Hammer Puller 91-34569A1 Torque Wrench (lb-in.) 91-66274 Clamp Plate 91-43559 Universal Puller Plate 91-37241 Threaded Rod 91-31229 Bearing Driver 91-89867 Bearing Driver 91-89868...
  • Page 268 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bravo Three Gear Housing Exploded View Drive Shaft and Propeller Shaft Components 77016 Page 3D-6 90-863160 MAY 2000...
  • Page 269 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Retainer 26 - Bearing Cup Coupler 27 - Tapered Bearing O-ring 28 - Front Gear Spacer 29 - Inner Propeller Shaft Shim(s) 30 - Thrust Bearing Tab Washer 31 - Thrust Race...
  • Page 270 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Pre-Disassembly Inspection 1. Remove propellers. 75899 Rear Propeller Nut Rear Propeller Rear Thrust Ring Front Propeller Nut Front Propeller Front Thrust Ring 2. Check for bent propeller shafts as follows: a. Inner Shaft - Position unit with shafts positioned up. Position dial indicator on inner propeller shaft.
  • Page 271 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 b. Outer Shaft - Position unit with shafts positioned down. Position dial indicator on out- er propeller shaft. Rotate outer propeller shaft while observing dial indicator. If de- flection is more than .010 in. (0.254 mm), a bent outer propeller shaft is indicated.
  • Page 272 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Remove anodic plate. a. Remove the rubber cap to gain access to the anode attaching bolt. Remove the bolt. 76832 Bolt b. Remove the bolt in the anode cavity. 76804 Bolt c.
  • Page 273 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 CAUTION Clamp plate must be installed on gear housing when gear housing is separated from drive shaft housing. 5. Install clamp plate, nuts and 4 washers on gear housing. Tighten securely. 72241...
  • Page 274 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 7. Remove outer propeller shaft bearing retainer, by turning clockwise, using outer propel- ler shaft bearing retainer tool. 75898 Bearing Retainer Tool (P/N 91-805382) Bearing Carrier Tool (P/N 91-805374) Bearing Retainer 8. Remove inner and outer propeller shaft assembly from gear housing.
  • Page 275 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 10. Remove drive shaft pinion gear retaining bolt and washer using drive shaft adaptor tool. 72246 Drive Shaft Adaptor Tool (91-61077T) Breaker Bar and Socket Pinion Gear 11. Remove clamp plate installed in Step 2, then remove O-ring, spacer, shim(s) and tab washer.
  • Page 276 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 12. Remove drive shaft and pinion gear. NOTE: Be careful not to lose rollers from drive shaft pinion bearing should they drop during drive shaft removal. 72248 Drive Shaft Drive Shaft Pinion Gear 13.
  • Page 277 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 14. Remove drive shaft bearing cup and shim(s). 72250 Bearing Cup Shim(s) 15. Unless you intend to remove the entire pinion bearing, remove needle bearings from pinion bearing race (See pinion bearing removal).
  • Page 278 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Driveshaft And Pinion Bearing Inspection and Cleaning 1. The condition of the drive shaft tapered bearing cups is an indication of the condition of the tapered roller bearings on the drive shaft. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating, or has embedded metal particles.
  • Page 279 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Drive Shaft Disassembly NOTE: Bearing assembly must be replaced if removed from drive shaft. Tapered roller bear- ings are damaged when removed. 1. Press tapered roller bearing from shaft using universal puller plate to support bearing.
  • Page 280 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Lubricate inner diameter of large tapered roller bearing with Quicksilver High Perform- ance Gear Lube. Press large tapered roller bearing onto drive shaft using suitable man- drel or old bearing race on inner race. Ensure larger outer diameter faces pinion end of shaft.
  • Page 281 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Installation 1. Install needles in casing. Use Needle Bearing Assembly Lubricant to help keep needles in place. Position bearing assembly over bearing driver with number on bearing casing facing up. Coat casing outer diameter with Quicksilver High Performance Gear Lube.
  • Page 282 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Disassembly 1. Remove inner propeller shaft and thrust bearing from assembly. 72255 Inner Propeller Shaft Thrust Bearing 2. Remove bearing cup from outer propeller shaft. 72256 Bearing Cup Outer Propeller Shaft 3. Remove thrust cap using a punch and hammer. Align punch with opening in snap-ring.
  • Page 283 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Remove snap ring, and driven gear and bearing assembly from outer propeller shaft. 72213 Snap Ring Driven Gear and Bearing Assembly Outer Propeller Shaft Propeller Shaft Spline Lash Check 1. Check inner propeller shaft spline lash as follows: a.
  • Page 284 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 d. Mount dial indicator to gear and position so that indicator probe aligns with mark on indicator rod. 72231 Dial Indicator Indicator Rod (91-806192) Mark Stamped on Indicator Rod e. Rotate gear back and forth while observing dial indicator. Record spline lash reading (for use later in this section).
  • Page 285 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Outer Propeller Shaft Servicing 1. To remove roller bearing and oil seal from outer propeller shaft using slide hammer puller with three-jaw puller. 72216 Slide Hammer Puller (P/N 91-34569A1) Outer Propeller Shaft 2.
  • Page 286 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Front Driven Gear And Bearing Inspection 1. Inspect driven gears for pitting, chipped or broken teeth, and excessive or uneven wear. If any of these conditions exist, replace both gear and bearing assemblies and drive shaft pinion gear.
  • Page 287 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bearing Cup Removal 1. Remove bearing cup and shims using slide hammer puller. Measure shims for reas- sembly reference. NOTE: When pulling bearing cup with puller, shims will be damaged. DO NOT reuse shims.
  • Page 288 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Bearing Carrier Seal And Bearing Inspection 1. Check bearing carrier for signs of corrosion, especially on gear housing to bearing carri- er mating surfaces. If corrosion is evident, replace bearing carrier. 2. Inspect needle bearing for pitting, grooves, discoloration or embedded particles. If any of these conditions exist, replacement is necessary.
  • Page 289 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 2. Coat outer diameter of oil seal with Loctite 271 and press oil seal into bearing carrier using seal installation tool until tool bottoms out against housing. Lubricate lips of oil seal and fill area between lips of seal with Quicksilver Special Lubricant 101.
  • Page 290 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Seal Removal 1. Pry water passage seal out with a suitable tool. 72450 Water Passage Seal Seal Installation 1. Lightly coat outer diameter of seal with 3-M Adhesive and install in speedometer water passage bore.
  • Page 291 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Gear Housing Reassembly and Shimming 1. Lubricate all bearings with Quicksilver High Performance Gear Lube before installing. Components must be lubricated to obtain accurate bearing preload readings. 2. Install water passage O-ring and oil passage quad ring. Hold in place using 3-M Adhe- sive.
  • Page 292 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 4. Apply a light coat of Loctite 242 to inside diameter of thrust cap. Ensure that Loctite does not contact shim mating surfaces. Install thrust cap and appropriate size shim on outer propeller shaft.
  • Page 293 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 7. Install original thickness shim(s) for lower bearing cup into gear housing. If shims were lost or ruined where original thickness cannot be determined, install a .050 in. (1.27 mm) shim pack for a starting point.
  • Page 294 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 9. Install drive shaft and pinion gear into gear housing. NOTE: Be careful not to lose rollers from drive shaft pinion bearing should they drop during drive shaft installation. 72264 Drive Shaft Drive Shaft Pinion Gear 10.
  • Page 295 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 11. Determine shim thickness required for drive shaft bearing preload. a. Install upper bearing cup and tab washer. Measure distance between top of gear housing and tab washer using a 0-1 in. depth micrometer.
  • Page 296 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 13. Reinstall clamping plate on gear housing with nuts and 4 washers. Tighten securely. 72266 Clamp Plate (P/N 91-43559T) 14. Using a dial-type lb-in. torque wrench, check the rolling preload by turning driveshaft with a slow steady motion (3-5 lb-in.
  • Page 297 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 16. Check pinion height as follows: a. Insert shimming tool into gear housing. b. Measure clearance between tool and pinion gear with feeler gauge. Clearance must be .023-.028 in. (0.575-0.700 mm). Take measurement at three locations on pinion gear (120 degrees apart).
  • Page 298 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Any thickness subtracted here must be added to shim thickness at upper bearing. 72451 Shims, Lower Bearing Cup, Lower Shims, Upper Spacer O-Ring c. Recheck clearance after changing shim(s) (Step “b” above).
  • Page 299 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 3. Install new shim pack of the same thickness as removed into gear housing. If shims were lost or ruined where original thickness cannot be determined, install a .050 in. (1.3 mm) shim pack for a starting point.
  • Page 300 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 5. Install outer propeller shaft bearing retainer nut, by turning counterclockwise, using out- er propeller shaft bearing retainer installation tools. Torque to 200 lb-ft (271 Nm). NOTE: To ensure proper thread engagement, start retainer nut by hand. Turn retainer nut clockwise until thread engagement is felt then turn counterclockwise.
  • Page 301 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 8. Front driven gear shimming. a. Remove clamp plate, O-ring, spacer and shim(s), and place drive shaft retaining tool on tab washer as shown. Do not tighten locking bolt at this time.
  • Page 302 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Example: Total Gear/Spline Backlash (Reading - Step 8d Above): .030 In. (0.75 mm) Minus Spline Lash (From Propeller Shaft Spline Lash Check on page 3D-22): .016 In. (0.4 mm) Equals Actual Gear Backlash: .014 In.
  • Page 303 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Example: Total Gear/Spline Backlash (Reading - Step 9c Above): .030 in. (0.75 mm) Minus Spline Lash (from Propeller Shaft Spline Lash Check from page 3D-22): .016 in. (0.4 mm) Equals Actual Gear Backlash: .014 in.
  • Page 304 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Installing Gear Housing On Drive Shaft Housing 1. Install gear housing to drive shaft housing as follows: a. Lower upper drive shaft housing down onto gear housing and install 6 locknuts and washers.

  • Page 305: Propeller Installation

    BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 Propeller Installation 1. Apply a liberal coat of one of the following Quicksilver lubricants to both the inner and outer propeller shafts: Special Lubricant 101, 2-4-C Marine Lubricant with Teflon, or Anti-Corrosion Grease.
  • Page 306 BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 3D-44 90-863160 MAY 2000...
  • Page 307 TRANSOM ASSEMBLY Section 4A - Service Procedures Requiring Minor Disassembly Table of Contents Bravo Transom Assembly Specifications 4A-2 Gimbal Bearing ..... .
  • Page 308 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bravo Transom Assembly Specifications Torque Specifications Description lb-in. lb-ft Shift Cable Core Wire Anchor Screws Hose Clamps Trim Wire Retainer Screw Hinge Pins Through Bolt Locknut Steering Arm Locknut Pivot Bolt...
  • Page 309 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK 90-863160 MAY 2000 Page 4A-3...
  • Page 310 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bravo Transom Assembly Exploded Views Inner Transom Plate Components 10 11 76857 Transom Plate Assembly 10 - Washer Pivot Bolts 11 - Locknut Tab Washers 12 - Shift Cable Casing Screw Engine Mounting...
  • Page 311 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bell Housing Components 75258 76627 Bell Housing 11 - Grounding Clip Stud 12 - Sleeve Washer 13 - Bellows Clamp Locknut 14 - Exhaust Bellows O-ring 15 - Exhaust Tube (Some Models) Gear Lube Valve 16 - Lube Monitor Hose...
  • Page 312 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring Components 75252 75272 76618 Page 4A-6 90-863160 MAY 2000...
  • Page 313 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring 16 - Flat Washer (Larger I.D.) Bushing 17 - Clamp Screw Bushing 18 - Locknut Flat Washer 19 - Hinge Pin 20 - Screw Trim Position Sender 21 - Clamp Plate Clip 22 -...
  • Page 314 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Housing Components 37 38 11 12 76642 Page 4A-8 90-863160 MAY 2000...
  • Page 315 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Housing 20 - Washer Stud 21 - Lower Swivel Pin Lower Swivel Shaft Bushing 22 - Cotter Pin Seal 23 - Stud Upper Swivel Shaft Bushing 24 - Gasket Clamp 25 - Hydraulic Manifold Lube Monitor Hose...
  • Page 316 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Special Information Trim Limit Switch The trim limit switch has a sealing system for improved water resistance and durability. The trim limit switch leads are connected internally to help ensure good electrical integrity. 71415 Trim Limit Switch - Port Trim Position Sender...
  • Page 317 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Remove trim position sender. 71220 Attaching Hardware 4. Remove U-joint bellows sleeve. 71527 Sleeve Removal Tool (P/N 91-862546) 5. Remove both hinge pins. 22113 Bell Housing Gimbal Ring Hinge Pin Tool (P/N 91-78310) 90-863160 MAY 2000 Page 4A-11...
  • Page 318 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 6. Pull back on bell housing and rotate it 90° to gain access to the trim wire clamp plate screw. 23363 Bell Housing 7. Remove trim wire clamp plate. 70197 Clamp Plate Screw 8.
  • Page 319 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 2. Reinstall retainer. Torque screw to 95 lb-in. (11 Nm). 70197 Clamp Screw 3. Install U-joint bellows on bell housing as follows: a. Position U-joint bellows on bell housing. Ensure that the bell housing flange rests in the second groove from the end of the bellows.
  • Page 320 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Apply Loctite 271 to bell housing threads and install hinge pins. Torque hinge pins to 150 lb-ft (203 Nm). 76619 Bell Housing Gimbal Ring Hinge Pin Tool (P/N 91-78310) 5. Install trim position sender as follows: a.
  • Page 321 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 6. Reinstall trim limit switch as follows: a. Place sterndrive unit in full DOWN/IN position. b. Turn center rotor of trim position sender to align index mark with index mark on sender body.

  • Page 322: Trim Position Sender Adjustment

    SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Trim Position Sender Adjustment 1. Turn ignition key to the RUN position. DO NOT START ENGINE. Rotate trim position sender until needle is at bottom of arc on gauge. 22175 2. Tighten trim position sender retaining screws and recheck gauge. Trim Limit Switch Adjustment WARNING When adjusting trim limit switch, use extreme care that engine is not started and...
  • Page 323 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to correct dimension. 71221 Rotate Counterclockwise to Adjust e. Retighten screws when adjustment is correct. 50464 21-3/4 in. (552mm) Maximum 90-863160 MAY 2000 Page 4A-17...
  • Page 324 Slowly raise the sterndrive unit(s) until the trim limit point is reached. The trim limit point can be determined by measuring the amount of trim cylinder extension. The dimension for the Bravo sterndrive units is 21-3/4 in. (552 mm), which is measured from front anchor point to rear anchor point centerlines as shown following.
  • Page 325 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Bearing IMPORTANT: Gimbal bearing and carrier are a matched set and must be replaced as an assembly. Tolerance ring must be replaced any time gimbal bearing is removed. Inspection 1. Remove sterndrive unit. 2.
  • Page 326 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Installation 1. Install grease seal using a suitable mandrel. 22171 Gimbal Housing Grease Seal 2. Install and position new tolerance ring. 22159 Carrier Carrier Grease Hole Tolerance Ring Align Opening in Tolerance Ring with Grease Hole in Carrier IMPORTANT: Ensure that notched edge of bearing carrier faces inward in bore.
  • Page 327 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Align gimbal bearing carrier grease hole and tolerance ring opening with grease cavity hole in gimbal housing. 76559 Gimbal Bearing Carrier Grease Hole Tolerance Ring Opening Bearing Carrier Notch - Face Inward 4.
  • Page 328 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Shift Cable Removal 1. Remove sterndrive unit. Refer to Section 2A. 2. Disconnect shift cable from shift plate and remove end guide. 22183 Anchor Screws (2) - Loosen End Guide 3. Remove flanged nut. 4.
  • Page 329 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 6. Loosen shift cable bellows crimp clamp. 50458 Crimp Clamp Shift Cable Shift Cable Bellows 7. Pull shift cable through shift cable bellows. Shift Cable Installation 1. Insert shift cable end into and through shift cable bellows. 76620 Shift Cable End Shift Cable Bellows...
  • Page 330 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 2. Apply Perfect Seal to flanged nut threads. Secure shift cable to bell housing. Hold shift cable retaining nut with wrench and torque flanged nut to 65 lb-in. (7 Nm). 50327 Shift Cable Flanged Nut Shift Cable Retaining Nut...
  • Page 331 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Install and compress shift cable bellows crimp clamp, maintaining a 1/2 in. diameter round O.D. Ensure that clamp is crimped evenly to maintain a good seal between bellows and shift cable. Refer to “Crimp Clamp Tool.” Do NOT allow bellows to flatten. 22117 Crimp Clamp 5.
  • Page 332 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 9. Install cable end guide over core wire and insert core wire through cable anchor. Ensure that core wire is visible in sight port. Tighten anchor screws evenly and torque to 20 lb-in. (2.3 Nm).
  • Page 333 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 13. Remove tools and install cable on shift plate assembly, being careful not to lose adjustment. 22120 Barrel Hole In Tool Exhaust Bellows (If Equipped) Removal 1. Remove sterndrive unit. Refer to Section 2A. 2.
  • Page 334 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Installation IMPORTANT: All replacement bellows should be P/N 18654. Do not use earlier model bellows. WARNING Be sure to follow label directions when using bellows adhesive. 1. Apply bellows adhesive to mounting surfaces on inside of bellows. Allow adhesive to dry until no longer tacky (approximately 10 minutes).
  • Page 335 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Install exhaust bellows on bell housing as follows: a. Place hose clamp over bellows end. b. Place expander tool into first bellows convolution. 22161 c. Pull tool until tool touches the flange on bell housing (hose starts to slip onto flange) and then release tool.
  • Page 336 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Exhaust Tube (If Equipped) Removal NOTE: It is not necessary to remove drive unit when replacing exhaust tube. CAUTION Support aft end of drive unit when working between bell housing and gimbal hous- ing.
  • Page 337 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Installation NOTE: Bellows adhesive is not used when installing an exhaust tube. CAUTION Exhaust tube clamp may corrode if grounding clip is not installed. 1. Position grounding clip on exhaust tube as shown. 22184 Exhaust Tube Grounding Clip...
  • Page 338 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Water Hose and Water Fitting Removal 1. Remove tapered inserts. 22080 50322 Tapered Inserts Tapered Insert Tool (91-43579) 2. Remove water hose. 22101 Gimbal Housing Bell Housing Water Hose Tapered Inserts Page 4A-32 90-863160 MAY 2000...
  • Page 339 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Installation CAUTION The water hose in the following step is a preformed hose and must be installed with the short end of the molded hose going into the gimbal housing. The hose must be held in place while installing the tapered inserts.
  • Page 340 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 2. Apply a small amount of 2-4-C Marine Lubricant with Teflon to threads and install tapered inserts with tapered insert tool. 75962 Tapered Insert Tapered Insert Tool (91-43579) Gimbal Housing 50322 Bell Housing Tapered Insert Tool Page 4A-34...
  • Page 341 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Crimp Clamp Tool 74148 Bevel Edges 3/4 in. Nut Pliers Nut (Cut In Half) 1. Weld a 3/4 in. nut to the jaws of a pair of pliers. 2. Saw the nut in half without damaging the pliers. 3.
  • Page 342 SERVICE PROCEDURES REQUIRING MINOR DISASSEMBLY SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 4A-36 90-863160 MAY 2000...
  • Page 343 ....4B-51 Gimbal Housing Servicing ... . . 4B-26 Bravo Access Plug Drilling Template ..4B-55 U-joint Bellows Replacement ..
  • Page 344 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bravo Transom Assembly Specifications Torque Specifications DESCRIPTION lb-in. lb-ft Shift Cable Core Wire Anchor Screws Hose Clamps Trim Wire Clamp Hinge Pins Bell Housing Studs Steering Arm Nut Rear Engine Mounting Bolt...
  • Page 345 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK 90-863160 MAY 2000 Page 4B-3...
  • Page 346 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bravo Transom Assembly Exploded Views Inner Transom Plate Components 10 11 76626 Transom Plate Assembly 10 - Washer Pivot Bolts 11 - Locknut Tab Washers 12 - Shift Cable Casing Rear Engine Mounting Bolt...
  • Page 347 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bell Housing Components 75258 76627 Bell Housing 12 - Sleeve Stud 13 - Bellows Clamp Washer 14 - Exhaust Bellows Locknut 15 - Exhaust Tube (Some Models) O-ring 16 - Lube Monitor Hose Gear Lube Valve 17 - Hose Clamp...
  • Page 348 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring Components 75252 75272 76897 Page 4B-6 90-863160 MAY 2000...
  • Page 349 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring 16 - Flat Washer (Larger I.D.) Bushing 17 - Clamp Screw Bushing 18 - Locknut Flat Washer 19 - Hinge Pin 20 - Screw Trim Position Sender 21 - Clamp Plate Clip 22 -...
  • Page 350 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Housing Components 37 38 11 12 76642 Page 4B-8 90-863160 MAY 2000...
  • Page 351 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Housing 20 - Washer Stud 21 - Lower Swivel Pin Lower Swivel Shaft Bushing 22 - Cotter Pin Seal 23 - Stud Upper Swivel Shaft Bushing 24 - Gasket Clamp 25 - Hydraulic Manifold Lube Monitor Hose...
  • Page 352 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bell Housing Removal 1. Remove sterndrive unit. Refer to Section 2A. 2. Remove shift cable from bell housing by loosening anchor screws and disconnecting shift cable end guide from shift bracket. 3.
  • Page 353 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 7. Remove gear lube monitor 90° quick disconnect fitting and through bulkhead fitting E-clip so that fitting will pull out of gimbal housing upon removal of bell housing. 76665 76640 Quick Disconnect Fitting E-Clip Through Bulkhead Fitting 8.
  • Page 354 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 11. Remove speedometer tubing clip from bell housing. 22121 Bell Housing Speedometer Tubing Clip 12. On Standard Transom Assembly - Remove hinge pins from port and starboard sides. 22113 Bell Housing Hinge Pins 13.
  • Page 355 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 b. Thread special tool into hinge pin. 71826 Slide Hammer Special Tool (91-63616) c. Remove hinge pins. 71828 Hinge Pin 90-863160 MAY 2000 Page 4B-13...
  • Page 356 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Access Plug Kit Installation NOTE: If steering lever cavity is not accessible, it will be necessary to drill access holes in gimbal housing. This procedure requires the following: Access Plug Kit 22-88847A-1 1-1/8 in.
  • Page 357 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Cut holes in gimbal housing (port and starboard) using 1-1/8 in. hole saw and pilot rod. 22652 70153 Hole Saw WARNING Always wear safety glasses when using compressed air. 4. Remove metal chips with compressed air. 5.
  • Page 358 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring, Swivel Shaft and Steering Lever Removal 1. Loosen U-bolt nuts. Â Â 70150 U-bolt Nuts (2) Washers (4) Gimbal Ring 2. Loosen steering lever clamping bolt and nut. Â Â...
  • Page 359 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Remove locknut. Â Â Â Â Â 70156 Engine And Transom Assembly Installed Pin Punch 22452 Engine And Transom Assembly Removed Locknut 1-1/16 in. Wrench 4. Disconnect trim cylinders from gimbal ring. Suspend cylinders to avoid damage to hoses.
  • Page 360 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 5. Disconnect continuity wire. 22261 Continuity Wire 6. Remove cotter pin, lower swivel pin and washer. 22461 Cotter Pin Lower Swivel Pin Washer Page 4B-18 90-863160 MAY 2000...
  • Page 361 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 7. Remove large I.D. washer, steering lever, small I.D. washer and locknut. 8. Remove upper swivel shaft using slide hammer puller (91-34569A1) and puller head (91-63616) from gimbal ring. 76661 22463 22492 Swivel Shaft Puller Head...
  • Page 362 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring Servicing GIMBAL RING IDENTIFICATION The gimbal ring used on various model transom assemblies can be identified as shown in the following illustration: 75272 Standard Gimbal Ring Identification (Two Ribs) Magnum and High Performance Gimbal Ring Identification (Filled Area) REMOVING BUSHINGS CAUTION...
  • Page 363 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Remove oil seal and large bushing from gimbal housing using a two-jaw puller and slide hammer assembly. 22452 Two Jaw Puller Slide Hammer Assembly 4. Remove small bushing from gimbal housing using a bushing removal tool. 22454 22438 Bushing Removal Tool (Snap-On Tool Company P/N CG40CB)
  • Page 364 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 b. Apply Resiweld Sealer to outer diameter of hinge pin bushing and position bushing on bearing and seal driver. 22440 Hinge Pin Bushing Bearing And Seal Driver (92-65150-1) c. Inspect bore for cleanliness and damage before installing bushing. d.
  • Page 365 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 c. Install bushing in gimbal ring by pressing or tapping in place with a hammer. NOTE: Pressing is preferred. When using a hammer, install a used hinge pin in the driver to protect the threads.
  • Page 366 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Install upper swivel shaft large bushing as follows: a. Place bushing on bearing and seal driver. 22436 Bushing Bearing And Seal Driver b. Install bushing by tapping it in place with a hammer. 22450 Hammer Page 4B-24...
  • Page 367 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 5. Install upper swivel shaft grease seal as follows: a. Place seal on bearing and seal driver with lip facing the small diameter end of tool. Apply Loctite 271 to outer diameter of seal. 22440 Seal Bearing And Seal Driver...
  • Page 368 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Housing Servicing U-joint Bellows Replacement 1. Remove U-joint bellows from gimbal housing. 50383 U-joint Bellows Hose Clamp 2. If reusing bellows, remove old adhesive from U-joint bellows using lacquer thinner. 50383 U-joint Bellows Page 4B-26...
  • Page 369 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Clean bellows mounting flange on gimbal housing with sandpaper and wipe clean with lacquer thinner. 76662 Mounting Flange WARNING Be sure to read and follow package label direction when using bellows adhesive. 4.
  • Page 370 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 CAUTION Bellows clamp may corrode if ground clip is not installed. 5. Position ground clip on bellows. 50383 Grounding Clip 6. Position U-joint bellows with TOP mark facing upwards and install U-joint bellows on gimbal housing flange and position clamp as shown.
  • Page 371 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Shift Cable Bellows Replacement 1. Remove shift cable. a. Disconnect shift cable from shift plate and remove end guide. 22183 Anchor Screws (2) End Guide 2. Remove flanged nut. Hold shift cable retaining nut with wrench. 76673 Shift Cable Retaining Nut Seal Washer...
  • Page 372 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Loosen shift cable bellows crimp clamp and pull shift cable through shift cable bellows. 50458 Crimp Clamp Shift Cable Shift Cable Bellows 5. Remove shift cable bellows from gimbal housing. 76663 Shift Cable Bellow Hose Clamp...
  • Page 373 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 7. Clean shift cable bellows mounting flange on gimbal housing with sandpaper and wipe clean with lacquer thinner. 76662 Mounting Flange WARNING Read and follow package label directions before using bellows adhesive. 8.
  • Page 374 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Exhaust Bellows Replacement NOTE: (For Exhaust Tube Replacement, see Section 4A) 1. Remove exhaust bellows from gimbal housing. 76660 Exhaust Bellows Hose Clamp 2. If old exhaust bellows will be reinstalled, remove old adhesive from exhaust bellows mounting surfaces with lacquer thinner.
  • Page 375 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Position grounding clips on bellows. Use bellows P/N 18654, only. Do not substitute earlier model bellows. 22079 Apply Bellows Adhesive Grounding Clips Part Number WARNING Read and follow package label directions when using bellows adhesive. 5.
  • Page 376 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Speedometer Hose Replacement 1. Remove hose from plastic adaptor fitting. 22461 Hose Plastic Adaptor Fitting 2. Remove hex fitting from inner transom and pull speedometer hose through transom. 76672 Hex Fitting 3.
  • Page 377 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 6. Install hex fitting. Torque fitting to 35 lb-in. (4 Nm). 76672 Hex Fitting 7. Install plastic adaptor fitting on speedometer hose. 22461 Hose Plastic Adaptor Fitting Gear Lube Monitor System Components MONITOR TO THROUGH BULKHEAD FITTING HOSE Check hose periodically for condition and replace as necessary.
  • Page 378 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Replace hose and hose clamps. 4. Tighten hose clamps securely. IMPORTANT: Hose and clamps are installed on bell housing hose barb and through bulkhead fitting, before through bulkhead fitting is reinstalled. 76664 Hose - 10 in.
  • Page 379 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Reassembly 1. Driveshaft Housing - insert spring, check ball and seal cup. Press or tap carefully on seal cup until outer face is flush with casting surface. Do not use sealant. 2.
  • Page 380 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Trim Position Sender and Trim Limit Switch Wire Replacement 1. Remove trim limit switch wires and trim position sender wires. 70197 Screw Trim Harness Clamp Trim Limit Switch Wires Trim Position Sender Wires 2.
  • Page 381 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Gimbal Ring / Swivel Shaft and Steering Lever Installation 1. Place large inner diameter washer, steering lever, small inner diameter washer and locknut into steering lever cavity in gimbal housing. 22492 22463 Large Inner Diameter Washer Steering Lever...
  • Page 382 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Install lower swivel pin and washer. Secure with cotter pin. Spread ends. 22461 22445 Swivel Pin Washer Cotter Pin 4. Clean ground wire ring terminal and screw. 5. Connect ground wire from gimbal housing to gimbal ring. Tighten securely. 22261 Ground Wire Page 4B-40...
  • Page 383 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 6. Tighten locknut until a clearance of .002 - .010 in. (0.05 - 0.25 mm) exists between lower swivel pin washer and gimbal housing mount. Â Â Â Â 70156 Engine And Transom Assembly Installed Pin Punch 22452 Engine And Transom Assembly Removed...
  • Page 384 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 7. Strike down on gimbal ring flanges using a plastic hammer. 8. Recheck clearance and tighten locknut as necessary. 22461 22445 Feeler Gauge - .001 - .010 in. (0.05 - 0.25mm) Washer Gimbal Housing Mount Gimbal Ring...
  • Page 385 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 10. Tighten steering lever clamping bolt and nut. Torque 50 lb-ft (68 Nm). Â Â 70157 Engine And Transom Assembly Installed Wrench Socket Wrench 22460 Engine And Transom Assembly Removed Wrench Wrench 11.
  • Page 386 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 13. Install trim cylinders on gimbal ring. 71489 Anchor Pin (1) Slots (2) Flat Washer (Large Inner Diameter) (2) Snap Rings (2) Bushings (4) Flat Washer (Small l.D.) (2) Locknut (2) Plastic Cap (2) 14.
  • Page 387 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bell Housing Installation Standard Transom Assembly 1. Install fiber washers on gimbal ring. 2. Secure with Resiweld Sealer. 3. Ensure that washer pilots on hinge pin bushing. 22454 Fiber Washers Gimbal Ring Hinge Pin Bushing 4.
  • Page 388 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 High Performance Transom Assembly 1. Thread hinge pin onto special tool. Lubricate hinge pins with Quicksilver Special Lubricant 101. 71828 Hinge Pin Special Tool (91-63616) 2. Slide hinge pin through gimbal ring and bell housing. Be sure to align screw holes in hinge pin with holes in gimbal ring.
  • Page 389 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 4. Apply Loctite 242 to threads of screws and install. Torque screws to 25-30 lb.in. (2.8- 3.3 N⋅m). 71825 Screws Standard And High Performance Transom Assemblies 1. Install speedometer hose clip onto bell housing. 22121 Speedometer Hose Clip Bell Housing...
  • Page 390 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 5. Place hose clamp over bellows end. 22450 Mounting Surface Grounding Clip Hose Clamp 6. Place bellows expander tool into first bellows convolution. 22161 Expander Tool (91-45497A1) 7. Pull tool until tool touches the mounting flange on bell housing (bellows starts to slip onto flange) then release tool.
  • Page 391 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 10. Tighten hose clamp. Torque to 35 lb-in. (4 Nm). 11. Remove tool. 22116 Exhaust Bellows Bell Housing Flange Hose Clamp - Tighten Securely 12. Position U-joint bellows on bell housing. Ensure that the bell housing flange (a) rests in the second groove from the end of bellows.
  • Page 392 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 13. Lubricate sleeve outer diameter with soapy water or engine cleaner and install sleeve installation tool and a suitable driving rod. 76898 Sleeve Sleeve Installation Tool (91-818162) Suitable Driving Rod 14. Position water hose so that approximately 1/8 in. (3 mm) protrudes from edge of bell housing opening.
  • Page 393 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Shift Cable Installation 1. Insert shift cable end into and through shift cable bellows. 76620 Shift Cable End Shift Bellows 2. Apply Perfect Seal to shift cable retaining nut threads. Secure shift cable to bell housing. 50327 76673 Shift Cable Retaining Nut...
  • Page 394 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 3. Install shift cable wrapping approximately 2 in. from gimbal housing. 76639 Shift Cable Wrapping CAUTION Water leakage may result if clamp is not installed properly. Check that bellows end is not flattened out when crimping in the followIng step. 4.
  • Page 395 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 5. Install core wire locating tool on face of bell housing. 50327 Bell Housing Core Wire Locating Tool (P/N 91-17263) 6. Install threaded tube until it contacts. Tighten finger tight. 7. Tighten jam nut securely. 22183 Threaded Tube Jam Nut...
  • Page 396 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 9. Place shift cable anchor adjustment tool on end of shift cable. 22120 Shift Cable Anchor Adjustment Tool (91-17262) Stud Hole - Barrel Placed Here 10. Ensure that bell housing end of core wire is positioned tight against core wire locating tool.
  • Page 397 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Bravo Access Plug Drilling Template IMPORTANT: Carefully cut out template - use straightedge to make accurate folds. Align centerline of template with centerline of dimple or grease fitting (on older mod- els).
  • Page 398 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Page 4B-56 90-863160 MAY 2000...
  • Page 399 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 Crimp Clamp Tool 74148 Bevel Edges 3/4 in. Nut Pliers 1. Weld a 3/4 in. nut to the jaws of a pair of pliers (as shown). 2. Saw the nut in half without damaging the pliers. 3.
  • Page 400 SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 4B-58 90-863160 MAY 2000...
  • Page 401 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 POWER TRIM Section 5A - Oildyne Trim Pump Table of Contents Trim Pump Specifications ....5A-2 Hydraulic Repair ..... 5A-25 Valve Pressure Specifications .
  • Page 402 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Pump Specifications Valve Pressure Specifications VALVE Up Circuit 2200-2600 15173-17932 Down Circuit 400-600 2759-4138 Electrical Specification PUMP AMPERAGE DRAW 115 Amps at: 2200-2600 15173-17932 Torque Specification DESCRIPTION lb-in. lb-ft Up Pressure Relief Valve Down Pressure Relief Valve Thermal Relief Valve Pump-to-Adaptor Mounting Screws...
  • Page 403 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Pump Exploded View Oildyne Trim Pump (Factory Installed Valve) (Replacement Valve) 50396 73519 Adaptor 13 - Screw Coupling 14 - Brush Holder Kit Pump 15 - Brush set Filter 16 - Armature O-ring-Motor End 17 - Thrust Washer...
  • Page 404 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Maintaining Power Trim Pump Oil Level CAUTION Avoid pump damage. Vent reservoir pressure by backing out the vent screw two turns after tightening completely. Units without a vent screw have a vented fill cap. Remove the fill neck seal on models without a vent screw.
  • Page 405 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Air Bleeding Power Trim System 1. The Power Trim System will purge itself of a small amount of air by raising and lowering the sterndrive unit several times. However, if a rebuilt trim cylinder is being installed (which has not been filled with oil), the bleeding procedure should be used to remove the air from the system.
  • Page 406 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 7. Lower the sterndrive unit to the full IN/DOWN position and refill the trim pump to the proper level. Run the trim system IN/DOWN and OUT/UP several times and recheck the fluid level. 50389 IN/DOWN Trim Hose Hydraulic Connector...
  • Page 407 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Connect the test gauge at the most convenient location at pump or hydraulic connector. 70596 Gauge Connected to Pump Hydraulic Test Gauge (91-52915A6) 50391 50390 Gauge Connected to Hydraulic Connector Hydraulic Test Gauge (91-52915A6) Gimbal Housing Hydraulic Connector Caps (Supplied with Gauge) Plugs (Supplied with Gauge)
  • Page 408 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 OUT/UP Pressure Test NOTE: The numbers in parentheses, e.g. (3), refer to the trim pump hydraulic system dia- gram on page 5A-11. 1. Leave valve “A” open and close valve “B.” 2. Run pump OUT/UP while observing the gauge. The reading should be 2200-2600 psi. (15173-17932 kPa).
  • Page 409 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Run the pump OUT/UP until the gauge reading reaches 2200-2600 psi (15173-17932 kPa). Stop pumping OUT/UP. The pressure should not fall below 1900 psi (13104 kPa). If gauge reading is 1900 psi (13104 kPa) or above, UP pressure test completed. If gauge reading is below 1900 psi (13104 kPa) perform the following: Check for External Oil Leaks, Check for External Oil Leaks,...
  • Page 410 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 IN/DOWN Pressure Test NOTE: The numbers in parentheses, e.g. (3), refer to the trim pump hydraulic system dia- gram. 1. Close valve “A” and open valve “B.” 2. Run the pump IN/DOWN while observing the gauge. The reading should be 400-600 psi (2759-4138 kPa).
  • Page 411 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Pump Hydraulic System 73552 Poppet Valves Thermal Relief Valve Pump Adaptor Fitting OUT/UP Pressure Relief Valve IN/DOWN Pressure Relief Valve 90-863160 MAY 2000 Page 5A-11...
  • Page 412 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Cylinder Internal Leak Test IMPORTANT: Before performing the following test, ensure that OUT/UP pressure meets specifications designated in OUT/UP pressure test. 1. Reconnect the trim cylinder hoses if disconnected. a. Remove the plugs and caps. b.
  • Page 413 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 2. Connect the gauge at the most convenient location. 70598 Gauge Connected to Pump Hydraulic Test Gauge Hose Connected to UP (Left Hole) Fittings - (Supplied with Gauge) BLACK Hose (From Gimbal Housing) GREY Hose (From Gimbal Housing) 50390 Gauge Connected to Hydraulic Connector...
  • Page 414 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 6. Stop pumping OUT/UP. Pressure should not fall below 1900 psi (13104 kPa). Reading below 1900 psi (13105 kPa) indicates a trim cylinder leak. Use the following steps to lo- cate the faulty cylinder. NOTE: If the gauge is connected at the pump, reconnect the gauge at the gimbal housing hydraulic connector.
  • Page 415 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Cylinder Shock Piston Test If all previous trim system test results meet specifications, but sterndrive unit will not trim IN/DOWN, the problem may be a leaky trim cylinder shock piston. Use the follow- ing test to check for this condition.
  • Page 416 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Motor and Electrical Bench Tests Trim Pump Motor Test (In Boat) WARNING Making electrical connections may cause a spark. DO NOT perform this test near flammables or explosives. WARNING Remain clear of the sterndrive unit when performing power trim pump motor tests with pump in the boat and hydraulic hoses connected.
  • Page 417 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 IN/DOWN OPERATION 1. Connect a jumper wire between the positive (+) solenoid terminal and the green-white motor lead terminal. 2. The motor should run. 73556 IN/DOWN Solenoid Positive Terminal (+) GREEN-WHITE Motor Lead Terminal Jumper Wire 3.
  • Page 418 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Pump Motor Test (Out of Boat) WARNING Making electrical connections may cause a spark. DO NOT perform this test near flammables or explosives. 1. Remove the trim pump from the boat. Refer to “Trim Pump Removal.” 2.
  • Page 419 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Solenoid Test (Pump In Boat) WARNING DO NOT perform this test near flammables or explosives as a spark may occur when making connections. CAUTION Remain clear of the sterndrive unit when performing power trim pump motor tests with pump in the boat and hydraulic hoses connected.
  • Page 420 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 IN/DOWN SOLENOID 1. Connect a jumper between the positive (+) solenoid terminal and the green/white har- ness wire terminal. 2. The motor should run. 22494 IN/DOWN Solenoid Positive (+) Solenoid Terminal GREEN/WHITE Harness Wire Terminal Jumper Wire 3.
  • Page 421 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Connect the ohmmeter leads to the large terminals on the solenoid. 22493 OUT/UP Solenoid 12 volt Positive (+) Supply Lead Negative (–) Supply Lead Ohmmeter Leads BLUE/WHITE Harness Wire Terminal Solenoid Ground Terminal 4.
  • Page 422 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 4. Zero Ohms Reading (Full Continuity)-Solenoid is OK. High Ohms Reading (No Continuity)-Replace solenoid. NOTE: See the wiring diagram on page 5A-51. 110 Amp Fuse Test (Pump in Boat) WARNING DO NOT perform this test near flammables (or explosives) as a spark may occur when making connections.
  • Page 423 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 110 Amp Fuse Test (Pump Out of Boat) 1. Connect the ohmmeter leads between the terminals on the fuse. 22493 110 Amp Fuse (Red) Ohmmeter Leads 2. Zero Ohms Reading (Full Continuity)-Fuse OK. High Ohms Reading (No Continuity)-Replace fuse.
  • Page 424 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 2. Connect one ohmmeter lead to each end of the fuse. 22497 20 Amp Fuse Ohmmeter Leads 3. Zero Ohms Reading (Full Continuity)-Fuse OK. High Ohms Reading (No Continuity)-Replace fuse. Trim Pump Removal 1.

  • Page 425: Hydraulic Repair

    OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Hydraulic Repair Disassembly 1. Disconnect the trim motor wires. 70359 BLUE/WHITE Motor Wire GREEN/WHITE Motor Wire BLACK Ground Wire 2. Remove the mounting bolts and trim pump from the floor bracket. 22548 Trim Pump Floor Bracket Mounting Bolts 90-863160 MAY 2000...
  • Page 426 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Remove the solenoids if replacement is necessary. 70232 UP Solenoid DOWN Solenoid Mounting Bolts (2 on Each Solenoid) 4. Remove the pump reservoir. 22547 76622 Pump Reservoir Bolt and O-ring Page 5A-26 90-863160 MAY 2000...
  • Page 427 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Filter Replacement 1. Remove the filters by twisting while pulling upward. 76887 Filters (2) 2. Install new filters. 76888 Filters (2) 5/8 in. Socket 90-863160 MAY 2000 Page 5A-27...
  • Page 428 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 UP Pressure Relief Valve Replacement NOTE: The UP pressure relief valve in the kit is color coded BLUE for easy identification. IMPORTANT: A difference exists between the factory installed and the replacement pressure relief valves. Once the jam nut is loosened on a factory installed relief valve, the valve is out of adjustment.
  • Page 429 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 DOWN Pressure Relief Valve Replacement NOTE: The DOWN pressure relief valve in the kit is color coded GREEN for easy identifica- tion. IMPORTANT: A difference exists between the factory installed and the replacement pressure relief valves.
  • Page 430 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Thermal Relief Valve Replacement NOTE: The Thermal Relief Valve in the kit is color coded GOLD for easy identification. IMPORTANT: The thermal relief valve is factory preset. do NOT loosen or attempt to separate the component parts.
  • Page 431 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Lubricate the lip of the adapter seal with light weight oil. 22545 O-rings Adapter Seal 4. Install the pump and torque the pump screws to 70 lb-in. (7.9 Nm) using a hex lobular socket or standard 3/16 in.
  • Page 432 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 2. Remove and discard the adapter to reservoir O-ring. 70869 Adapter O-ring 3. Remove and discard the motor to adapter O-ring. 4. Ensure that the coupling is installed with the shallow slot is toward the reservoir. 5.
  • Page 433 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 6. Align the motor shaft with the coupling and install the motor onto the adapter. 7. Position the motor as shown and secure with screws. Tighten securely. 22548 22496 Motor Shaft Coupling Screws (Opposite Corners) Adapter Repair INTERNAL O-RING and POPPET VALVE REPLACEMENT 1.
  • Page 434 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 2. Remove and discard the poppet valves. 76889 Poppet Valve CAUTION Use care in removing check valve bodies from adapter, so as not to damage poppet valve seat surface on valve body. 3. Remove the check valve bodies and spool using a 1/4 in. diameter metal rod and plastic hammer.
  • Page 435 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 6. Clean the hex plug retainers and spool. 70867 O-rings Hex Plug Retainers Springs Poppet Valves Check Valve Bodies Spool 7. Lubricate the check valve body O-rings with Power Trim and Steering Fluid or with 10W-30 or 10W-40 motor oil.
  • Page 436 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 12. Thread the hex plug retainers into the adapter by hand until the retainer contacts the check valve body. 70871 Spring (2) O-ring Hex Plug Retainer (2) IMPORTANT: Hex plug retainers MUST BE turned into adapter exactly as outlined or damage to check valve body O-rings may result.
  • Page 437 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Pump Shaft Oil Seal Replacement 1. Remove the pump attaching screws with a hex lobular socket or standard 3/16 in. (5 mm) socket. 2. Remove pump. Do NOT loosen or remove the pump assembly screws. 70870 Screw Pump Assembly Screw...
  • Page 438 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 6. Lubricate the lip of the seal with light weight oil. 22545 Oil Seal O-rings Pump 7. Install the pump. Torque the attaching screws to 75 lb-in. (8 Nm) using a hex lobular socket or standard 3/16 in.

  • Page 439: Motor Repair

    OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Motor Repair Disassembly 1. Remove the trim motor from the adapter. 70363 Trim Motor Adapter Screws 2. Remove the motor to adapter O-ring. 70600 Adapter O-ring 3. Remove the motor end cover and washer from the armature shaft. 22640 22639 Cover...
  • Page 440 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 4. Loosen the brush hold down arms. 22648 Brush Hold Down Arms Screws IMPORTANT: Use care in removing brush holders so as not to lose springs. 5. Remove the brush holders and springs. 22638 Brush Holder Spring...
  • Page 441 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 7. Remove the brush assembly mounting bracket. 22636 Brush Assembly Bracket Screws 8. Remove the armature and thrust washer from the motor housing. 22499 Armature Thrust Washer Motor Housing 9. Remove the field assembly from the motor housing. 22501 Field Assembly Motor Housing...

  • Page 442: Armature Tests

    OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 10. Remove the motor housing O-ring. 22645 O-ring Motor Housing Armature Tests Continuity Test 1. Set the ohmmeter on the Rx1 scale. 2. Place the alligator clip meter lead on the armature shaft. 3.
  • Page 443 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Test for Shorts 1. Check the armature on a growler (follow the growler manufacturers instructions). Re- place the armature if it has a short. Cleaning Commutator 1. Clean the commutator with “00” garnet grit sandpaper. DO NOT use emery paper. 2.
  • Page 444 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Connect the ohmmeter between the field brush lead and the GREEN/WHITE lead. 22642 Ohmmeter Lead - Connected to Brush Lead Ohmmeter Lead - Connected to GREEN/WHITE Lead 4. Zero ohms indicated (full continuity) - Field OK. Zero ohms not indicated (no continuity) - Replace field assembly.
  • Page 445 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Thermal Switch Continuity Test 1. Connect the ohmmeter between the spade connector and the brush lead. 22631 Thermal Switch Spade Connector Brush Lead 2. Zero ohms indicated (full continuity) - Proceed to next step. Zero ohms not indicated (no continuity) - Replace thermal switch.
  • Page 446 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Brush Replacement 1. Loosen the brush hold down arms. 22648 Brush Hold Down Arms Screws IMPORTANT: Use care in removing brush holders. Do NOT lose springs. 2. Remove the brush holders and springs. 22638 Brush Holder Spring...
  • Page 447 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 IMPORTANT: When replacing the brush that is connected to the field wires, cut the brush wire as close to the brush as possible. 4. Cut the brush wire as close to the brush as possible and discard the brush. 22632 Brush Wire Brush...
  • Page 448 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 6. Reinstall the spring and brush in the brush holder. 22638 Brush Holder Spring Brush 7. Position the brush hold down arms and tighten them securely. Do NOT overtighten. 22648 Brush Hold Down Arms Screws 8.
  • Page 449 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Reassembly 1. Install the motor housing O-ring. 22645 O-ring Motor Housing IMPORTANT: The field assembly wires must face the front of the motor housing. Use the notched area in the housing as a reference in determining the front. 22633 Motor Housing Front...
  • Page 450 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 3. Install the thrust washer on the armature and install the armature into the motor housing. 22499 Armature Thrust Washer Motor Housing 4. Install the brush assembly mounting bracket. Tighten the screws securely. 22636 Brush Assembly Mounting Bracket Screws...
  • Page 451 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 6. Install the springs and brushes in the brush holders. 22638 Brush Holders Springs Brushes 7. Position the brush holders and secure them with the brush hold down arms. Do NOT overtighten the screws. 22648 Brush Hold Down Arms Screws...
  • Page 452 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 8. Install the motor end cover. Apply Loctite 271 to the screws and tighten securely. Do NOT overtighten. 22639 Motor End Cover Screws 9. Install the motor to adapter O-ring. 70600 Adapter O-ring Page 5A-52 90-863160 MAY 2000...
  • Page 453 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 10. Align the motor shaft with the coupler and install the trim motor on the adapter. Torque the screws to 25 lb-in. (2.8 Nm). 22548 22496 Trim Motor Adapter Screws (2 in Opposite Corners) Coupler Motor Shaft 11.
  • Page 454 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 12. Connect the trim motor wires to solenoids as shown. 70359 Blue/White Motor Wire Green/White Motor Wire Black Ground Wire CAUTION Solenoid terminal cover screw is attached to 12 volt positive source. DO NOT GROUND the screw driver when installing cover.
  • Page 455 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Pump Installation 1. Secure the pump and mounting bracket to the boat using lag bolts and washers. 2. Reconnect the trim hoses to the pump; black hose to the left connection, gray hose to the right connection.
  • Page 456 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Trim Pump Wiring Diagrams Model With Three-Button Trim/Trailer Panel BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE...
  • Page 457 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 Model With Trim In Handle and Trailer Switch Separate BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE...
  • Page 458 OILDYNE TRIM PUMP SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 5A-58 90-863160 MAY 2000...
  • Page 459 5B-3 Reassembly ..... . 5B-14 Bravo Trim System Components ..5B-4 Installation ......
  • Page 460 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Specifications Torque Specifications DESCRIPTION lb-in. lb-ft Piston Rod Bolt End Cap Anode Screw Lubricants / Sealants / Adhesives NOTE: Prior to reassembly of trim cylinder(s), lubricate all internal parts with Quicksilver Power Trim and Steering Fluid or (if not available) 10W-30 or 10W-40 motor oil. DESCRIPTION PART NUMBER Loctite 271...
  • Page 461 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Trim Cylinder Exploded Views Bravo Trim Cylinders NOTE: Prior to reassembly of trim cylinder(s), lubricate all internal parts with Quicksilver Power Trim and Steering Fluid or (if not available) 10W-30 or 10W-40 motor oil.
  • Page 462 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Bravo Trim System Components 73554 IN/DOWN Hose to Trim Pump (Gray) 14 - UP/OUT Hose to Trim Pump (Black) 15 - Hose to Trim Cylinder 16 - Rear Pin Starboard Trim Cylinder 17 -...
  • Page 463 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Power Trim Hydraulic Schematic 73552 Shuttle IN/DOWN Pressure Relief Valve Pump Adaptor UP/OUT Hose UP/OUT Pressure Relief Valve IN/DOWN Hose Thermal Relief Valve Poppet Valves Trim Cylinder 90-863160 MAY 2000 Page 5B-5...
  • Page 464 IN at higher speeds. Increased trim IN range may cause handling problems on some boats which could result in personal injury. IMPORTANT: On Bravo One, Two and Three Models, the Trim-In Limit Insert , must be properly positioned before installing the trim cylinder anchor pin in the following steps.
  • Page 465 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Trim Cylinder Internal Leak Test Refer to Power Trim Pump SECTION 5A. Trim Cylinder Shock Piston Test Refer to Power Trim Pump SECTION 5A. Trim Cylinder Repair Removal 1. Disconnect OUT/UP trim hose from front hole on trim cylinder. 2.
  • Page 466 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 3. Remove front and rear power trim cylinder mounting hardware. 71489 Anchor Pin (1) Slots (2) Flat Washer (Large I.D.) (2) Snap Rings (2) Bushings (4) Flat Washer (Small I.D.) (2) Locknut (2) Plastic Cap (2) 22029 Rear Anchor Pin Large I.D.
  • Page 467 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Disassembly CAUTION Ensure work area is clean before disassembling power trim cylinders. Cylinder parts can be damaged by dirt entering into power trim system. NOTE: Spanner Wrench Tool Part No. 91-821709. 71233 CAUTION DO NOT clamp center section of power trim cylinder during assembly or disassem- bly.
  • Page 468 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 2. Remove trim cylinder anodes. 76902 Trim Cylinder Trim Cylinder Anode Screw (2) Washer (2) 3. Remove trim cylinder end caps (Use special tool 91-821709). 71677 4. Remove tilt-limit insert. 76623 76624 Tilt Limit Insert Page 5B-10 90-863160 MAY 2000...
  • Page 469 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 5. Remove piston rod assembly from cylinder. 22133 End Cap Cylinder Piston Rod Assembly 6. Remove floating piston from cylinder and remove O-ring by tapping cylinder on block of wood. 22131 Floating Piston Trim Cylinder O-ring 90-863160 MAY 2000 Page 5B-11...
  • Page 470 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 7. Disassemble shock piston assembly. Ensure that check balls are not lost. 22132 Bolt Flat Washer Spring Guide Spring Spring Guide Washer Check Balls (3) Shock Piston Assembly O-ring 8. Remove and disassemble end cap. 22133 End Cap Piston Rod...
  • Page 471 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 9. Remove small O-ring from end of piston rod. 22132 Small O-ring Piston Rod 10. Clean all parts in solvent. Be sure all parts are dry before reassembly. 90-863160 MAY 2000 Page 5B-13...
  • Page 472 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 Reassembly CAUTION Ensure that work area and all components are clean before reassembling trim cylin- ders. Power Trim components can become damaged if dirt gets into system. 1. Install small O-ring into end of piston rod. 22132 Small O-ring End Of Piston Rod...
  • Page 473 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 5. Install end cap onto piston rod. 22133 22132 Small O-rings Continuity Spring End Cap Rod Scraper Plain Washer Retaining Ring Large O-ring 6. Install large O-ring on shock piston. 7. Install check ball, check ball eyelet, spring and spring pin into shock piston. 8.
  • Page 474 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 9. Install shock piston, three check balls, spring guide washer, spring, spring guide, spring guide washer and bolt onto piston rod. Torque to 17 lb-ft (23 Nm). 22133 22132 Large O-ring Shock Piston Check Ball check Ball Eyelet Spring Spring Pin...
  • Page 475 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 10. Apply oil to parts. Install O-ring onto floating piston and insert floating piston into cylinder. 22132 O-ring Floating Piston Cylinder IMPORTANT: Some boat configurations may require tilt-limit inserts to limit the total upward travel of the drive unit. Be sure to install the same number of inserts that were originally removed.
  • Page 476 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 12. Apply 2-4-C Marine Lubricant with Teflon to end cap threads and install piston rod as- sembly into cylinder. 22133 End Cap Piston Rod Cylinder 13. Using Spanner Wrench Tool, torque end cap 45 lb-ft (61 Nm). 71677 Spanner Wrench (P/N 91-821709) Page 5B-18...
  • Page 477 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 14. Install trim cylinder anodes. 76902 Trim Cylinder Trim Cylinder Anode Screw (2) Washer (2) 15. Position trim cylinder rear connecting ends as shown. 22135 Port Trim Cylinder Starboard Trim Cylinder Connecting Ends (Angled as Shown) 90-863160 MAY 2000 Page 5B-19...
  • Page 478 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 16. Install IN/DOWN trim hose. 22130 “Down” Trim Hose Clamping Plate Screws 17. Check painted areas of trim cylinders for scratches that expose metal and paint if neces- sary. Page 5B-20 90-863160 MAY 2000...
  • Page 479 If you are not sure of it’s original position, contact the boat manufacturer for their recommendation. Refer to Special Information at the front of this section before reinstalling the Trim-In Limit Insert. 4. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model. 75157...
  • Page 480 TRIM CYLINDERS SERVICE MANUAL NUMBER 28 6. Coat anchor pin threads with 2-4-C Marine Lubricant with Teflon to prevent threads from galling. 7. Hand thread locknuts onto anchor pin. Install plastic caps. 22029 Aft Anchor Pin (Shorter) Washers (2) - Large I.D. Bushings Washers (2) - Small I.D.
  • Page 481 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 POWER TRIM Section 5C - Dual Power Trim System Table of Contents Important Information ....5C-2 Diode Module Replacement .
  • Page 482 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Important Information When testing this Dual Power Trim system, take special note of the following: • The control box harness connectors must be disconnected and the key switch must be OFF. • Make certain that the jumper lead used between terminals 3 and 5 is used only when specified.
  • Page 483 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 TESTING RELAY NO. 2 1. Test for continuity between terminals 13 and 9. • Continuity indicated, proceed to “2.” • No continuity indicated, replace the relay. 2. Connect a jumper wire between terminals 3 and 5. Test for continuity between terminals 13 and 9.
  • Page 484 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Trailer Switch Test CAUTION Remove fuse from RED/PURPLE harness lead before proceeding with test. 1. Set the ohmmeter on the Rx1 scale. 2. Push down on the “Trailer” switch and check for continuity between terminals 10 and 3. •...
  • Page 485 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Dual Power Trim System Component Repair Important Information Use care when removing and installing components. Do not force or pull wiring during replacement. Use care to prevent wiring from stretching, pinching or chafing. Coat all terminal connections with Quicksilver Liquid Neoprene.
  • Page 486 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 INSTALLATION 1. Install new relay. IMPORTANT: Use 63/67 (Tin/Lead) alloy solder. DO NOT use acid core solder as damage to relay can result. Coat terminal connections with Quicksilver Liquid Neoprene. 2. Resolder wires from terminal block to relay as shown. 3.
  • Page 487 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Diode Module Replacement Removal 1. Remove control box cover. 22086 Screws Cover 2. Disconnect leads from terminal block. Installation 1. Replace diode module. 22086 Diode Module Bolt 2. Reconnect numbered leads to respective terminals. 3.
  • Page 488 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Trim Control Panel Switch(es) Replacement Removal 1. Remove trim control panel from dash. 2. Cut leads (from switch to be replaced) as close to switch terminals as possible. 22086 No. 10-24 Studs Flat Washers And Nuts U-Bracket 3.
  • Page 489 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Installation 1. Replace switch. 22086 Bezel Nut Switch 2. With new switch properly positioned in control panel, loop leads through their respective terminal eyelets. Refer to Wiring Diagram. 3. Using 60/40 (tin/lead) alloy rosin core solder, solder leads to terminals. 4.
  • Page 490 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Wiring Diagrams Dual Trim Harnesses BLK D Black BLU D Blue BRN D Brown GRY D Gray GRN D Green ORN D Orange PNK D Pink PUR D Purple RED D Red TAN D Tan WHT D White YEL D Yellow...
  • Page 491 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 Electrical Box Wiring 22129 90-863160 MAY 2000 Page 5C-11...
  • Page 492 DUAL POWER TRIM SYSTEM SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 5C-12 90-863160 MAY 2000...
  • Page 493 AUTO TRIM II SERVICE MANUAL NUMBER 28 POWER TRIM Section 5D - Auto Trim II Table of Contents Auto Trim II System ....5D-2 Auto Trim Limit Adjustment .
  • Page 494 AUTO TRIM II SERVICE MANUAL NUMBER 28 Auto Trim II System Description The Auto Trim System consists of the following major components: • Auto Trim Pump - same pump that is used on the standard power trim models. • Control Module - a solid-state electronic device that senses engine rpm and regulates the time at which the sterndrive unit trims IN and OUT when operating in the AUTO mode.
  • Page 495 AUTO TRIM II SERVICE MANUAL NUMBER 28 Auto Mode Operation WARNING Sterndrive unit will automatically lower from the raised position when the ignition switch is turned to the RUN position and mode switch is placed in the AUTO mode. BE SURE THAT NO ONE IS IN THE AREA OF THE STERNDRIVE UNIT. With mode switch in the AUTO mode, the sterndrive unit will move automatically to properly trim the boat while underway.
  • Page 496 AUTO TRIM II SERVICE MANUAL NUMBER 28 “Manual” Mode Operation Placing the mode switch in the MANUAL position will deactivate the AUTO system and allow the operator to adjust sterndrive unit position, using the manual trim control. Typical controls are shown following. Manual trimming may be desirable to fine tune the trim angle for a particular water condition or boat load, or in situations where greater control over the trim operation is needed.
  • Page 497 AUTO TRIM II SERVICE MANUAL NUMBER 28 TRIMMING STERNDRIVE UNIT OUT (BOW UP) 1. Press UP/OUT Button until sterndrive unit moves to properly trim boat or trim limit switch stops outward travel. 22174 UP/OUT Button CAUTION NEVER trim the sterndrive unit OUT using the “Trailer” switch(es) while boat is un- derway.

  • Page 498: Electrical System Overload Protection

    AUTO TRIM II SERVICE MANUAL NUMBER 28 Electrical System Overload Protection The Auto Trim electrical system is protected from overload by a 110-amp fuse, and a 20-amp in-line fuse at control module positive (+) battery lead and a 20-amp in-line fuse at ignition switch (if Quicksilver ignition switch is used).
  • Page 499 AUTO TRIM II SERVICE MANUAL NUMBER 28 Adjusting Sterndrive Unit Trim Angle WARNING When adjusting trim limit use extreme care that engine is not accidentally started and keep clear of area near propeller. Also, use care to prevent placing hands in an area where they could be injured by sterndrive unit movement.
  • Page 500 AUTO TRIM II SERVICE MANUAL NUMBER 28 6. With the assistance of another person actuate manual trim control switch used to trim sterndrive unit OUT (DO NOT use “Trailer” switch) and turn trim limit switch SLOWLY counterclockwise until trim cylinders extend to dimension shown. Retighten trim limit switch retaining screws.
  • Page 501 AUTO TRIM II SERVICE MANUAL NUMBER 28 Control Module Adjustment 1. Completely turn adjustment knob on control module COUNTERCLOCKWISE. 2. Turn knob back CLOCKWISE four clicks. 3. With auto trim mode switch in AUTO position and the sterndrive unit trimmed full IN/DOWN, accelerate boat slowly while watching trim gauge.
  • Page 502 AUTO TRIM II SERVICE MANUAL NUMBER 28 Trim Position Indicator Adjustment With ignition key in the RUN position, check Auto Trim indicator to make sure that needle points to bottom of the scale when sterndrive unit is IN/Down. If needle is not at bottom of scale, perform following steps: 22175 Trim Position Indicator...

  • Page 503: Wiring Diagram

    AUTO TRIM II SERVICE MANUAL NUMBER 28 Wiring Diagram BLK = BLACK BLU = BLUE BRN = BROWN GRY = GRAY GRN = GREEN ORN = ORANGE PNK = PINK PUR = PURPLE RED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT DRK = DARK...
  • Page 504 AUTO TRIM II SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 5D-12 90-863160 MAY 2000...
  • Page 505 POWER STEERING SERVICE MANUAL NUMBER 28 STEERING SYSTEMS Section 6A - Power Steering Table of Contents Specifications ......6A-2 Power Steering Assembly .
  • Page 506 POWER STEERING SERVICE MANUAL NUMBER 28 Specifications Torque Specifications NOTE: Securely tighten all fasteners not listed below. FASTENER LOCATION lb-in. lb-ft Steering Cable Coupler Nut Steering System Pivot Bolts Power Steering Hydraulic Hose Fittings Power Steering Pump Housing Studs Pump Flow Control Valve Fitting Tie Bar Locknut Special Tools DESCRIPTION...

  • Page 507: Control Valve

    POWER STEERING SERVICE MANUAL NUMBER 28 Description The Power Steering system utilizes an engine-driven, vane-type hydraulic pump that sup- plies fluid flow and pressure by means of hoses to a control valve that, in turn, controls fluid flow and pressure to-and-from a booster cylinder. Three modes make up the basic function of the Power Steering system: 1) neutral mode, 2) left turn mode, and 3) right turn mode.

  • Page 508: Power Steering System

    POWER STEERING SERVICE MANUAL NUMBER 28 Power Steering System RIGHT TURN PISTON CONTROL VALVE PUMP OIL COOLER RELIEF VALVE HIGH PRESSURE 1150-1250 PSI LOW PRESSURE 70-125 PSI PUMP HOUSING 75238 (VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM) Page 6A-4 90-863160 MAY 2000...
  • Page 509 POWER STEERING SERVICE MANUAL NUMBER 28 Power Steering System LEFT TURN PISTON CONTROL VALVE PUMP OIL COOLER RELIEF VALVE HIGH PRESSURE 1150-1250 PSI LOW PRESSURE 70-125 PSI PUMP HOUSING 75239 (VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM) 90-863160 MAY 2000 Page 6A-5...
  • Page 510 POWER STEERING SERVICE MANUAL NUMBER 28 Power Steering System NEUTRAL PISTON CONTROL VALVE PUMP OIL COOLER RELIEF VALVE HIGH PRESSURE 1150-1250 PSI LOW PRESSURE PUMP HOUSING 70-125 PSI 75237 (VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM) Page 6A-6 90-863160 MAY 2000...

  • Page 511: Steering Helm And Cable

    POWER STEERING SERVICE MANUAL NUMBER 28 Steering Helm and Cable The power steering unit is shipped preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. The steering cable cou- pler nut must also have a means of locking it to the guide tube, as specified in ABYC require- ments.
  • Page 512 POWER STEERING SERVICE MANUAL NUMBER 28 CAUTION POWER STEERING EQUIPPED UNITS ONLY - If cables with improper dimensions are installed, severe damage to transom assembly and/or steering system may re- sult. 1. Steering cable must be the correct length, particularly when installed in larger boats. 2.
  • Page 513 POWER STEERING SERVICE MANUAL NUMBER 28 Filling and Air Bleeding Power Steering System Checking Fluid Level Engine Warm 1. Stop engine. Position drive unit so that it is straight back. 2. Remove fill cap / dipstick from power steering pump and note fluid level. 74908 Fill Cap / Dipstick Power Steering Pump...
  • Page 514 POWER STEERING SERVICE MANUAL NUMBER 28 4. If level is below bottom of dipstick, but fluid is still visible in pump reservoir, add required amount of Quicksilver Power Trim and Steering Fluid or automatic Dexron III transmis- sion fluid (ATF), through fill cap opening, to bring level up to FULL COLD mark on dip- stick.
  • Page 515 POWER STEERING SERVICE MANUAL NUMBER 28 Power Steering Assembly Removal 1. Remove rear clevis pin from steering lever. 2. Remove forward clevis pin from steering cable. 3. Using suitable wrenches hold the flat surfaces on the cable guide tube in the vertical position then loosen the coupler nut and remove the steering cable.
  • Page 516 POWER STEERING SERVICE MANUAL NUMBER 28 Installation WARNING Steering cable outer casing MUST BE free to move back-and-forth for steering to function properly. DO NOT fasten any wires, cables or other items to steering cable, as this may prevent it from moving. 1.
  • Page 517 POWER STEERING SERVICE MANUAL NUMBER 28 7. Connect the power steering unit to the steering lever. a. Lubricate the clevis pins with Special Lubricant 101. b. Install the clevis pin in the clevis from the top. c. Secure the pin in the clevis with a cotter pin. Spread the cotter pin ends. 8.
  • Page 518 POWER STEERING SERVICE MANUAL NUMBER 28 11. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical posi- tion. Torque coupler nut to 35 lb-ft (47 Nm). Be certain the flat surfaces are still aligned vertically after torque is applied to coupler nut.
  • Page 519 POWER STEERING SERVICE MANUAL NUMBER 28 Power Steering System Pressure Test IMPORTANT INFORMATION The following instructions are arranged so that a defective part can be detected by the pro- cess of elimination. It is suggested that the order of the instructions be followed so that the Power Steering System can be tested effectively.
  • Page 520 Cooling system is full when water is discharged through the propeller. DO NOT use full water tap pressure. 22029 Standard Bravo Shown 6. Start engine and run at 1000-1500 RPM until engine reaches normal operating tempera- ture.
  • Page 521 POWER STEERING SERVICE MANUAL NUMBER 28 CAUTION DO NOT lug pump at maximum pressure for more than 5 seconds, in next step, or damage to Power Steering pump may occur. 8. Push in then pull steering cable momentarily. Gauge reading should show an instant increase in pressure when block is pushed in both directions.
  • Page 522 2. Connect a flush test device to drive unit. Partially open water tap (approximately 1/2 max.) and allow water to enter cooling system. DO NOT use full water tap pressure. 22029 Standard Bravo Shown 3. Start engine and run at 1000-1500 RPM until engine reaches normal operating tempera- ture.
  • Page 523 POWER STEERING SERVICE MANUAL NUMBER 28 Power Steering Pump Removal 1. Loosen the adjusting stud and remove the serpentine belt from the power steering pulley. 75483 Adjusting Nut NOTE: Use a suitable container catch ant power steering fluid when removing the power steering hoses.
  • Page 524 POWER STEERING SERVICE MANUAL NUMBER 28 3. Remove mounting fasteners from pump. 75798 75228 Power Steering Pump Typical Location Bolts 4. Remove the power steering pump from the bracket. Flow Control Valve Servicing 1. Drain fluid from pump. 2. Remove components shown. 76869 Fitting Assembly Control Valve Assembly...
  • Page 525 POWER STEERING SERVICE MANUAL NUMBER 28 4. Install components shown. Torque fitting to 35 lb-ft (47 Nm). 76869 Fitting Assembly Control Valve Assembly Flow Control Spring New O-rings Pump Shaft Oil Seal Replacement 1. Remove pump pulley. 76895 Kent Moore Pulley Removal Tool (J-25034) 2.
  • Page 526 POWER STEERING SERVICE MANUAL NUMBER 28 3. Remove oil seal. Remove shim stock. 22152 Seal Suitable Tool 4. Install new oil seal. Properly support pump reservoir so that reservoir back does not dis- tort. 22151 New Oil Seal - Metal Side Up Suitable Mandrel Pump Reservoir 5.
  • Page 527 POWER STEERING SERVICE MANUAL NUMBER 28 e. Check pulley installation for correct alignment. 76896 Power Steering Pump Pulley Stud Do NOT Use Spacer Bearing Shaft Crankshaft Pulley (Shown) or Water Circulating Pump Pulley Long Straight Edge Drive Belt Parallel Disassembly 1.
  • Page 528 POWER STEERING SERVICE MANUAL NUMBER 28 4. Discard o-rings and retain the other parts. 22155 Fitting Assembly Control Valve Assembly Flow Control Spring Studs Reservoir O-rings 5. Position retaining ring so that ring end is 1 in. (25 mm) from end of hole in housing. 6.
  • Page 529 POWER STEERING SERVICE MANUAL NUMBER 28 9. Remove pump components shown. 22155 Spring Pressure Plate Pump Ring Pump Vanes Pump Shaft and Rotor Assembly Dowel Pins 10. Remove and discard O-rings from housing. 22155 O-rings 11. Remove retaining ring, rotor and thrust plate. 22155 Retaining Ring Rotor...
  • Page 530 POWER STEERING SERVICE MANUAL NUMBER 28 12. Remove magnet. 22154 Magnet Cleaning And Inspection 1. Clean and inspect all metal parts. Reassembly NOTE: All references to Power Steering fluid refer to Quicksilver Power Trim and Steering Fluid, or Dexron II if Quicksilver product is not available. NOTE: Obtain and install a new seal kit 5688044 from a local GM automotive dealer when reassembling pump.
  • Page 531 POWER STEERING SERVICE MANUAL NUMBER 28 3. Install dowel pins. 22150 Pressure Plate O-ring Dowel Pins 4. Assemble pump shaft and rotor assembly. Rotor should be installed with the counter- sunk side toward the thrust plate. 22155 Pump Shaft Thrust Plate Rotor Retaining Ring 5.
  • Page 532 POWER STEERING SERVICE MANUAL NUMBER 28 6. Install pump ring by placing the 2 smaller holes over the dowel pins. 22154 Pump Ring 7. Install vanes in rotor slots with rounded edges toward pump ring. Vanes must slide free- 22154 Vanes 8.
  • Page 533 POWER STEERING SERVICE MANUAL NUMBER 28 9. Lubricate end plate O-ring with power steering fluid and place in second groove in hou- sing. 22150 End Plate O-ring 10. Install pressure plate spring, end plate and retaining ring. Use care not to damage end plate and O-ring.
  • Page 534 POWER STEERING SERVICE MANUAL NUMBER 28 12. Place magnet on housing. 22153 Magnet 13. Secure reservoir to pump housing. Torque studs to 35 lb-ft (47 Nm). 22153 Reservoir Pump Housing Studs 14. Install components shown. Torque fitting assembly to 35 lb-ft (47 Nm). 22153 Flow Control Spring Control Valve Assembly...
  • Page 535 POWER STEERING SERVICE MANUAL NUMBER 28 15. Install pulley, as follows, using Pulley Pusher Assembly 91-93656A1, and a long straight edge: a. Place pulley on pump shaft. b. Thread stud ALL-THE-WAY into pump shaft. Place bearing over stud. DO NOT use spacer from kit.
  • Page 536 POWER STEERING SERVICE MANUAL NUMBER 28 Installation IMPORTANT: Be careful to not cross-thread or overtighten hose fittings. 1. Place the power steering pump on the bracket and install the screws and nut. Torque to 30 lb-ft (41 Nm). 75798 75228 Power Steering Pump Typical Location Bolts 2.
  • Page 537 (Part Number 90362A3) should be installed to limit this potential tilt differential to about 20°. IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with no internal tie bar when using the internal power steering system. This can cause excessive loads on the steering components on the drive connected to the in- ternal power steering system.
  • Page 538 POWER STEERING SERVICE MANUAL NUMBER 28 Determining Tie Bar Length WARNING ON DUAL INSTALLATION USING STARBOARD TIE BAR KIT. The steering cable MUST have a minimum radius of 8 in. (203 mm) at the transom end. A radius less than 8 in. (203 mm) may kink the steering cable which, in turn, may affect steering operation.
  • Page 539 POWER STEERING SERVICE MANUAL NUMBER 28 Selection TIE BAR CHART For Dual Installations with Steering Cable Attached to Starboard Power Package * 16” to 30” 92020A1 * 30” to 46” 92020A2 46” to 62” 92020A3 * If centerline distance is the same as maximum figure, use next larger size tie bar. TIE BAR CHART For Dual Installations with Steering Cable Attached to Port Power Package * 28”...
  • Page 540 POWER STEERING SERVICE MANUAL NUMBER 28 5. Attach tie bar end using clevis pin (f), and cotter pin (g). 6. Spread cotter pin ends. 7. Apply Loctite 277 to exposed tie bar threads. 8. Tighten locknut against tie bar to 50 lb-ft (68 Nm). 22079 22211 Adjustable End...
  • Page 541 POWER STEERING SERVICE MANUAL NUMBER 28 7. Spread cotter pin ends. 8. Apply Loctite 271 or equivalent to exposed tie bar threads. 9. Tighten locknut (against tie bar) to 50 lb-ft (68 Nm). 22079 22211 Adjustable End Clevis Pin Cotter Pin Locknut 90-863160 MAY 2000 Page 6A-37...
  • Page 542 POWER STEERING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 6A-38 90-863160 MAY 2000...
  • Page 543 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 STEERING SYSTEMS Section 6B - Compact Hydraulic Steering Table of Contents Important Information About Single Station With Single Cylinder . . . 6B-7 Thru-Transom Exhaust ....6B-2 Purging .
  • Page 544 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Important Information About Thru-Transom Exhaust This Hydraulic Steering system is not designed for use with Through-Transom exhaust sys- tems. Do not use this Hydraulic Steering System with a Through-Transom Exhaust System. Torque Specifications DESCRIPTION lb-in.
  • Page 545 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Removal CAUTION Avoid product malfunction and diminished steering control. Dirt and contamination introduced into the hydraulic system can result in damage to internal parts of steer- ing system. Do not allow dirt or contamination to enter the helm, lines or cylinder of this steering system.
  • Page 546 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 3. Remove cotter pin from port clevis pin and remove clevis pin. 4. Bend pivot bolt tab washer tabs away from bolts. 5. Remove pivot bolts. 76087 Pivot Bolts Port Clevis Pin Tab Washer 6.
  • Page 547 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 2. Install steering cylinder assembly as follows: a. Position steering cylinder assembly so that upper and lower pivot bolts (with tab washers and spacers) can be threaded by hand into transom plate. b. Ensure that tab washer tangs straddle the ridge on transom plate. c.
  • Page 548 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 IMPORTANT: Do not connect clevis to steering lever at this time. Bleed and purge the system before connecting clevis to steering lever. 3. Connect hoses to steering cylinder as follows: a. Apply a small amount of clean hydraulic fluid to the hydraulic hose end O-ring area. b.
  • Page 549 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Single Station With Single Cylinder FILLING IMPORTANT: Hydraulic fluid must be visible in the filler tube during the entire filling procedure. DO NOT allow the bottle of fluid used for filling to empty causing the filler tube to empty.
  • Page 550 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Purging Turning the steering wheel in direction shown moves the cylinder rod as indicated by arrow. 76090 1. Remove caps from bleeder valves on T-Fittings at cylinder assembly. NOTE: Place temporary hoses (obtain locally - clear hose is recommended) on bleeder out- lets and position these hoses in a container to avoid spillage and air return to bleeder.
  • Page 551 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 6. Turn the steering wheel slowly COUNTERCLOCKWISE while your assistant opens the PORT bleeder valve on the steering cylinder. 7. Continue to turn steering wheel until a stream of air free fluid is visible out of bleeder. 8.
  • Page 552 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Connecting The Clevis 1. Lubricate clevis pin and clevis with Special Lubricant 101. 2. Connect clevis to steering lever. Be sure to spread both ends of cotter pin. IMPORTANT: Ensure that the clevis is positioned as shown below. The angled notch in the clevis must face the rear.
  • Page 553 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 Hydraulic Fluid Level Setting Fluid Level WARNING Avoid serious bodily injury or death due to loss of steering control. This system op- erates with an unbalanced steering cylinder volume. Proper fluid level in the helm can only be set or checked with the cylinder rod fully retracted.
  • Page 554 COMPACT HYDRAULIC STEERING SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 6B-12 90-863160 MAY 2000...
  • Page 555 7A-6 and Troubleshooting ....7A-15 Bravo One Sterndrive Units ..7A-6 Test Equipment Set-Up ... . .

  • Page 556: Continuity Circuit

    CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Specifications Special Tools DESCRIPTION PART NUMBER MerCathode Reference Electrode Test 76675T1 Quicksilver VOA Meter* 91-93572 *If you do not already have this meter, use a digital multi-meter. Do NOT use a standard ana- log meter as inaccurate readings will result.
  • Page 557 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 77079 22650 Inner Transom Plate To Gimbal Housing Ground Wire Driveshaft Housing To Gear Housing Ground Plate (Inside Anode Cavity) 77100 Gimbal Housing To Gimbal Ring Ground Wire Gimbal Ring To Trim Cylinder Ground Wires 22028 50242 Gasoline Models...
  • Page 558 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 22755 22031 Gimbal Ring To Bell Housing Ground Wire Sterndrive Unit To Bell Housing Ground Plate 22230 70575 Driveshaft Housing To Gear Housing Anodic Plate Hydraulic Connector Block To Gimbal Housing Ground Washer 22079 50383 U-joint Bellows Ground Clip...

  • Page 559: Trim Cylinder Anodes

    CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Trim Cylinder Anodes CAUTION DO NOT paint new trim cylinder anodes, as this will render them ineffective as a gal- vanic corrosion inhibitor. 1. Remove screws that secure anodes to trim cylinders. Remove anodes. 71966 Screws Trim Cylinder Anodes...
  • Page 560 Anodic Plate CAUTION DO NOT paint new anodic plate, as this will render it ineffective as a galvanic corro- sion inhibitor. Bravo One Sterndrive Units 1. Remove plug from driveshaft housing to gain access to attaching screw. 22093 Rubber Plug 2.
  • Page 561 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 CAUTION To be effective, new anodic plate MUST make good electrical contact with gear housing. 3. Scrape anodic plate mounting surface on gear housing down to bare metal. 4. Install anodic plate. Torque screw to 30 lb-ft (41 Nm). 76800 Anodic Plate Rubber Plug (Removed)
  • Page 562 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Bravo Two Sterndrive Units 1. Use a 1/2 in. standard socket to loosen screw and remove anodic plate. 2. Scrape anodic plate mounting surface down to bare metal to ensure continuity.
  • Page 563 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Integral MerCathode System Removing Electrode Assembly 1. Disconnect electrode assembly wires from MerCathode Controller. 22232 ORANGE Lead - From Electrode On Transom Assembly RED/PURPLE Lead - Connect To Positive (+) Battery Terminal BLACK Lead - From Engine Harness BROWN Lead - From Electrode On Transom Assembly 2.
  • Page 564 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Installing Electrode Assembly CAUTION O-ring MUST BE properly seated in groove of electrode assembly or water leakage into boat will result. 1. Electrodes have a factory installed rubber grommet and Do NOT require an O-ring. 71862 Electrode Rubber Grommet...
  • Page 565 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 4. Guide wire through hole until wire protrudes through cavity on the bottom of exhaust pipe. 22235 Wire 5. Secure ring terminals to tracer wire. 6. Guide leads through center hole in connector block. IMPORTANT: Orange lead is approximately 6 in.
  • Page 566 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 CAUTION DO NOT paint sacrificial anodes or MerCathode System electrode assembly, as this will render them ineffective as galvanic corrosion inhibitors. 8. Position and secure electrode assembly to gimbal housing using two 1-3/8 in. (35 mm) long screws, flat washers and lockwashers.
  • Page 567 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Wiring Diagrams MerCathode Monitor 74251 Instrument Panel Ground Screw, Nut and Sleeve Electrode 20 Amp Fuse Controller 90-863160 MAY 2000 Page 7A-13...
  • Page 568 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 MerCathode Controller 73596 Controller 20 Amp Fuse Electrode Page 7A-14 90-863160 MAY 2000...
  • Page 569 Test requires the us of MerCathode Reference Electrode Test 76675A1 and Quicksilver VOA meter 91-62562A1. This meter is no longer available from Mercury Marine. If you do not already have this meter, a digital multi-meter must be used. A STANDARD ANALOG METER CANNOT BE USED, AS AN INACCURATE READING WILL RESULT.
  • Page 570 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 The MerCathode Reference Electrode Tester 76675A1 is equipped with a special jack con- taining a resistor to provide the proper scale reading when used with a digital multimeter. Do NOT remove this plug or use analog meters. Resistor jack can be left in place when using digital meters.
  • Page 571 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 4. Immerse Electrode Tester in the water within 6 in. (150 mm) of aft end of sterndrive unit. IMPORTANT: There will be different voltage readings depending on the type of Mer- Cathode System you are testing.
  • Page 572 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Test Equipment Set-Up 6 IN. (150 MM) (MAX.) 70755 Page 7A-18 90-863160 MAY 2000...
  • Page 573 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Low Readings Cause Special Instructions Loss of continuity between sterndrive unit Ensure that continuity devices are not components and negative (-) battery missing or damaged and that connections terminal. are clean and tight. Shore power green safety grounding lead Disconnect shore power and verify if not isolated from the power package...
  • Page 574 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 Low Readings (continued) Cause Special Instructions Faulty MerCathode reference electrode. Disconnect the reference electrode lead(brown) from the controller “R” terminal. Connect the lead to the positive (+) terminal of a digital multimeter (set on 0-2000 millivolt scale).
  • Page 575 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 High Reading Cause Special Instructions Stray current corrosion. If an electrical Observe the reading while disconnecting current flowing along a metal conductor the electrical components one at a time leaves the metal for a water path, it will until you eliminate the high reading.
  • Page 576 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 TRIM CYLINDER CORRODING Cause Special Instructions Continuity lost between trim cylinder Install proper continuity devices. and drive unit. ONLY ONE OR TWO COMPONENTS CORRODING Cause Special Instructions Continuity lost between drive unit and If not already done, install Continuity components.
  • Page 577 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 STAINLESS STEEL COMPONENTS CORRODING Cause Special Instructions Foreign matter (fishing line, marine Remove foreign matter and prevent growth, etc.) covering the steel and surfaces from being covered by sand starving it of oxygen. This causes a or silt.
  • Page 578 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 28 THIS PAGE IS INTENTIONALLY BLANK Page 7A-24 90-863160 MAY 2000...
  • Page 579 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 ACCESSORIES Section 8A - All Models Table of Contents Specifications ......8A-2 Shift Cable Replacement and Adjustment 8A-14 Torque Specifications...
  • Page 580 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Specifications Torque Specifications Description lb-in. lb-ft Dust Cover Inlet Flange Valve Guide Bracket Through Bolts End Plate to Valve Guide Bracket End Plate to Cylinder Lubricants / Sealants / Adhesives DESCRIPTION PART NUMBER 2-4-C Marine Lubricant with Teflon 92-825407A1 Power Shift (P/N 38638A4)

  • Page 581: General Information

    ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 General Information Control Cables - Use quicksilver control cables for the input cable, output cable and throttle cable. ATTACHING OUTPUT SHIFT CABLE TO STERNDRIVE UNIT Refer to the Sterndrive Unit Installation Manual or Installation Section of this manual and follow the procedure outlined for attaching and adjusting the shift cable.
  • Page 582 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 DETERMINING INPUT CABLE LENGTH 1. Measure the distance from the remote control where the cables leave the housing, to the power shift cylinder where the vacuum hose attaches; make the cable bends of a 12 in.
  • Page 583 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Checking Vacuum Drop-Off 1. Connect a leak proof shut-off valve and pressure gauge between the Power Shift cylin- der input flange and the vacuum connection at the engine manifold. Position the valve toward the manifold side and the gauge toward the power shift cylinder.
  • Page 584 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Power Shift Cylinder Repair Removal 1. Loosen the clamps (2) and remove the dust cover from the valve guide brackets. 2. Remove the inlet hose clamp at the inlet flange and remove the inlet hose. 3.
  • Page 585 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 5. Remove the piston by removing the O-ring from the shaft (behind the piston, next to the 2nd snap ring) and then removing the snap ring. 6. Remove the shaft end plug. 50423 50339 Shaft End Plug...
  • Page 586 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 8. Remove the 2 thru-bolts which secure the end plate to the valve guide bracket. 50453 2 Thru-bolts 9. Slip the end plate from the valve guide bracket, and off of the shaft. It may be necessary to tap off the plate with a rawhide mallet.
  • Page 587 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Reassembly 1. Press the new oil seals into the end plate/housing until the seals bottom out. The seal lips face in the direction shown. 50452 New Oil Seals 2. Wrap the diameter of the shaft (area “a,”) with masking tape to protect the seal lips. 3.
  • Page 588 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 7. Lubricate the I.D. of the seal with 2-4-C Marine Lubricant with Teflon. 50452 Seal Tube New Seal 8. Place masking tape over the shaft end to protect the seal. 9. Lubricate the shaft with 2-4-C Marine Lubricant with Teflon. 10.
  • Page 589 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 15. If the piston seal is not pre-cut, make a diagonal cut/separation as shown. 50339 16. Install the O-ring in the O.D. groove in the piston. 17. Install the piston seal over the O-ring. 18.
  • Page 590 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 24. Install a new O-ring onto the shaft end plug. 25. Lightly lubricate the O-ring with 2-4-C Marine Lubricant with Teflon and insert the plug into the shaft end. Be careful not to damage the O-ring. A damaged O-ring will cause a vacuum leak.
  • Page 591 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 29. Attach the cylinder to the end plate with 4 bolts and lock washers. Torque the bolts to 204-276 lb-in. (23-31 Nm). 50425 50339 Cylinder End Plate 4 Bolts and Lockwashers Paper Gasket 90-863160 MAY 2000 Page 8A-13...
  • Page 592 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Shift Cable Replacement and Adjustment Installation Preparation If installing a new shift cable(s), complete the hookup to the remote control and route the shift cable(s) before starting the following procedures. Shift Cable Barrel Adjustment 1.
  • Page 593 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Installing Input Cable 1. Install the input cable as shown. Take care not to change the position of the barrel. 2. Place a round felt plug in the valve guide bracket hole on top of the cable barrel. 50419 50176 Input Cable Barrel...
  • Page 594 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Installing Output Cable 1. Install output cable as shown. 2. Place a rectangular felt spacer in the recess of the valve guide bracket. 50419 50176 Output Cable Barrel Cotter Pin Yoke Threaded Stud Valve Guide Bracket Output Cable End Rectangular Felt Spacer...
  • Page 595 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 Mounting Power Shift Cylinder 1. Securely fasten the power shift cylinder to the boat with lag screws or bolts. 2. Fasten the input cable to the boat. Do not fasten the cable within 18 in. (457 mm) of the power shift cylinder.
  • Page 596 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 28 4. Place the hose clamp over the end of the hose and slide the hose over the fitting. Tighten the hose clamp securely. 50152 Engine WITHOUT Vacuum Gauge Installed Vacuum Hose Hose Clamp Hose Connector Fitting Reducer Fitting 50152...
  • Page 597 Click below to find more Mipaper at www.lcis.com.tw Mipaper at www.lcis.com.tw...

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