Greetings:

My friend just had the lower seal in the top half blow out
on his 1990 5.7L Sea Ray. The bottom half came off uneventfully. It appears
to have been separated before at some time as the impeller and water pump
in general looked like they were brand new out of the box. The top half is
another story. I sort of doubt that it has ever been off the boat. When the
seal blew and water got in (Chesapeake Bay salt) it made it into the drive
shaft bellows.

I believe the drive shaft splines are corroded to the drive plate.
We can get about 3/16" separation or so between the unit and the bell
housing. I think a little play in the u joints is allowing this to occur.
But pulling on it with more force results in no budge. We pulled using a
winch on the front of his Rubicon Jeep and all it did was pull the Jeep!

So: Has anyone faced this problem before and what did you do about
it? My plan at this point is to cut open the drive shaft bellows and try to
get some penetrating oil into the area. I can't think of much else. I know
the potential for damage with the "hammer mechanics" approach and am
looking for a finesse method, possibly from someone more experienced.

Thanks in advance for any ideas or help anyone might have.

-Jason

What engine and drive is it?

If its an Merc Alpha drive, the throttle must be in FULL forward position.
Else, the lower shift shaft is stuck and the drive won't come off.

Your description/analysis of the sequence of events is somewhat confusing.
If the drive (alpha) is stuck, 2 possible places, the gimbal bearing or the
drive coupler on the engine and its not going to be fun getting it out.

Try posting/looking at http://www.iboats.com/ for help.



"Jason Bourne" wrote in message
...
Greetings:

My friend just had the lower seal in the top half blow out
on his 1990 5.7L Sea Ray. The bottom half came off uneventfully. It
appears
to have been separated before at some time as the impeller and water pump
in general looked like they were brand new out of the box. The top half is
another story. I sort of doubt that it has ever been off the boat. When
the
seal blew and water got in (Chesapeake Bay salt) it made it into the drive
shaft bellows.

I believe the drive shaft splines are corroded to the drive plate.
We can get about 3/16" separation or so between the unit and the bell
housing. I think a little play in the u joints is allowing this to occur.
But pulling on it with more force results in no budge. We pulled using a
winch on the front of his Rubicon Jeep and all it did was pull the Jeep!

So: Has anyone faced this problem before and what did you do about
it? My plan at this point is to cut open the drive shaft bellows and try
to
get some penetrating oil into the area. I can't think of much else. I know
the potential for damage with the "hammer mechanics" approach and am
looking for a finesse method, possibly from someone more experienced.

Thanks in advance for any ideas or help anyone might have.

-Jason

"Jason Bourne" wrote
The bottom half came off uneventfully.
The top half is another story.
I believe the drive shaft splines are corroded to the drive plate.

More likely it's stuck in the gimbal bearing.

I know the potential for damage with the "hammer
mechanics" approach and am looking for a finesse
method, possibly from someone more experienced.

This may not sound very finesse-ish, but I got it from a merc mechanic
friend. Lift the upper unit up on its pivots and let it drop down to the
stop. Repeat as necessary. If gravity alone doesn't do the trick, give it a
little push, kind of slamming it down and being very careful to apply just
enough force to not break something. (Nobody knows exactly how much force
that is.) If you get any movement, drive a couple of wedges in between the
drive and bell housing to keep the pressure on as you continue. Failing
that, proceed as you suggested by cutting off the bellows. If the penetrant
doesn't work, you could try applying heat, but that's definitely dangerous.
I'm told this is how the professionals do it, that there's no magic
procedure or tool. If you're reasonably competent mechanically and you can't
get it off without breaking something, a real mechanic probably couldn't
either.

Joe Blizzard wrote:
[snip]

This may not sound very finesse-ish, but I got it from a merc mechanic
friend. Lift the upper unit up on its pivots and let it drop down to the
stop. Repeat as necessary. If gravity alone doesn't do the trick, give it
a little push, kind of slamming it down and being very careful to apply
just enough force to not break something. (Nobody knows exactly how much
force that is.) If you get any movement, drive a couple of wedges in
between the drive and bell housing to keep the pressure on as you
continue. Failing that, proceed as you suggested by cutting off the
bellows. If the penetrant doesn't work, you could try applying heat, but
that's definitely dangerous. I'm told this is how the professionals do it,
that there's no magic procedure or tool. If you're reasonably competent
mechanically and you can't get it off without breaking something, a real
mechanic probably couldn't either.

We got it off by removing the cap from the unit and making a tool that fit
the bolt holes. Two pieces of angle iron about 2 feet long with another,
heavier piece of angle cut off a trailer hitch bracket (a left over) at the
far end. We bonked on it couple of times with a sledge hammer and it popped
right off. Once the tool was in place it took just two swings of the hammer
and about 3 seconds. Now awaiting parts...

-Jason

--

PGP Fingerprint:Â*Â*CA481E501CCDAEA6DC28940488833E0887 E064D7

"Jason Bourne" wrote
Once the tool was in place it took just two
swings of the hammer and about 3 seconds.

Glad it worked out. A little percussive force can do wonders.