I have a 1989 Stingray with a 3.0 liter Mercruiser engine with an
Alpha one outdrive. I have been getting about a half a cup of water
in the foot after about every 4 hours of operation. I have been
changing the foot oil after every use (4hours) so as to keep things
from going poop until I could put it in the shop. I recently changed
from the expensive Mercruiser outdrive lube (quicksilver) to a cheaper
80W90 gear oil (seeing as I was changing it after every 4 hours of
operation). I have been noticing what I thought was gear oil in the
bilge, but was not sure until I changed lubes. Now I am positive that
I have gear oil from the foot in the bilge. My question(s) are
these.... would it be that the upper water seals in the outdrive are
causing the water to get into the foot and the oil to leak into the
bilge? Question number two....I am a decent mechanic.....without
having specialized tools, is it practical for me to replace the seals
myself (I did rebuild a Porsche motor several years ago....to give
you a benchmark of my mechanical capabilities)

Any help would be appreciated.

Dave

Dave,

I am far from an expert, but it sounds like you may have a number of problem.

If you're positive you're getting gear oil in the bilge are you also
getting a lot of water? Could be a cracked driveshaft bellows and bad
o-ring(s) on the driveshaft. If there is no water it could be bad
driveshaft o-rings, and perhaps a bad waterpump seal.

I think the only seals you can replace without specialized tools are the
outdrive kit, the water pump base, and those found in the waterpump
housing kit.

I hope this helps.

Bob Dimond


In article , D.B.
wrote:

I have a 1989 Stingray with a 3.0 liter Mercruiser engine with an
Alpha one outdrive. I have been getting about a half a cup of water
in the foot after about every 4 hours of operation. I have been
changing the foot oil after every use (4hours) so as to keep things
from going poop until I could put it in the shop. I recently changed
from the expensive Mercruiser outdrive lube (quicksilver) to a cheaper
80W90 gear oil (seeing as I was changing it after every 4 hours of
operation). I have been noticing what I thought was gear oil in the
bilge, but was not sure until I changed lubes. Now I am positive that
I have gear oil from the foot in the bilge. My question(s) are
these.... would it be that the upper water seals in the outdrive are
causing the water to get into the foot and the oil to leak into the
bilge? Question number two....I am a decent mechanic.....without
having specialized tools, is it practical for me to replace the seals
myself (I did rebuild a Porsche motor several years ago....to give
you a benchmark of my mechanical capabilities)

Any help would be appreciated.

Dave

Thanks Bob

On Thu, 29 Apr 2004 10:59:47 -0400, (Bob
D.) wrote:

Dave,

I am far from an expert, but it sounds like you may have a number of problem.

If you're positive you're getting gear oil in the bilge are you also
getting a lot of water? Could be a cracked driveshaft bellows and bad
o-ring(s) on the driveshaft. If there is no water it could be bad
driveshaft o-rings, and perhaps a bad waterpump seal.

I think the only seals you can replace without specialized tools are the
outdrive kit, the water pump base, and those found in the waterpump
housing kit.

I hope this helps.

Bob Dimond


In article , D.B.
wrote:

I have a 1989 Stingray with a 3.0 liter Mercruiser engine with an
Alpha one outdrive. I have been getting about a half a cup of water
in the foot after about every 4 hours of operation. I have been
changing the foot oil after every use (4hours) so as to keep things
from going poop until I could put it in the shop. I recently changed
from the expensive Mercruiser outdrive lube (quicksilver) to a cheaper
80W90 gear oil (seeing as I was changing it after every 4 hours of
operation). I have been noticing what I thought was gear oil in the
bilge, but was not sure until I changed lubes. Now I am positive that
I have gear oil from the foot in the bilge. My question(s) are
these.... would it be that the upper water seals in the outdrive are
causing the water to get into the foot and the oil to leak into the
bilge? Question number two....I am a decent mechanic.....without
having specialized tools, is it practical for me to replace the seals
myself (I did rebuild a Porsche motor several years ago....to give
you a benchmark of my mechanical capabilities)

Any help would be appreciated.

Dave

In article , D.B.
wrote:

Thanks Bob



Your welcome, Dave. I don't know if you need to check gear tolerances
and reshimm the gears when redoing seals. Assuming you do, TanPS
mentioned most of the tools needed for dealing with the upper and lower
housings.

Here are the cost from www.mercstuff.com:

Upper housing retainer wrench $48.00
Upper housing gear shimming tools $102.00 (both)
Pinion Shimming tool $100.00
Bearing carrier retainer wrench $55.00
Shim Kits $32.00 (all)

Total thus far almost $350.00

Not including the $70.00 shaft alignment tool (which SHOULD be done
whenever the upper is removed), if you need all the tools listed on the
mercstuff tools page, your looking at about $550.00 without tax or
shipping.

This does not even take into account the health of the driveshaft assembly
(yokes, ujoints), or gearsets once you tear into the drive.

Over the winter an aftermarket manufacturer of Alpha One drives came
online, Sterndrive Engineering Incorporated. Their website:
www.sterndrive.cc

They have complete new drives from $1195.00 with uppers at $595.00 and
lowers at $695.00. Units come with a 1 year warranty (warranty vague), and
is completely interchangeable with all OEM parts, although they state
gearsets should be either one type or the other.

So if your problem is upper seals, for the price of efforts and tools, you
can pretty much order a drive that is ready to bolt on.

I'm going to post a message to both the group and company to try to get
more information, as I am in the market for at least one new lower.

Hope this helps.

Bob Dimond

Bob, you da man!! I agree, after purchasing all of the necessary
tools and replacement parts and not to mention the BEER needed to do
the job AND my time involved.....whew!! A bolt on unit is sounding
better and better.

Thanks again,

Dave


On Wed, 05 May 2004 10:07:42 -0400, (Bob
D.) wrote:

In article , D.B.
wrote:

Thanks Bob



Your welcome, Dave. I don't know if you need to check gear tolerances
and reshimm the gears when redoing seals. Assuming you do, TanPS
mentioned most of the tools needed for dealing with the upper and lower
housings.

Here are the cost from www.mercstuff.com:

Upper housing retainer wrench $48.00
Upper housing gear shimming tools $102.00 (both)
Pinion Shimming tool $100.00
Bearing carrier retainer wrench $55.00
Shim Kits $32.00 (all)

Total thus far almost $350.00

Not including the $70.00 shaft alignment tool (which SHOULD be done
whenever the upper is removed), if you need all the tools listed on the
mercstuff tools page, your looking at about $550.00 without tax or
shipping.

This does not even take into account the health of the driveshaft assembly
(yokes, ujoints), or gearsets once you tear into the drive.

Over the winter an aftermarket manufacturer of Alpha One drives came
online, Sterndrive Engineering Incorporated. Their website:
www.sterndrive.cc

They have complete new drives from $1195.00 with uppers at $595.00 and
lowers at $695.00. Units come with a 1 year warranty (warranty vague), and
is completely interchangeable with all OEM parts, although they state
gearsets should be either one type or the other.

So if your problem is upper seals, for the price of efforts and tools, you
can pretty much order a drive that is ready to bolt on.

I'm going to post a message to both the group and company to try to get
more information, as I am in the market for at least one new lower.

Hope this helps.

Bob Dimond

Presuming you do not have the remote resevoir the only way for drive lube to
get into the boat is through the seal where the drive shaft enters the upper
unit. I would concentrate on figuring out how you're getting water into the
unit first. It should not be getting into the unit from the upper drive
shaft seal. That part is inside the bellows and if there was a water leak
you would be getting a lot of water in your boat. The seals are designed to
deal with a slight pressure but not a lot. The additional water could be
forcing the lube out. Or the loss of lube could be encouraging the water to
come in. The upper and lower units both have seals on the shafts going in
and out. On the lower this includes the shift shaft. They share the lube
through a hole in the cases with a o-ring on it where they bolt together,
not through the shafts. A shop would probably replace all the seals on the
upper and lower. It takes a number of specialized tools and you also should
check the gear setup and play when you put it back together. Closest auto
thing that comes to mind is installing a set of rear differential gears, the
mesh is adjustable. You could check around, some dealers would probably
give you a break if you bring the lower and upper units in alone. And
replace the water pump yourself when they're done. That would knock and
hour or two off the labor and keep them from having to jocky the boat
around. You'll want to get a service manual as the procedures for doing
anything to the drive are specific and not always obvious when you're just
unbolting things. I suspect from your post that you've not ever taken the
drive off, how it works will be a lot more obvious when you've done that
once.

"D.B." wrote in message
...
I have a 1989 Stingray with a 3.0 liter Mercruiser engine with an
Alpha one outdrive. I have been getting about a half a cup of water
in the foot after about every 4 hours of operation. I have been
changing the foot oil after every use (4hours) so as to keep things
from going poop until I could put it in the shop. I recently changed
from the expensive Mercruiser outdrive lube (quicksilver) to a cheaper
80W90 gear oil (seeing as I was changing it after every 4 hours of
operation). I have been noticing what I thought was gear oil in the
bilge, but was not sure until I changed lubes. Now I am positive that
I have gear oil from the foot in the bilge. My question(s) are
these.... would it be that the upper water seals in the outdrive are
causing the water to get into the foot and the oil to leak into the
bilge? Question number two....I am a decent mechanic.....without
having specialized tools, is it practical for me to replace the seals
myself (I did rebuild a Porsche motor several years ago....to give
you a benchmark of my mechanical capabilities)

Any help would be appreciated.

Dave

Thanks Lawrence

On Thu, 29 Apr 2004 20:05:47 GMT, "Lawrence James"
wrote:

Presuming you do not have the remote resevoir the only way for drive lube to
get into the boat is through the seal where the drive shaft enters the upper
unit. I would concentrate on figuring out how you're getting water into the
unit first. It should not be getting into the unit from the upper drive
shaft seal. That part is inside the bellows and if there was a water leak
you would be getting a lot of water in your boat. The seals are designed to
deal with a slight pressure but not a lot. The additional water could be
forcing the lube out. Or the loss of lube could be encouraging the water to
come in. The upper and lower units both have seals on the shafts going in
and out. On the lower this includes the shift shaft. They share the lube
through a hole in the cases with a o-ring on it where they bolt together,
not through the shafts. A shop would probably replace all the seals on the
upper and lower. It takes a number of specialized tools and you also should
check the gear setup and play when you put it back together. Closest auto
thing that comes to mind is installing a set of rear differential gears, the
mesh is adjustable. You could check around, some dealers would probably
give you a break if you bring the lower and upper units in alone. And
replace the water pump yourself when they're done. That would knock and
hour or two off the labor and keep them from having to jocky the boat
around. You'll want to get a service manual as the procedures for doing
anything to the drive are specific and not always obvious when you're just
unbolting things. I suspect from your post that you've not ever taken the
drive off, how it works will be a lot more obvious when you've done that
once.

"D.B." wrote in message
.. .
I have a 1989 Stingray with a 3.0 liter Mercruiser engine with an
Alpha one outdrive. I have been getting about a half a cup of water
in the foot after about every 4 hours of operation. I have been
changing the foot oil after every use (4hours) so as to keep things
from going poop until I could put it in the shop. I recently changed
from the expensive Mercruiser outdrive lube (quicksilver) to a cheaper
80W90 gear oil (seeing as I was changing it after every 4 hours of
operation). I have been noticing what I thought was gear oil in the
bilge, but was not sure until I changed lubes. Now I am positive that
I have gear oil from the foot in the bilge. My question(s) are
these.... would it be that the upper water seals in the outdrive are
causing the water to get into the foot and the oil to leak into the
bilge? Question number two....I am a decent mechanic.....without
having specialized tools, is it practical for me to replace the seals
myself (I did rebuild a Porsche motor several years ago....to give
you a benchmark of my mechanical capabilities)

Any help would be appreciated.

Dave

"D.B." wrote
I have been getting about a half a cup of water
in the foot after about every 4 hours of operation.
I have gear oil from the foot in the bilge.

The easiest way to locate a leak is with a pressure test.
http://www.mercstuff.com/pressuregage.htm Apply a little air pressure and
watch/listen for where the oil and water squirt out.

without having specialized tools, is it practical
for me to replace the seals myself

If you replace the entire drive with them, yes. That is to say, you can take
the drive off with common tools but if you want to rebuild it, you'll need a
boat load of special and expensive mercruiser tools. I'm pretty sure if I
was in your situation I'd weigh the cost of all the tools and parts and
aggravation against one of these:
http://www.sterndrive.cc/alpha-one-s...e/alphaone.htm

Thanks Joe


On Fri, 30 Apr 2004 16:03:48 -0400, "Joe Blizzard"
wrote:

"D.B." wrote
I have been getting about a half a cup of water
in the foot after about every 4 hours of operation.
I have gear oil from the foot in the bilge.

The easiest way to locate a leak is with a pressure test.
http://www.mercstuff.com/pressuregage.htm Apply a little air pressure and
watch/listen for where the oil and water squirt out.

without having specialized tools, is it practical
for me to replace the seals myself

If you replace the entire drive with them, yes. That is to say, you can take
the drive off with common tools but if you want to rebuild it, you'll need a
boat load of special and expensive mercruiser tools. I'm pretty sure if I
was in your situation I'd weigh the cost of all the tools and parts and
aggravation against one of these:
http://www.sterndrive.cc/alpha-one-s...e/alphaone.htm

It looks like your upper drive oil seal is leaking. Water is getting into
the foot and pushing oil out into the drive boot and finally flowing out of
the vent hole through the transom into the bilge. Drop your drive to take a
look.

Recommend that you fix this quick, especially if you are in salt water.
Your U-joints are probably wet, gimbal bearing, all gears and bearings may
have started corrosion. If bad, bearings, gears, u-joints and drive shafts
may need changing. I got similar water damage on my upper gear housing,
changed practically everything except for the housing.

If you want to attempt this, you will need a few tools,
1. upper housing retainer wrench
2. Upper housing gear shimming tool, one for driven gear and one for input
gear
3. For the lower drive, similar tool for shimming the gears
4. Bearing carrier retainer wrench
5. a 150ft-lb torque wrench

Check out mercstuff.com, sterndrive.com on tools and write-up on the
subject.

Good luck.

TanPS

"D.B." wrote in message
...
I have a 1989 Stingray with a 3.0 liter Mercruiser engine with an
Alpha one outdrive. I have been getting about a half a cup of water
in the foot after about every 4 hours of operation. I have been
changing the foot oil after every use (4hours) so as to keep things
from going poop until I could put it in the shop. I recently changed
from the expensive Mercruiser outdrive lube (quicksilver) to a cheaper
80W90 gear oil (seeing as I was changing it after every 4 hours of
operation). I have been noticing what I thought was gear oil in the
bilge, but was not sure until I changed lubes. Now I am positive that
I have gear oil from the foot in the bilge. My question(s) are
these.... would it be that the upper water seals in the outdrive are
causing the water to get into the foot and the oil to leak into the
bilge? Question number two....I am a decent mechanic.....without
having specialized tools, is it practical for me to replace the seals
myself (I did rebuild a Porsche motor several years ago....to give
you a benchmark of my mechanical capabilities)

Any help would be appreciated.

Dave