Sterndrives, Transom Assemblies and Hydraulic Systems

Transcription

806
90-899907001
Technician's Guide
Sterndrives, Transom Assy's and Hydraulic Systems
Sterndrives, Transom Assemblies
and Hydraulic Systems
© 2006 Mercury Marine
MerCruiser Training Course
1
Table of Contents
Section 1A - Drive Unit General Information
Section 2A - Alpha Drive Unit History
Section 3 - Alpha Drive Unit Service
A - Alpha Drive Unit Components
B - Alpha Gear Housing - Standard Rotation Unit Service
C - Alpha Driveshaft Housing Service
D - Alpha Gear Housing - Counter Rotation Unit Service
E - Shift Cable Installation, Drive Unit Installation and Shift Setup
Section 4 - Alpha and Bravo Transom Assemblies
Section 5 - Hydraulic Systems
A - Hydraulic Systems – Power Trim
B - Hydraulic Systems – Power Steering
Section 6 - Corrosion Protection
Section 7A - Bravo Drive Unit History
Section 8 - Bravo Drive Unit Service
A - Bravo Drive Unit Components
B - Bravo Driveshaft Housing Set Up - Earlier Models (Serial Number
0M198372 and Below)
C - Bravo Driveshaft Housing Set Up - Later Models (Serial Number
0M198373 and Above)
D - Bravo One Gear Housing Setup
E - Bravo Three Gear Housing Setup
F - Bravo Shift Cable Installation, Drive Unit Installation and Shift Setup
Section 9 - Service Literature
A - Alpha Reference Materials
B - Transom Assembly and Hydraulic System Reference Materials
C - Bravo Reference Materials
MC Alpha Drives Course Worksheets and Homework
MC Transom Assemblies and Hydraulic Systems Course Worksheets
MC Bravo Drives Course Worksheets and Homework
2
Drive Unit General Information
Drive Unit Information
1
A
Section 1A - Drive Unit General Information
Table of Contents
MerCruiser Engine/Drive Model Year Reference Chart
..................................................................................2
Alpha U-joint Splined Yoke Identification..................7
Bravo U-joint Splined Yoke Identification .................8
Calculating Overall Drive Unit Ratios......................10
Alpha Drive Unit Gear Tooth Counts and Related Drive
Ratios......................................................................10
Bravo Drive Shaft Housing Gear Tooth Counts and
Related Drive Ratios (Model Year 2000 and Later)
................................................................................11
Sterndrive and Transmission Lube Capacity Chart
................................................................................12
Gear Lube Monitors Used On Alpha and Bravo
Models.................................................................13
Sterndrive Unit 10-Hour Break-In Period (New or With
Replacement Gears)...............................................13
Serial Number Locations.........................................13
Gear Housing Pressure Test...................................14
Drive Unit Rotation..................................................15
Trim Tab Adjustment (to equalize steering pressure)
................................................................................16
MC-1 Propeller Shaft Parts Comparison.................17
90-899907001 JULY 2006
Tapered Roller Bearing Diagnosis..........................17
Good Bearing......................................................18
Bent Cage-End....................................................18
Bent Cage-Side...................................................18
Galling.................................................................18
Abrasive Step Wear.............................................19
Etching.................................................................19
Misalignment.......................................................19
Indentations.........................................................19
Fatigue Spalling...................................................20
Brinelling..............................................................20
Cage Wear..........................................................20
Abrasive Roller Wear...........................................20
Cracked Inner Race.............................................21
Smears................................................................21
Frettage...............................................................21
Heat Discoloration...............................................21
Stain Discoloration...............................................22
Mercury Marine Backlash Flags..............................23
Bravo Shim Kit Listing.............................................24
Bravo One, Two and Three Series......................24
Page 1A-1
3
MerCruiser Engine/Drive Model Year Reference Chart
Use only as a reference for determining drive model to be used with specific engine models.
Model
Cu. In.
Mfg.
39D
108
MCD
60D
139
60
1963 1964
I
1967
1968
IA EZ
IA EZ IA EZ
Rov.
IA EZ
IA EZ IA EZ
67
Ren.
0" 60
0" 60
0" 60
80
89
Ren.
0" 80
0" 80
90
95
Ren.
100D
311
MCD
II
II
II
110
153
GM
I
IA
IA EZ
IA EZ
120
153
GM
IB
IB EZ
MC-I
140(6)
194
GM
IC
IC EZ
140(4)
181
GM
150
230
GM
160
250
GM
165(6)
250
GM
470
224
MM
888
302
Ford
190(8)
283
GM
200
292
GM
215H
302
Ford
215E
302
Ford
225
327
GM
225S
302
Ford
225TR
302
Ford
233
351
Ford
250
327
GM
255TR
351
Ford
255TR
350
GM
255TRS
351
Ford
270
350
GM
310
409
GM
315
409
GM
325
427
GM
390
482
GM
I
IA
1965 1966
IC
IC EZ
1970
1971
1972 1973
0" 90
0" 90 0" 90
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
1974
1975 1976
MC-I
MC-I
MC-I MC-I
MC-I
MC-I
MC-I MC-I
MC-I
MC-I
MC-I MC-I
0" 80
IC EZ
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
II
II
MC-I
MC-I
MC-I MC-I
II
II
II
215H 215H
215E 215E
II
II
II
II
II
MC-I
II-TR
II-TR
MC-I
III
III
III
MC-I
III
II-TR
II-TR
II-TR II-TR
II-TRS
II
II
III
III
III
III
III
III
III
III
II
II
III
GM - General Motors
MM - Mercury Marine
Ren. - Renault
Rov. - Rover
Page 1A-2
MC-I
1969
III
MCD - Mercedes-Benz
90-899907001 JULY 2006
4
Model
Cu. In. Mfg. 1977
MC-I
1978
1979
1980
1981
1982
1983
1984
1985
1986
MC-I
MC-I
MC-I
MC-I
MC-I
I-R
I-R
I-MR
A
1987
1988
1989
A
A
A
A
A
A
120
153
GM
2.5L
153
GM
140(4)
181
GM
3.0L
181
GM
530D-TA
183
VM
165(6)
250
GM
165(4)
224
MM
3.7L
224
MM
170
224
MM
175
262
GM
4.3L
262
GM
470
224
MM
180
224
MM
3.7LX
224
MM
636D-TA
219
VM
185
229
GM
185
262
GM
I-MR
A
190(4)
224
MM
I-MR
A
485
224
MM
488
224
MM
898
305
GM
200
305
GM
I-MR
A
5.0L
305
GM
205
262
GM
4.3LX
262
GM
228TR
305
GM
228
305
GM
230
305
GM
5.0LX
305
GM
250
350
GM
260
350
GM
5.7L
350
GM
350MAG
350
GM
330TR
454
GM
330TRS
454
GM II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS
7.4L
454
GM
370
454
GM II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS II-TRS
454MAG
454
GM
502MAG
502
GM
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
I-R
I-R
I-MR
A
B2
MC-I
MC-I
MC-I
MC-I
MC-I
A
I-MR
A
A
A
A
A
A
A
A
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
I-R
I-R
A
B2
I-R
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
MC-I
I-R
MC-I
MC-I
I-R
I-R
I-R
I-R
I-MR
II-TR
A
A
A
A
A
A
A
A
A
II-TR
MC-I
MC-I
MC-I
MC-I
I-R
I-R
I-MR
A
A
MC-I
MC-I
MC-I
MC-I
MC-I
I-R
I-R
I-MR
A
A
A/II-TR A/B2
II-TR
II-TR
II-TR
II-TR
II-TR
II-TR
II-TR
II-TR
II-TR
A
A
II-TR
II-TR
A
A
B1/B2 B1/B2
A
A
B1
B1
GM - General Motors
A - Alpha One (R.H.)
B1 - Bravo One
MM - Mercury Marine
AC - Alpha One, Counter Rotation (L.H.)
B2 - Bravo Two
VM - VM Motor Co. (Diesel)
A2 - Alpha One, Generation Two (R.H.)
B3 - Bravo Three
Nav - Navistar (Diesel)
A2C - Alpha One, Generation Two, Counter Rotation (L.H.)
BH - BlackHawk
MR - MerCruiser Redesigned
R - Redesigned
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B1
Page 1A-3
5
Model
Cu. In. Mfg.
1990
1991
1992
1993
1994
3.0L
181
GM
A,AC
A,AC
A2,A2C
A2,A2C
A2,A2C
3.0LX
181
GM
A,AC
A,AC
A2,A2C
A2,A2C
A2,A2C
D183-TA
183
VM
B1,B2
B1,B2
B1,B2
B1,B2
D3.0L
183
VM
4.3L
262
GM
A,AC
A,AC
A2,A2C
A2,A2C
A2,A2C
4.3LX
262
GM
A,AC
A,AC
A2,A2C
A2,A2C
A2,A2C
D219-TA
219
VM
B1,B2
B1,B2
B1,B2
B1,B2
D3.6L
219
VM
5.0L
305
GM
A,AC
A,AC
A2,A2C,B2
A2,A2C,B2
A2,A2C,B2
5.0LX
305
GM
A,AC
A,AC
A2,A2C
A2,A2C
A2,A2C
5.0 HB
305
GM
D254-TA
254
VM
B1,B2
B1,B2
B1,B2
B1,B2
D4.2L
254
VM
5.7L
350
GM
5.7L EFI
350
GM
350 MAG
350
GM
350 MAG EFI/MP
350
GM
D7.3L
444
Nav.
7.4L
454
GM
7.4L PT
454
GM
454 MAG
454
GM
454 MAG EFI
454
GM
454 MAG EFI/MP
454
GM
454 MAG MPI
454
GM
502 MAG
502
GM
502 MAG EFI
502
GM
502 MAG EFI/MP
502
GM
502 MAG MPI
502
GM
B1,B2
B1,B2
B1,B2
A,AC,B2
A,AC,B2
A2,A2C,B2
A,AC
A,AC
A2,A2C
A2,A2C,B1,B2 A2,A2C,B2,B3
B3
A2,A2C
B3
B1,B2
B1
B1,B2
B1
B1,B2
B1
B1,B2
B1,B2
B3
B3
B1
B1
B1
B1
B1
B1,B2
B1,B2
B1
GM - General Motors
B1 - Bravo One
MM - Mercury Marine
B2 - Bravo Two
B3 - Bravo Three
A2C - Alpha One, Generation Two, Counter Rotation (L.H.)
BH - BlackHawk
Page 1A-4
A2,A2C
B1,BH
R - Redesigned
90-899907001 JULY 2006
6
Model
Cu. In. Mfg.
1995
1996
D2.8L
169
VM
3.0L
181
GM
3.0LX
181
GM
A2,A2C
A2,A2C
D3.0L
183
VM
B1,B2
B1,B2
4.3L
262
GM
A2,A2C
A2,A2C
4.3L EFI
262
GM
4.3LX
262
GM
4.3LXH
262
GM
4.3LH
262
GM
262 MAG EFI,
Gen+
262
GM
D3.6L
219
VM
B1,B2
5.0L
305
GM
A2,A2C
5.0L EFI
305
GM
5.0LX
305
GM
A2,A2C
5.0 HB
305
GM
B2
D254-TA
254
VM
B2
D4.2L
254
VM
5.7L
350
5.7L EFI
A2,A2C
1997
1998
1999
B1,B2,B3
B1,B2,B3
B1,B2,B3
A2,A2C
A2,A2C
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
B1,B2,B3
B1,B2,B3
A2,A2C
A2,A2C,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
B1,B2
B1,B2,B3
A2,A2C,B1,B2,B3 A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3 A2,A2C,B1,B2,B3
B2
B2
B2
B2
B1,B2
B1,B2
B1,B2,B3
B1,B2,B3
B1,B2,B3
GM
A2,A2C,B2
A2,A2C,B2,B3
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3 A2,A2C,B1,B2,B3
350
GM
A2,A2C,B1
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3 A2,A2C,B1,B2,B3
5.7LX
350
GM
A2,A2C,B2,B3
A2,A2C,B1,B2,B3
5.7LX EFI
350
GM
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
5.7LX EFI Gen
+
350
GM
B1,B2,B3
350 MAG
350
GM
A2,A2C
A2,A2C
350 MAG EFI/
MP
350
GM
B1
A2,A2C
350 MAG MPI
Gen+
350
GM
D7.3L
444
Nav.
B3
B3
7.4L
454
GM
B1,B2
B1,B2,B3
7.4LX EFI
454
GM
7.4L MPI
454
GM
7.4L PT
454
GM
B3
B1,B3,BH
B1,B2,B3,BH
A2,A2C,B1,B2,B3 A2,A2C,B1,B2,B3
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1,B2,B3
454 MAG
454
GM
B1
454 MAG EFI/
MP
454
GM
B1
454 MAG MPI
454
GM
502 MAG EFI/
MP
502
GM
502 MAG MPI
502
GM
B1,B2,B3
B1,B2,B3
B1
B1,B2,B3
B1, B3, BH
B1,B2,B3,BH
B1,B2,B3
B1,B2,B3
B1,B2,B3,BH
B1,B2,B3,BH
B1,B2,B3
B1,B2,B3
B1,BH
GM - General Motors
B1 - Bravo One
MM - Mercury Marine
B2 - Bravo Two
B3 - Bravo Three
A2C - Alpha One, Generation Two, Counter Rotation (L.H.) BH - BlackHawk
MR - MerCruiser Redesigned R - Redesigned
90-899907001 JULY 2006
Page 1A-5
7
Model
Cu. In. Mfg.
2000
2001
2002
2003
A2,A2C
A2,A2C
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X
D1.7L DTI (2002 -)
103
I
D2.8L D-Tronic (1997 -)
169
VM
B1,B2,B3
D3.6L
219
VM
B1,B2,B3
D4.2L
254
VM
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X
D4.2LD (1999 -)
254
VM
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X
D4.2L D-Tronic (1997 -)
254
VM
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X
D7.3L D-Tronic (1997 -)
444
Nav.
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X
D7.3L D-Tronic LD (1999 -)
444
Nav.
B1,B2,B3
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X
3.0L
181
GM
A2,A2C
A2,A2C
A2,A2C
A2,A2C
4.3L
262
GM
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
4.3LH
262
GM
A2,A2C,B2,B3
A2,A2C,B2,B3
4.3L EFI
262
GM
A2,A2C,B2,B3
A2,A2C,B2,B3
4.3L MPI
262
GM
5.0L
305
GM A2,A2C,B1,B2,B3 A2,A2C,B1,B2,B3 A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B1,B2,B3
5.0L EFI
305
5.0L MPI
305
GM
A2,A2C,B2,B3
A2,A2C,B1,B2,B3
5.7L
350
A2,A2C,B1,B2,B3
5.7L EFI
350
350 MAG MPI
350
A2,A2C,B1,B2,B3
350 MAG MPI Horizon
350
B1,B2,B3
MX 6.2 MPI
377
GM
B1,B2,B3
B1,B2,B3
MX 6.2 MPI Horizon
377
GM
A2,A2C,B2,B3
B1,B2,B3
7.4L MPI
454
GM
B1,B2,B3
454 MAG MPI
454
GM
B1,B2,B3
454 MAG MPI Horizon
454
GM
B1,B2,B3
496 MAG MPI
496
GM
B1,B2,B3
B1,B2,B3
B1,B2,B3
496 MAG HO MPI
496
GM
B1,B2,B3
B1,B2,B3
B1X,B2X,B3X, B1XZ,B1XR
502 MAG MPI
502
GM
CMD - Cummins MerCruiser Diesel
GM - General Motors
A2,A2C,B1,B2,B3
B1,B2,B3
B1X - Bravo One X
B1XZ - Bravo One XZ
MM - Mercury Marine
B2 - Bravo Two
Nav. - Navistar (Diesel)
A2C - Alpha One, Generation Two,
B2X - Bravo Two X
I - Isuzu (Diesel)
R - Redesigned
Page 1A-6
Counter Rotation (L.H.)
B1 - Bravo One
B1XR - Bravo One XR
B3 - Bravo Three
B3X - Bravo Three X
90-899907001 JULY 2006
8
Model
Cu. In.
Mfg.
2004
2005
2006
D1.7L DTI (2002 -)
103
I
CMD Product
CMD Product
CMD Product
D2.8L D-Tronic (1997 -)
169
VM
CMD Product
CMD Product
CMD Product
D3.6L
219
VM
CMD Product
CMD Product
CMD Product
D4.2L
254
VM
CMD Product
CMD Product
CMD Product
D4.2LD (1999 -)
254
VM
CMD Product
CMD Product
CMD Product
D4.2L D-Tronic (1997 -)
254
VM
CMD Product
CMD Product
CMD Product
D7.3L D-Tronic (1997 -)
444
Nav.
CMD Product
CMD Product
CMD Product
D7.3L D-Tronic LD (1999 -)
444
Nav.
CMD Product
CMD Product
CMD Product
3.0L
181
GM
A2,A2C
A2,A2C
A2,A2C
4.3L
262
GM
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
4.3LH
262
GM
4.3L EFI
262
GM
4.3L MPI
262
GM
A2,A2C,B2,B3
A2,A2C,B2,B3
A2,A2C,B2,B3
5.0L
305
GM
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
5.0L EFI
305
GM
5.0L MPI
305
GM
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
5.7L
350
GM
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
5.7L EFI
350
GM
350 MAG MPI
350
GM
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
A2,A2C,B1,B2,B3
350 MAG MPI Horizon
350
GM
B1,B2,B3
B1,B2,B3
B1,B2,B3
MX 6.2 MPI
377
GM
B1,B2,B3
B1,B2,B3
B1,B2,B3
MX 6.2 MPI Horizon
377
GM
B1,B2,B3
B1,B2,B3
B1,B2,B3
7.4L MPI
454
GM
454 MAG MPI
454
GM
454 MAG MPI Horizon
454
GM
496 MAG MPI
496
GM
B1,B2,B3
B1,B2,B3
B1,B2,B3
496 MAG HO MPI
496
GM
B1X,B2X,B3X, B1XR
B1X,B2X,B3X, B1XR
B1X,B2X,B3X, B1XR
502 MAG MPI
502
GM
CMD - Cummins MerCruiser Diesel
GM - General Motors
B1X - Bravo One X
B1XZ - Bravo One XZ
MM - Mercury Marine
B2 - Bravo Two
Nav. - Navistar (Diesel)
A2C - Alpha One, Generation Two,
B2X - Bravo Two X
I - Isuzu (Diesel)
Counter Rotation (L.H.)
R - Redesigned
B1 - Bravo One
B1XR - Bravo One XR
B3 - Bravo Three
B3X - Bravo Three X
Alpha U-joint Splined Yoke Identification
An identification letter is stamped on the U-joint splined yoke.
This chart represents the letter stamps found on model year 2000 and newer drive units (new or
untampered with drive units). The letter stamp represents the drive unit overall gear ratio.
Older (pre-model year 2000) drive units would have the U-joint yoke stamped with a letter that
represented the gear ratio in the driveshaft housing. Two drive units with different overall gear
ratios could have the same U-joint letter stamp. On these drives a technician would have to check
the gear housing gear tooth count to determine the overall drive gear ratio.
90-899907001 JULY 2006
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9
Later (model year 2000 and newer) drive units have a stamped letter that represents the overall
drive gear ratio. Now two drive units could have different letter stamps, but the gear ratio in the
drive shaft housings could be the same.
Service Note: When you order a service replacement complete driveshaft housing, the U-joint
splined yoke may have a different letter stamp than the one found on the unit that is being replaced.
The letters used on service replacement units follow the pre-model year 2000 method of
identification. As long as the correct replacement drive shaft housing assembly has been ordered,
from the parts catalog, you should disregard the letter stamp.
Alpha One Standard Description
U-joint I.D.
Alpha One - 1.32 Standard Rotation
H
F
C
D
B
Alpha One Counter Description
U-joint I.D.
Alpha One - 1.50 Counter Rotation
F
C
D
B
Alpha One, Gen II Standard Description
U-joint I.D.
Alpha One, Gen II - 1.47 (Earlier 1.50) Standard Rotation
F
C
D
B
Alpha One, Gen II - 2.00 Standard Rotation
A
Alpha One, Gen II - 2.40 Standard Rotation
K
Alpha One, Gen II Counter Description
U-joint I.D.
Alpha One, Gen II - 1.47 (Earlier 1.50) Counter Rotation
F
C
D
B
Alpha One, Gen II - 2.00 Counter Rotation
A
All tampered-with sterndrives: A sterndrive could have had the gear ratio changed for high
altitude use, or if the drive was used in a different boat, which would void the decal and the yoke
stamp information. The gear ratio would then have to be determined by counting the teeth on the
sterndrive gears in the driveshaft housing and in the gear housing. These tooth counts would then
be used in a calculation to determine the overall drive unit gear ratio.
Bravo U-joint Splined Yoke Identification
An identification letter is stamped on the U-joint splined yoke.
This chart represents the letter stamps found on Model Year 2000 and newer drive units (new or
untampered with drive units). The letter stamp represents the drive unit overall gear ratio.
Older (pre-Model Year 2000) drive units would have the U-joint yoke stamped with a letter that
represented the gear ratio in the driveshaft housing. Two drive units with different overall gear
ratios could have the same U-joint letter stamp. On these drives a technician would have to check
the gear housing gear tooth count to determine the overall drive gear ratio.
Page 1A-8
90-899907001 JULY 2006
10
Later (Model Year 2000 and newer) drive units have a stamped letter that represents the overall
drive gear ratio. Now two drive units could have different letter stamps, but the gear ratio in the
drive shaft housings could be the same.
Service Note: When you order a service replacement complete driveshaft housing, the U-joint
splined yoke may have a different letter stamp than the one found on the unit that is being replaced.
The letters used on service replacement units follow the pre-model year 2000 method of
identification. As long as the correct replacement drive shaft housing assembly has been ordered,
from the parts catalog, you should disregard the letter stamp.
NOTE: Diesel Sterndrives are listed as Bravo X series.
Driveshaft Housing—Gear Ratio and U-joint Marking
Sterndrive model
Ratio
U-joint shaft marking
Standard Bravo Three and Bravo Three X series
2.43:1
N
2.20:1
K
2.00:1
B
1.81:1
G
1.65:1
C
1.50:1
F
1.36:1
H
1.50:1
R
1.35:1
L
1.26:1
M
2.00:1
R
Standard Bravo Two and Bravo Two X series
Standard Bravo One and Bravo One X series
Bravo One XR
Bravo Three XR
All tampered-with sterndrives: A sterndrive could have had the gear ratio changed for high
altitude use, or if the drive was used in a different boat, which would void the decal and the yoke
stamp information. The gear ratio would then have to be determined by counting the teeth on the
sterndrive gears in the driveshaft housing and in the gear housing. These tooth counts would then
be used in a calculation to determine the overall drive unit gear ratio.
90-899907001 JULY 2006
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11
Calculating Overall Drive Unit Ratios
c
d
e
a
b
f
g
h
i
20333
abcde-
Driveshaft housing
Gear housing
Input shaft (gear end of yoke shaft)
Drive gear
Driven gear
fghi-
Driveshaft
Drive gear
Driven gear
Propeller shaft
Example:
Gear #1 - 22 Tooth
Overall Ratio = Ro
Gear #2 - 20 Tooth
Ro = {Driven(2)/Drive(1)} x {Driven(4)/Drive(3)}
Gear #3 - 13 Tooth
Ro = {20/22} x {21/13}
Gear #4 - 21 Tooth
Ro = .909 x 1.615
Ro = 1.468 = 1.47
Ro = 1.47 turns of input shaft to 1 turn of propshaft
Alpha Drive Unit Gear Tooth Counts and Related Drive Ratios
The gear housing tooth count, overall gear ratio and corresponding driveshaft housing gear tooth
counts are displayed below. The same driveshaft housing gear tooth count can be found in a
number of drive units with different overall drive ratios. Overall drive ratios are changed by using
different gear sets in the gear housing.
Page 1A-10
90-899907001 JULY 2006
12
Gear Housing Tooth Count
Ratio
DSH Drive Gear
DSH Driven Gear
14-28
2.40:1
20
24
14-28
2.0:1
24
24
17-28
1.98:1
20
24
13-21
1.94:1
20
24
17-28
1.84:1
17
19
13-21
1.81:1
17
19
17-28
1.65:1
24
24
13-21
1.62:1
24
24
17-28
1.50:1
22
20
13-21
1.47:1
22
20
17-28
1.32:1
20
16
Bravo Drive Shaft Housing Gear Tooth Counts and Related Drive
Ratios (Model Year 2000 and Later)
The drive model, overall gear ratio and corresponding driveshaft housing gear tooth counts are
displayed. The same driveshaft housing gear tooth count can be found in a number of drive units
with different overall drive ratios. Overall drive ratios are changed by using different gear sets in
the gear housing.
NOTE: Diesel Sterndrives are listed as Bravo X series.
Driveshaft Housing—Gear Ratio and Gear Tooth Count
Sterndrive model
Ratio
Pinion (drive) gear teeth
Driven gear teeth
2.43:1
23
30
2.20:1
23
30
2.00:1
27
32
1.81:1
27
29
27
32
23
30
27
32
27
29
27
29
16
19
27
32
1.65:1
1.50:1
1.36:1
1.50:1
Bravo One XR
1.35:1
1.26:1
Bravo Three XR
90-899907001 JULY 2006
2.00:1
Page 1A-11
13
Sterndrive and Transmission Lube Capacity Chart
MODELS
CAPACITY 1.
PRODUCTION
MODELS
CAPACITY 1.
II (H.P. gear housing)
6.6 liter (7 qt.)
60
541 ml (18-1/4 fl. oz.)
215E-215H
3.8 liter (4 qt.)
80-90
651 ml (22 fl. oz.)
IITR-TR
3.8 liter (4 qt.)
I 2.
237 ml (8 fl. oz.)
IITRS-TRS
2.8 liter (3 qt.)
I 3.
532 ml (18 fl. oz.)
HIGH PERFORMANCE MODELS
IA-IB-IC 2.
37 ml (8 fl. oz.)
Alpha SS
946 ml (32 fl. oz.)
IA-IB-IC 3.
680 ml (23 fl. oz.)
II SSM
4.25 liter (4-1/2 qt.)
I (120-260)-R-MR-Alpha One
946 ml (32 fl. oz.)
III Clubfoot
5.32 liter (5.63 qt.)
Alpha One Generation Two (excluding
monitor)
1160 ml (39.2 fl. oz.)
III SSM/III-A SSM
8.9 liter (9.38 qt.)
Alpha One Generation Two (including
monitor B)4.
1892 ml (64 fl. oz.)
IV SSM - V SSM (std.)
6.39 liter (6-3/4 qt.)
Alpha One Generation Two (including
monitor A)4.
2247 ml (76 fl. oz.)
IV SSM - V SSM (1 in. spacer)
7.10 liter (7-1/2 qt.)
Bravo One (excluding monitor)
1.9 liter (2 qt.)
7.80 liter (8-1/4 qt.)
Bravo One (including monitor B)4.
2.65 liter (2.8 qt.)
8.50 liter (9 qt.)
Bravo One (including monitor A)4.
3.36 liter (3.55 qt.)
VI SSM (std.)
19 liter (20 qt.)
Bravo One LWP/DWP excluding monitor
1833 ml (62 fl. oz.)
VII SSM (std.)
15.2 liter (16 qt.)
4.
2188 ml (74 fl. oz.)
BORG WARNER TRANSMISSIONS
Bravo One (Monit. B) - 2004 4. 5.
2.3 liter (77.5 oz./2.4 qt.)
1:1
1.9 liter (2 qt.)
Bravo Two (excluding monitor)
2.4 liter (2-1/2 qt.)
1.5:1 - 3.0:1
2.8 liter (3 qt.)
Bravo Two (including monitor B)4.
3.03 liter (3.2 qt.)
V-Drive
4.25 liter (4-1/2 qts.)
Bravo Two (including monitor A)4.
3.73 liter (3.95 qt.)
5000 1.5:1 (8 deg. down angle)
2.4 liter (2-1/2 qt.)
Bravo Two (Monit. B) - 20044. 5.
3.8 liter (130 oz./4.1 qt.)
HURTH TRANSMISSIONS
Bravo Three (excluding monitor)
1.9 liter (2 qt.)
Hyd. Shift
4.0 liter (4-1/2 qt.)
Bravo Three (includ. monitor B)4.
2.9 liter (3 qt.)
V-Drive
4.7 liter (5 qt.)
Bravo Three (Monit. B) - 2004 4. 5.
2.94 liter (99.5 oz./3.1 qt.)
630A (8 deg. down angle)
4.0 liter (4.2 qt.)
Blackhawk (excluding monitor)
1.66 liter (1-3/4 qt.)
800AM (8 deg. downangle)
4.1liter (4.4 qt.)
Blackhawk (including monitor B)4.
2.61liter (2.5 qt.)
MERCURY MARINE TRANSMISSIONS
II
4 liter (5-3/4 qt.)
All
Bravo One LWP/DWP(including monitor B)
1.9 liter (2 qt.)
1. Capacities given are approximate. Proper filling procedure is specified in the Service manuals and Operations and Maintenance
manuals.
2. Driveshaft housing.
3. Gear housing.
4. Following are types of gear lube monitors available for Alpha and Bravo models.
5. Bravo with redesigned driveshaft housing.
Page 1A-12
90-899907001 JULY 2006
14
Gear Lube Monitors Used On Alpha and Bravo Models
20316
TYPE A – ROUND [473ml (16 fl. oz.)]
20317
TYPE B – SQUARE [355ml (12 fl. oz.)]
Sterndrive Unit 10-Hour Break-In Period (New or With Replacement
Gears)
•
•
•
•
Avoid full throttle starts.
Do not operate at any one constant speed for extended periods of time.
Do not exceed 75% of full throttle during the first 5 hours. During the next 5 hours, operate at
intermittent full throttle.
Drive unit should be shifted into forward gear a minimum of 10 times during break-in, with
run-in time at moderate RPM after each shift.
Serial Number Locations
a
20323
Transom assembly decal
a - Transom assembly serial number location
90-899907001 JULY 2006
Page 1A-13
15
a
b
20324
Sterndrive unit - Port side decal
a - Sterndrive unit serial number location
b - Drive unit gear ratio location (or opposite side on Alpha S/N 0W500025 and above
and Bravo S/N 0M198373 and above)
Gear Housing Pressure Test
1. Drain gear lube and install lower drain plug.
2. Remove vent plug and install pressure test gauge. Tighten securely.
20326
3. Pressurize housing to specification and observe gauge for 5 minutes.
Gear housing
Pressure
48 - 69 kPa (7-10 psi)
NOTE: If test is being performed while drive unit is mounted on transom assembly, the cap on the
oil monitor bottle is sealed, so it should hold pressure, if it is functioning correctly.
Page 1A-14
90-899907001 JULY 2006
16
4. Rotate driveshaft, propshaft and move shift rod while housing is pressurized to check for leaks.
20328
5. Pressurize housing to specification and observe gauge for 10-15 minutes.
Gear housing
Pressure
103-110 kPa (15-16 psi)
6. Rotate driveshaft, propshaft and move shift rod while housing is pressurized to check for leaks.
7. If pressure drop is noted, immerse housing in water (or use liquid soap and water mixture).
8. Re-pressurize to specification and check for air bubbles.
9. Replace leaking seals as necessary. Retest housing.
NOTE: Vacuum tests are not recommended due to the design of the labrinth seal (it will not hold
vacuum).
10. Remove tester from housing, fill with lubricant and install vent/drain plugs.
Drive Unit Rotation
There are two types of drive unit rotations, standard and counter. Following are shown when the
drive unit is viewed from the propeller end.
20329
Standard-rotation (right-hand)
90-899907001 JULY 2006
20330
Counter-rotation (left-hand)
Page 1A-15
17
Trim Tab Adjustment (to equalize steering pressure)
•
If boat turns more easily to left than to right-turn back edge of trim tab to the left
•
If boat turns easily left or right you have balanced steering torque-set back edge of trim
tab to center position
22357
22358
•
If boat turns more easily to right than to left-turn back edge of trim tab to the right
22359
Page 1A-16
90-899907001 JULY 2006
18
MC-1 Propeller Shaft Parts Comparison
a
b
a
b
22379
a - 1973 and older-gimbal housing casting, propshaft parts and shift cable adjustment
dimension
b - 1974 and newer-gimbal housing casting, propshaft parts and shift cable adjustment
dimension
Tapered Roller Bearing Diagnosis
Consider the following factors when diagnosing bearing condition:
• General conditon of all parts during disassembly and inspection.
90-899907001 JULY 2006
Page 1A-17
19
•
•
•
Classify the failure with the aid of the illustrations.
Determine the cause.
Make all repairs following recommended procedures.
Good Bearing
21046
Bent Cage-End
•
•
Cage damage due to improper handling or tool usage.
Replace bearing.
21047
Bent Cage-Side
•
•
Cage damage due to improper handling or tool usage.
Replace bearing.
a
17181
a - Cage damage
Galling
•
Page 1A-18
Metal smears on roller ends due to overheat, lubricant failure or overload.
90-899907001 JULY 2006
20
•
Replace bearing - check seals and check for proper lubrication.
17539
Abrasive Step Wear
•
•
Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check seals and bearings and replace if leaking, rough or noisy.
21048
Etching
•
•
Bearing surfaces appear gray or grayish black in color with related etching away of material,
usually at roller spacing.
Replace bearing - check seals and check for proper lubrication.
17182
Misalignment
•
Outer race misalignment due to foreign object.
•
Clean related parts and replace bearing. Make sure races are properly seated.
17184
Indentations
•
Surface depressions on race and rollers caused by hard particles of foreign material.
90-899907001 JULY 2006
Page 1A-19
21
•
Clean all parts and housings, check seals and replace bearing if rough or noisy.
21049
Fatigue Spalling
•
•
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
17187
Brinelling
•
Surface indentations in raceway, caused by rollers, either under impact loading or vibration
while the bearing is not rotating.
•
Replace bearing if rough or noisy.
17543
Cage Wear
•
•
Wear around outside diameter of cage and roller pockets, caused by abrasive material and
inefficient lubrication.
Check seals and replace bearing.
17545
Abrasive Roller Wear
•
Page 1A-20
Pattern on races and rollers, caused by fine abrasives.
90-899907001 JULY 2006
22
•
Clean all parts and housings, check seals and bearings and replace if leaking, rough or noisy.
17550
Cracked Inner Race
•
•
Race cracked due to improper fit, cocking or poor bearing seats.
Replace bearing. Inspect installation area for defects.
17552
Smears
•
•
•
Smearing of metal due to slippage. Slippage can be caused by poor fits, lack of lubrication,
overheating, overloads or handling damage.
Replace bearing. Clean related parts and check for proper fit and lubrication.
Replace shaft if damaged.
17554
Frettage
•
•
Corrosion set up by small relative movement of parts with no lubrication.
Replace bearing. Clean related parts. Check seals and check for proper lubrication.
17556
Heat Discoloration
•
Heat discoloration can range from faint yellow to dark blue, resulting from overload or incorrect
lubricant.
90-899907001 JULY 2006
Page 1A-21
23
•
•
•
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers a simple file test may be made. A file drawn
over a tempered part will grab and cut metal, whereas, a file drawn over a hard part will glide
readily with no metal cutting.
Replace bearings if overheating damage is indicated. Check seals and other parts.
17188
Stain Discoloration
•
•
•
Discoloration can range from light brown to black, caused by incorrect lubricant or moisture.
Re-use bearings if stains can be removed by light polishing, or if no evidence of overheating
is observed.
Check seals and related parts for damage.
21050
Page 1A-22
90-899907001 JULY 2006
24
Mercury Marine Backlash Flags
Stampings
Measurement 1.
1
17 mm (0.660 in.)
2
15 mm (0.585 in.)
3
13 mm (0.520 in.)
4
10 mm (0.390 in.)
I
19 mm (0.750 in.)
II
24 mm (0.935 in.)
III
29 mm (1.130 in.)
1
12 mm (0.455 in.)
2
16 mm (0.625 in.)
1
12 mm (0.455 in.)
2
16 mm (0.625 in.)
3
12 mm (0.490 in.)
40B
10 mm (0.410 in.)
85A
12 mm (0.480 in.)
55A
31 mm (1.215 in.)
60A
34 mm (1.330 in.)
30A
27 mm (1.070 in.)
91– 805481
15– 19/16– 27
35 mm (1.370 in.)
Bravo 3 (inner shaft) 3.
91– 805482
15– 19/16– 27
22 mm (0.850 in.)
Bravo 3 (outer shaft) 3.
91– 806192
15– 19/16– 27
30 mm (1.165 in.)
Bravo 3 (spline lash) 3.
91-865116
16/19
Bravo "Shimmable" Driveshaft Housing 4.
91-865082
23/30
91-865081
27/29
91-865080
27/32
Part Number
91– 78473
91– 53459
91– 19660 2.
91– 19660– 1
91– 84725M
1.
2.
3.
4.
Application
Standard outboard flag. Also some MerCruiser
models
Standard MerCruiser Flag. Also some outboard
models.
100– 125 hp outboard (4–cylinder inline)
Outboard (as above) Also some 40–60 hp 3–
cylinder models.
Mariner Outboards (Japanese product)
Inside of hose clamp to stamped mark.
Supersedes to the 91-19660-1 flag.
Used on the BlackHawk drive.
2004 Bravo drives, serial number 0M198373 and above.
90-899907001 JULY 2006
Page 1A-23
25
Bravo Shim Kit Listing
Bravo One, Two and Three Series
Driveshaft Housing
Driven gear(s) location 2.3 mm (0.091 in.)
23–87560091 (1999 and earlier)
23–87560094 (1999 and earlier)
23–87560097 (1999 and earlier)
23–861782061 (2000 and later)
23–861782064 (2000 and later)
Gear Housing
Pinion gear location
15–92914A1
Driveshaft preload
15–86749A1
Driven gear location (B1/3)
15–87157A1
Driven gear location (B2)
15–55499A1
Load ring (B1)
67440T
Load ring (B2)
23–66093T
Aft driven gear (B3)
15–805078A1
Propshaft end play (B3)
15–805627A1
NOTE: U-joint pinion gear shims and driven gear thrust bearing races for 2004 (and later) Bravo
"shimmable" driveshaft housings (S/N 0M198373 and above) are listed in the driveshaft housing
setup section.
Page 1A-24
90-899907001 JULY 2006
26

Sterndrives, Transom Assemblies and Hydraulic Systems

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