"Tan PS" wrote in message
...
Just bought a Trophy with a 5.7 V8 coupled to an Alpha drive, 1991.
Started
with some servicing to get things in order before venturing out. The
sterndrive is interesting and below are some experience I like to share.

1. U-joint bellows replacement
Pretty straightforward, not to worry.

2. Exhaust bellow
Real pain. Bought the tool as recommended but it is quite useless
unless you remove the upper shift-shaft as it cannot be inserted. Any
parts
removal in an old engine is an adventure in its own right. Gave up that
idea, finally split the tool and used one arm to do the job.

You might want to take the shift shaft out to replace the bushings and
seals. A leaking seal is probably why the shift cable got damaged.


3. Lower shift cable
Fitting needed a special tool, welded a 3/8 drive 9/16 socket to a
1/2 inch pipe and another socket at the other end to give it the square
drive. 2 sockets, 1 pipe and welding later, quite useless, damn cable
fitting is stuck. Finally drilled it out, watch it, its a NPT thread with
a
taper. Can't they just use regular threads with an o-ring and sealant to
seal it against water-just needed to ventilate....
Installing the cable, haven't done it yet. After surveying the
job,
can see it coming...****.

Drill out the end of a cheap chinese 6" 3/8 drive extension so the plastic
cable guide can fit into it.


4. Bell housing hinge pin
As all old boat stuff, stuck. Tool now used as paperweight.
Didn't
want to push it, if something breaks = more money or less for me depending
on which side you are on.

The hinge pins are set in with locktite at 90 ft. lbs. of torque. Use some
heat to soften the locktite.

Something to share.

Tan PS



Have fun,
Jim