A Safety Warning This Workshop Manual will alert you to certain procedures that must be done very carefully. If you ignore this information, you could... * Injure yourself or people around you © Injure the boat operator, boat passengers, or people around the boat * Damage the Volvo Penta product or its systems Understand the following symbols before proceeding: Alerts you to the possibility of danger and ing | identifies information that will help pre- vent injuries. A Safety Wai Identifies information that will help pre- [Note] vent damage to machinery. Appears next to information that controls mportan correct assembly and operation of the product. This Workshop Manual is written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools. This Workshop Manual tells you how to correctly maintain and service Volvo Penta products and systems. When correctly serviced, the Volvo Penta product will be reliable and safe to operate. When Volvo Penta special tools are called for, use them. Where mentioned, the tools are required to perform the service procedure. If you use service procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the Volvo Penta product.Contents General Information ............... 5.0.00 cc cee ee eee es Transom Bracket .........0 00.0 e eee e eee eens Upper Gear Housing .............000c cece eee eee Lower Gearcase Single Prop Models Dual Prop Models Vertical Drive Removal/Installation ..............65 a Trim/Tilt System - Hydraulics Propeller Selection .................. 0.0022 c cee ee eee eee‘This workshop manual is one of a set of eight that covers Volvo Penta sterndrive models. All eight books can be ordered as a set from Volvo Penta Parts, Order PIN 7797360-0. Individual workshop manuels covering these models are also available. Or- der the following part numbers from Volvo Penta Parts, + P/N 7797361-8 Engine Components Includes information on Engine service and troubleshooting; Engine removal and installation; Steering systems, Throttle and Shift Control systems; and Cooling systems. + P/N 7797362-6 Electrical & Ignition System Includes service and troubleshooting information on Cranking systems; Charging systems; TrimyTit electrical systems; Ignition systems; and Engine and Instrument wiring diagrams. + PIN 7797363-4 Fuel System Includes service and troubleshooting information on all carburetor, MFI and. ‘TBI fuel systems and related components, * PIN 7797364-2 EF] Diagnostic Manual GM Contains troubleshooting procedures for all Electronic Fuel Injected GM mod- els and related components. + PIN 7797365-9 PJX WaterJet Contains service information for repair and overhaul of the waterjet system, + P/NT797366-7 DPX - Workshop Manual Includes specific information for repair and overhaul of the DPX Sterndrive and Xact™ steering systems, + PIN 7797367-5 SX and DP-S Sterndrives and Transom Shield Includes information on Transom Shield, Upper Gear Unit and Lower Gear Unit service; Drive Unit removal and installation; Propellers; and TrinvTilt hydraulic operation + P/N 7797368-3 SP and DP Workshop Manual Includes Upper Gear Unit and Lower Gear Unit overhaul procedures, installa- tion and removal. ii VoraThis Volvo Penta Workshop Manual Covers The Following Volvo Penta “LK" Models i, 30 LITER a3 TER TA LTER 20GSMLKO seseeas || 43GLPLKD sseesta | | 74GLPLKD 3868626 30GSPLKD saessa7 || 4acsPLKO ssee6ie | | 74ciPLKOCE 3068627 49GIPLKDCE 3868620 | | 74GSIPLKD 3868742 87 LITER a2uTER S7GLPLKD 3e6s621 | | 82GsiPLKD 3868743 STGLPLKR. 3888699, S7GSPLKD 3868598 S7GLIPLKDCE 3888732 STGIPLKDCE 3868622 STGSIPLKD 3868624 STGSICPLKD 3888686 TAN SN SGT 7568404 SxcLTt 3868432 SX-CIAC 3888515 SXC2AC 3868820 St oxo 1431 3esss02 | [DPS 2.304 3e6er6s | [DPXST 1501 3858637 SkCt 1.5141 3ees303 || DP-s 1.95: se6e164 | | DPxS1 1.681 3868638 Sk&C1 60:1 seeszea || DPS 1.784 seestes || DPxs1 1781 3868839 SxC1 1.661 3assz0s || 0P-S 1.681 3868166, SkOTr 1.974 3ess297 || pP.st — 2:20-1 3868601 SKRT1 1.66:1 3ess3e3 || pst 1.951 3868602 SKRT2 1.66:1 3esase7 || ppt 1.78:1 3868603 sxc2 1411 seeese1 || vP-st 1.681 3868604 SKC2 1.811 3968562 8X62 1.60:1 3868683 Sxc2 1.661 3868584 SkC1 1854 3068465 SKRTI | 2.48:1 3868333, SKRT2—2.18:1 3868588 Set Di iV CaS PIXC 3868504 PIX.C1 3868594POM eae ny Note] aii sterndrive systems must be matched for either single or dual engine installations. Failure to properly match engine, transom bracket and sterndrive will result in poor boat performance, and risk or damage to the engine and or drive because of incorrect drive gear ratio. ‘The model identification is located on the engine valve cover, and MUST correspond withthe transom bracket and sterndrive numbers as listed in this document. + Engine Made! Number [1] [23] + Transom Bracket Model Number [41] + Sterndrive Mode! Number [5]Section 1 General Information Table of Contents Conversion Charts Drill Size . 144 Metric . 1-13 Introduction a 42 Lubrication ‘Gimbal Bearing Power Trim/Tilt Sterndrive - SX Models Sterndrive - DP-S Models - Ujoints eae aey Off-Season Storage Preparations Perodic Maintenance Chart Preparation for Boating After Storage... Recommendations for Antifouling Paints . ‘Symbols a 20-Hour Check . A Safety Warnings Before beginning work in this section, read Safety chapter at end of this manual. Proper installation is important for the safe, reliable operation of all me- chanical products. The procedures we recommend and describe in these instructions are effective methods to be followed when installing Volvo Penta sterndrive products, Some of these methods require the use of tools specially designed for the purpose. The special tools should be used when and as recommended. 1Introduction This service manual covers Volvo Penta sterndrive models. It’s divided into sections concerning various systems and assemblies. Refer to the Contents tolocate the section covering the system or assembly requiring service. Each section ile page has en additional listing thet will describe the section's con- tents in more detail. Be sure to read the Safety Section at the end of this ‘manual, and pay special attention to all safety warnings as they appear through- ut the text. Since models are subject to change at any time, some photos. ‘may not depict actual product Good Service Practice Service for Volvo Penta stemdrives are generally one of three kinds: ® Normal care and maintenance - which includes putting a new stern drive into operation, storing engines, lubrication, ‘and care under special operating conditions such 2s salt water and cold weather. © Operating malfunctions - due to improper engine or drive ‘mounting, propelier condition or size, boat condition, or the ‘maifunction of some part of the engine. This includes engine servicing procedures to keep the engine in prime ‘operating condition, © Complete disassembly and overhaul - such as major service or rebuilding a unit. It's important to determine before disassembiy just what the trouble is and how to correct it quickly, with minimum expense to the owner. When repairing an assembly, the most reliable way to ensure a good job is to do a complete overhaul on that assembly, rather than just to replace the bad part, Wear not readily apparent on other parts could ceuse malfunction soon afer the repair job. Repair kits and seal kits contain all the parts needed to ensure 2 complete repair, to eliminate guess work, and to save time, Repair time can also be minimized by the use of special tools. Volvo Penta Special Toots are designed to perform service procedures unique to the prod- uct that cannot be completed using tools from other sources. They also speed repair work to help achieve service flat rate times. In some cases, the use of substitute tools can damage the part Note Do not operate engine out of water even momentarily. If operated in test tank, use proper test wheel. Failure to do so can damage water pump, overneal engine, or alow excessive engine RPL 12Preparation for Service Proper preparation is extremely helpful for efficient service work. A clean work ‘atea atthe start of each job will minimize tools and parts becoming misplaced Clean an engine that is excessively dirty before work starts. Cleaning will occasionally uncover trouble sources. Obtain tools, instruments and parts needed forthe job before work is started. Interrupting a job to locate special tools or repair Kits is a needless delay. AX use prose iting ana handing equipment. Working on stm crives without proper equipment can cause damage and personal nury Always use clean fresh fuel when testing engines. Troubles can often be traced to the use of old or dirty fuel Service Policy Whether within or following the warranty period, Volve Penta has a constant interest in their products. Itis Volvo Penta's policy to provide dealers with service knowledge so they can give professional service demanded by today's consumer. Volvo Penta Training Centers, Service Bulletins, Letters and Promotions, Special Tools and this Service Manual represent Volvo Pente's efforts to assist dealers in giving consumers the best and most prompt service possible. If a service Question does not appear to be answered in this manual, you are invited to call, fax, or write to the Volvo Penta Service Department for additional help. ‘Always be sure to give complete information, including engine model number and serial number. Be sure that you are familiar with Volvo Penta’s Warranty. If you have any questions, call, fax or write the Volvo Penta Service Department. If other than genuine Volvo Penta replacement components or parts are used, Volvo Penta may refuse subsequent warranty claims involving that engine, ‘When a brand-name product or specific tool Is called for, another item may be used. However, the substitute must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product maifunction and personal injury to anyone. To avoid haz- ards, equivalent products which are used must meet all current U.S. Coast Guard Safety Regulations and ABYC standards, ‘Starndrive A Safety Related 13Replacement Parts AX vinen repiacerent parts are required, always use genuine Volvo Penta parts, or parts with equivalent characteristics, including type, strength, and ‘material, Failure to do so may result in product malfunction and possible in- jury to the operator and/or passengers, Parts Catalogs Parts catalogs are a good source of information for ordering replacement parts. ‘They are not a good source for disassembly and reassembly of sterndrives land accessories. The exploded views in the Parts Catalogs are for illustra- tion of parts only, nota source of assembly instructions. The Workshop manual has detailed information and is the only source of information for disassembly and reassembly. Volvo Penta Special Service Tools Volvo Penta has specially designed tools to simplify some of the disassembly ‘and assembly operations, These tools are illustrated in this Service Manual, in many cases in actual use. All Volvo Penta special tools can be ordered from Volve Penta Parts and Accessories, Individual purchasers of Service Manuals must order Special Tools through an authorized Volvo Penta dealer. Product References, illustrations & Specifications Volvo Penta reserves the right to make changes at anytime, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such ‘change. All information,ilustrations and specifications contained in this manual are based on the latest product information available at the time of printing, The right is reserved to make changes at anytime without notice. {All photographs and illustrations used in this manual may not depict actual models of equipment, but are intended as representative views for reference only. The continuing accuracy of this manval cannot be guaranteed. A satetyratates 14Sterndrive Lubrication - Volvo Penta SX Models Adding Lubricant to Sterndrive Volvo Penta SX Models CILZ] cxcasionatly check oil level in the sterndrive. Screw dipstick ® fully nto hole, Remove and read oil level in reference to markon dipstick. Ici level is low, add oil trough dipstick opening. Add only enough lubricant to bring the oll level to the proper level somewhere in the range ® on the dip- stick Sterndrive Oil Capacity ‘Change Lubricant Every 100 Hours or Once Each Season Use Volvo Penta DuraPlus™ Synthetic GL-5 Gear case Lubricant + All Volvo Penta SXModels 71 oz, (2100 cc) Draining and Filling Sterndrive ‘When a complete change of lubricant is required in the stemdrive, proceed as. follows: 1. Place sterndrive in the full down position. Place a 4 liter drain pan under lower gear case to catch oil, 3] 2. Remove oil drain plug © (port side of lower gear case) and dipstick ® (top of stemdrive). Removing dipstick vents sterndrive to improve oil drain- ing. Allow oil to drain completely. 3] [B] 2 Remove three screws securing the shit ink acoess cover to access the ol level plug ©. Fil sternrive with DurePus™ GL-5 Syntnetic Gear Lubricant through ol drain plug hole ©. Fillstowl to purge air. Stemdrive is property filed when the cil evel appears atthe ol level plug hole. When filed tothe proper level, instal ol level cipstick ® and the cl level plug © frst to prevent excessive ol loss, then the ol drain plug ©. Tighten cil level gauge, plug, and drain plug finger tight Note | Fiting stendrive too quickly may form air pockets that will cause an inaccurate ol level reading. Running the sterndrive with improper oil evel will result in immediate internal damage. if lubricant has been com- pletely changed, oil level must be rechecked after unit has been run and ‘trapped air purged. Improper oll level will result in serious internal sterndrive damage. Add makeup oil through dipstick opening to bring oil up to proper level. [1)« check oilievel with dipstick. Oil level must appear on the blade of the dipstick. Add oll # required, through the dipstick hole following procedures under Adding Lubricant to Sterndrive, 155. Tighten drain plug to 60-84 in. Ibs. (6,8-9,5 Nm). Tighten oil evel dipstick to 48-72 in. Ibs. (5,4-8,1 Nem) 6. Install access cover and tighten screws to 108-132 in. Ibs. (12 - 14 Nem). Note] riuvicanthas been completely changed, cllevel mustbe rechecked after unit has been run and trapped air purged. Improper oil level will result in. serious internal sterndrve damage. Add make-Up cl trough dipstick open- ing to brn ol upto proper level Sterndrive Lubrication -Volvo Penta DP-S Models Adding Lubricant to Sterndrive Volvo Penta SX Modols CZ) occasionally check oil level in the sterndrive. Screw dipstick @ faly into hole. Remove and rea oilevel in reference to mark on dipstick Hoi levels low, add oll through dipstick opening, Add only enough lubricant to bring the i level othe proper level somewhere inthe range @ on tne dip- stick Sterndrive Ol Capacity Change Lubricant Every 100 Hours or Once Each Season Use Volvo Penta DuraPlus™ Synthetic GL-5 Gear case Lubricant + AN Volvo Penta DP-S Models 81 oz, (2400 mi) Draining and Filling Sterndrive 1. Move shif control to reverse. Using @ 30 mm socket, remove the rear propeller retaining nut and propeller. Move the shift contralto forward, Using Prop Tool, PIN 3855876-3, remove the front propeller retaining nut and pro- peli. AX bo not attempt to courterholdpropeles by hand wile removing or Instating propeller nus, serious injury may resuk 2. With the sterndrive in the full down position, place a 4 iter oil drain pan under the gear case. 31s. remove ai furan screw © using an 8 mm Allen wrench, Discard the O-ring, Let the stemerive drain completely [7]4. remove the oi evel dipstick ® so the oll cavity can vent while drain- ing Note] po not fil the sterndrive with oil unless it passes both pressure and vacuum tests. Stemdrives that fail either test will alow water entry when in use and cause subsequent damage to internal parts.[211 1. Remove the three screws ® securing the shift link access cover to access the ol level plug © Remove the ol level plug ©. Discard the plug and dipstick O-ring. Replace them with new ones. 2 Install Fill Adap- tor, PIN 2855932-4, Fil the sterndrive with DuraPlus™ GL-6 Synthetic Gear Lubricant through oil rin plug hole ©. Fill slowly to purge trapped air. Stop filing when the ol level reaches the bottom ofthe oil level hole ©. Rotate propshatt several times to purge any trapped air. Note] po not overfill, This will cause the cil cavity to overpressurize during operation and damage oll seals. Filling drive too quickly may form air pockets that will cause an inaccurate oll level reading, Running drive with improper oil level may result in internal damage. Damage caused ftom running the drive cil too high or too Jow will not be covered under Volvo Penta's limited war- ranty. [1 12. instal propelers. Move the shit contol to forward. instal the front propelier © and propeller nut ©, Using Prop Tool, PIN 3855876-5 torque to 4457 Ibs. (60 Nm), Move shit control toreverse, Insta the ear propeller © and propeller nut @). Using a 30 mm socket, torque to 50 ft. Is. (70 Nem) Power Trim/Tilt-Fluid Level TE] the trinvtit assembly contains the electric motor, hydraulic pump, and reservoir. At the beginning of each boating season, check the fluid level in the reservoir as follows: AM the trimtit hydraulics are pressurized when the sterndrive is in the down position. The sterndrive must be tilted full up to relieve hydraulic pressure before removing level/fill plug @. Failure to tilt the sterndrive to the full up position before removing level/ill plug would result in a hazardous spray of hydraulic oil. Caution should always be taken when removing level/ill plug by placing a rag over the levelfill plug to prevent residual pressure from spraying oil AN satety Related 1741. With the sterndrive tilted full up, stowly and carefully re- move the levelfil plug 2. Check the fluid level. The fluid should be level with the bottom of the fill hole when the sterndrive is at full tlt 3, Itnecessary, add DuraPlus™ Power Trim/Tit & Steer- ing Fluid. Replace the levelfil plug and tighten securely, Note] when checking fluid level, inspect the tri unit {for leaks and proper operation. Repair or replace defective ‘components. Off-Season Storage - SX and DP-S Models. 1. Change Sterndrive Lubricant: Drain and refill with fresh Volvo Penta DuraPlus™ Syn- thetic GL-6 gear oil. Refer to Sterndrive Lubrication. 2. Lubricate Gimbal Bearing and Universal Joints: Refer to information elsewhere in this manual, 3, Inspect Sterndrive Water Pickup Screens for Ob- structions. Note] see Engine Components Workshop Manual for additional engine off-season storage procedures. Painting 4, Remove alt marine growth. 2, Remove all lose paint and corrosion by sanding or sand- blesting. If sandblasting, use an aluminum oxide blasting media with a particulate size of 0.2 - 0.7mm. 3. Remove all trace of grease and wash with hot water and detergent. Roughen all painted surfaces with medium 3M Scotchbrite™ pad. Rinse thoroughly with water. 4, Treat any bare aluminum with chromate conversion coat- ing. Clean the entire bare area with an acid cleaner that does not contain fluoride, such as Du Pont® $717. Scrub surface with 3M Scotchbrite™ pad unti it is completely "wetted" with no beads of water. AM Fveridein a cleaner causes a smut (derkcscoloa- tion on sileon-aley aluminum castings, and paint wil not stick o"smut if thishappens, sand the surface and start ver using aalferent ac leaner 18 A Do not use steel wool. Small pieces of steel will become imbedded in the aluminum and wil cause severe corrosion. 5. Rinse thoroughly with water. The area must appear “wetted,” or the surface is not clean and the paint will not, adhere. 6. While the surface is stil wel from rinsing, treat all bare aluminum with Du Pont® 2268 chromate conversion solu- tion, Brush the chromate solution on the surface. Adging ‘additional solution as required for 2 to minutes to prevent itfrom drying on the surface. Rinse the surface thoroughly with water and allow to air dry. Follow label instructions exactly If the chromate is allowed to dry any- where on the bare aluminum surface, chromic acid salts will form which will prevent paint adhesion and promote corrosion. Sand the surface to bare metal Itis best to let the part air dry, but if you must wipe the surface to speed up drying, use lint free wipes not treated with anything that may contaminate the Surface. Do not scrub the surface, wipe very lightly Do not blow dry the part with shop alr Unless it is completely free of dir, oil, and water. Do not heat the part above 150°F, before painting, Do not touch the treated surface with bare hands before painting ‘The part should be primed soon after it dries, or atleast within 24 hours. 7. Where the prime coat is thin or where the surface is ‘unpainted, prime with Volvo Penta PIN 1141562-7 or PPG® ‘Super Koropon epoxy primer. Do not apply primer over hard finish coat. Primer solvents must be allowed time to ‘evaporate and the primer must harden before applying the finish coat. Allow 8 to 12 hours drying time, 8. Apply finish coat. The parts catalogs and the Volvo Penta Parts & Accessories catalogs list part numbers for finish- ing products.Gimbal Bearing and Universal Joint Lubrication ‘The gimbal bearing and universal joint must be lubricated each year. Lubri- cate the gimbal bearing and universal joint when preparing your boat for the ff season storage. This requires the removal of the drive unit; therefore, Volvo Penta recommends that your Volvo Penta dealer perform this opera~ tion. Note] Faiture to lubricate the gimbal bearing and universal joint each year will result in damage to the transom shield and drive unit. (TILE the gimbal bearing is lubricated by a grease fitting located on the starboard side @, Volvo Penta SX and DP-S models, of the gimbal housing, Volvo Penta recommends that lubrication of the gimbal bearing be done with drive unit eemoved. This will allow observation of old grease as its being replaced by new grease. Ifthere is evidence of water, the bearing should be inspected for damage endlor replaced. Lubricate simbel bearing with EP whee! bearing grease. Apply grease unti all he old grease is removed and new grease appears. [2] the sternorive must be removed to lubricate the universal int. Lubri- cale Ujoint with EP Wheel Bearing grease. Apply grease tothe U-joint grease fitings ® until old grease is forced out. When the sterndrive is removed, wipe old grease and dirt off driveshaft spines, then throughly clean spines before applying new grease. The driveshatt splines © must be lubricated with Molybdenum Grease, and light ol applies to the shaft O-rings ©. The bellows should be checked for damage and deterioration, Replace if neces- sary. Engine alignment must also be checked. Refer to Sterndrive Installa- tion in Sterndrive Removal and Installation section of this manual, 19Recommendations for antifouling Paints on boats equipped with sterndrives. All antifouling paints that prevent marine growth are poi- sonous and may harm our marine environment. The legis- lation concerning antifouling paints has changed in many countries and others have announced coming changes in their legislation In general the newlegisiation is or willbe considerably more restrictive as far as the allowed leakage of the active ingre- dients in the paints to the water is concemed. Several coun- tries have put into practice (or will put into practice) a more restrictive legisiation for pleasure boats than for commer- cial boats and vessels. The reason is that leisure boat har- bors often are situated in shallow waters, which are spawn- ing grounds for fish. Contrary to commercial boats, leisure boats spend most of their ime tied up in the harbor, which ‘adds to the impact on the environment in these waters Since the protection of the environments in the best inter- est of all concerned, itis important to minimize the use of antifouling paints. As far as smaller boats are concemed trailer boats, which can be taken out of the water, we rec- ‘ommend teflon type paint only, combined with cleaning a few times during the season. This procedure can prove somewhat impractical as far as larger boats are concerned and therefore aniifouling paints might have to be used. How- ever, always take care to find out the valid legistation in the area where you intend to use the boat prior to starting the treatment of the boat! The legistation can also provide rules as to the boat weight or overall length. Always follow these directions. [Note] may be completely forbidden to use antifoutin y pletely ig paints on leisure boats in some instances (e.g. in fresh water) Painting the sterndrive with antifouling paint Clean the sterndrive carefully. De-grease and flush thor- oughly with water. Sand the surface with a water-abrasive paper (grit size 200-240). Make sure not to sand through the original paint of the sterndrive. Damage to drive paint must be carefully repaired with primer and original Volvo Penta paint. Pure metal must be cleaned prior to the appii- cation of primer. Make sure to let the primer and the paint harden in accordance with the manufacturer's instructions. Mask the hull around the transom shield and spots on the sterndrive which are not to be painted Note} po not paint the zinc anodes! ‘AIMPORTANT take sure that you have a good contact between the zinc anodes and the sterndrive. Prior to launching the boat the zinc anodes must be cleaned (activated) with emery cloth in order to remove the oxide layer. Never use a steel brush when cleaning. The steel brush reduces the gal- vani¢ protection. The engine and stemndrive must never be in metallic contact with the keel, rudder or other metallic components below the water line. Electrical equipment (such as charging equipment, navigational aids, VHF radio, etc.) must never be grounded to the engine or to the stemdrive PAINT FOR STERNDRIVES | PARTNo.| COLOR | DESCRIPTION Vinarsere [Bée-oray 270 | , 1415676 |reaa toa? |2PartPaintO.S abs (Sy 250A | part Paint 0.5 gts |SPC1, DPD2) [raisvea ‘ i Gray (290A- in waters Seo PR | 2-PartPaint 1.095 po sper. ope2) | | Gry 2000. | inats769 SEA’ Bpoe) Aerosol Spray can | | \sestzre0 [ser Mettic [AeroeclSpraycan | —EE—E—_e—E—E-_E—XE OO i Daksner | | A " |38st2208 Gp _ [Aerosol Spey ca Painting the hull with antifouling paint Always follow the manufacturer's instructions. When making the purchase, make sure that you receive the correct product meeting the legistation prevail- ing in the area where you are going to use the boat. The product mu st contain the correct properties for the boat hull type. Aluminum hulls often require an initial treatment with an etching primer. Use a pure copper based antifouling paint, containing cop- per tiocyanate, not copper oxide. Tin-based (TBT- Paints) are no longer allowed. Make sure to pre- pare the hull in accordance with the directions of the paint manufacturer. AIMPORTANT [eave a 1" strip unpainted around the transom shield/sterndrive.Preparing Boat After Storage ‘See Engine Components Workshop Manual for specific information con- cerning the engine preparation, Volvo Penta Dealer Service - 20 Hour Check 20 - Hour check includes: © Change engine oil and filter. ‘© Drain and refil sterndrive, Check the tittrim reservoir for proper fluid level . Lubricate steering cable ram with grease and check power steering pump reservoir for correct fluid level. Change fuel ftertwater separator. Check tension on all drive belts. Check engine timing, eevee Carbureted Models: Check and adjust carburetor for correct idle mixture and idle RPM © Check engine mounts, © Lubricate gimbal bearing and U-joint. © Check engine alignment. ‘© Check for any deficiencies, malfunctions, signs of neglect oF abuse, ete. Correcting any problems discovered at this time will prevent worsening of a minor problem and help ensure a trouble-free boating season. @ Inspect exhaust system, check all hose clamps for security. (© Make sure engine can achieve maximum rated RPM, For the U.S., Canada, and Mexico, the 20-Hour Check is paid for by the boat owner and performed = by your. = Volvo. Penta dealer at local shop rates. In other markets the Warranty Inspection is pad for according to the Warranty Policy for Importers.inches? inches* inches? quarts gallons feet feet” fluid oz yards* ounces (av) pounds (av) tons (2000 Ib) tons (2000 Ib) ic ounces - f (av) pounds - f (av) kilograms -f METRIC CONVERSION CHART X 25.4 millimetres (mm) X 0.3048 = metres (m} X0.9144 = metres (m) X 1.6093 = kilometres (km) X 254 centimetres (cm) X 645.16 = millimetres? (mm) X6.452 = centimetres* (em*) X 0.0929 = metres? (m’) X 0.8361 = metres? (m*) XOdoa7 = hectares (10' m) (ha) X 2.590 ilometres? (km) X 16387 = millimetres? (mm*) X 16.387 = centimetres® (m’) X 0.01639 X 0.94635 X3.7864 = X 28317 = X 0.02832 = metres? (m*) X 29.57 = millilitres (ml) X 0.7646 = metres® (m’) X 28.35 = grams ig) X.0.4536 = kilograms (ko) X 907.18 x 0.90718 X0.278 = newtons (N) feet/sect inches/sec* X 4.448 yewtons (N) X 9807 = newtons (N) X 0.3048 = metres/sec? (m/S*) X 0.0254 = metres/sec® (m/S*) foot-pounds X 1.3558 = joules (j) calories ‘X 4.187, joules (j) Btu ‘X 1055 joules (j) watt-hours ‘X 3500 joules (j) kilowatt -hrs 3.600 = megajoules (MJ) FUEL ECONOMY AND FUEL CONSUMPTION milesigal —-X 0.42514 = kilometresilitre (krn/} Not 235.2i(mi/gal) = litres/100 km 235.21(litres/100 km) = milgal footcandies —X 10.76 = lumens/metre (Im/m*) PESOS inches HG (60°F) X 3.377 = kilopascals (kPa) pounds/sq in X 6.895 = kilopascals (kPa) inches H,0 (60°F) X 0.2488 = kilopascals (kPa) bars X 100 = kilopascals (kPa) poundsisq ft --X 47.88 = pascals (Pa) horsepower X 0.746 = kilowatts (kW) felbfimin X 0.0226 = watts (W) aR Celsius = 0.586 X (°F -32) Fahrenheit = (1.8 X °C) +32 pound-inches yewton-metres (N-m) pound-feet ewton-metres (N-m) mileshour X41 dometeshour kmh) feetsec XO. metres/sec (m/s) Semetresnr 027178 = metrexees (mi) maieohour’” — XBaa7o™ = metesees (ms)Drill Size Conversion Chart ‘SHOWING MILLIMETER SIZES, FRACTIONAL AND DECIMAL INCH SIZES AND NUMBER DRILL SIZES Mili. Dec. Frac Num-|Mii- Dee. Frac: Num-|Miliz Dee. Frac: Num- Dec. Fra. Num-|Mill- Dee. Frac Moter Eauiv. tional_ ber” | Metor Equiv. tional bor’ |Meter Equiv. tional bor” [Motor Equiv. tonat_ber [Motor Equi. tional 19039 175.9689 4570 2 | 68 267 hove 4219 118.0050 <. 0700 so [ao srs 6s 2716 [110 4330 2 hon ia’ ‘ores 590 a ERO vo fia Taare ae 28 0098 tes ‘0728 Shere 2 | 70 2786 ns ‘4528 2 one 2 o70 ao fai Sou eit a fast agate 0135 eo ia’ lovaa 32 “esa i Tres N81 “4687 380138 0760 ae |. 60 9 |e. en k |i20 ‘ar8 ong 79 |i96 ‘over 626 “673 Tia 2612 oe h230 “apts 2% 33 O18 198 ‘07a me a3 “3693, 72. 735 h2s ‘a92t & 187 + 0785 ‘af. fees re | 725 2064 127 ‘8000 v 160 7 |20° ‘ova a57 “1710 4 73 270 so site 4 ow 205 ‘oan? 1730 a ‘2900 L310 [5155 ae 0180 ” 10 ag [aa 1732 74 213 jis40 ssa mm 197 9820 6 3770 6 2350 m iiss ‘sats 10200 ye |2i° bea7 asc 2953 1389 5459 mu cL 210 75 [215 0648 -- 1800 6 2968 my... [140512 5 027 1960 ae [és er 202 jte29 623% 0225 va |22 ‘058 1820 1% ‘3020 Nn hiss ‘5709 6 236 225 855, a7’ “3850 3 3031 1268 ‘5781 ‘280 73 | oaa0 4s |a75 “870 3051 hs ‘905 0250 72 |23° 0005, 476 1875 He. [15.08 5037 Me 0256 23s ‘os aa” “3890 2 15.48 ‘soa 10260 n ‘9038 a |e. foo " % 188 ‘6102 0260 70 | 238 (0037 om SS. fae’ “ozo 18.88 16250 4 0276 2a “oes 3935 10 © fio ‘e203 ci. 9202 ea |. 0960 a 1980 ° 16.27 ‘6405 75 oa, 2.5 ‘0960 50° “r988 hes ‘G40, 310 6 ‘0960 ry 1990, 8 Pp hes ‘e562 % 78 0812 Me... |25 0884 51 2008 W720 ‘6693, a oS (0995 8 2010 7 1705 ‘5719 0320 7 1038 a8 [sie 20a ome he 17.86 ‘6875 0330 66 |26 ‘1024 2040 é 175 ‘6890, 8 ORs 040 a7 [83° ou a |iia6 F081 360 6s |27° “oss ‘2066 5 hao” 7087 8 0364 S. Toes 36 [525 2067 1826 7187 ae 0360 ea |275 “082 53 2096, R hes. 7263 0370 63/278 ‘1094 me. 2000 4 18.65 “748 ee ‘98 ba ‘1100, as [sa’ 226 879 3457 Me noo 7490 ‘380 62 |28 ‘t102 2130 3 | 975 ‘sas 19.05 "7500 % ‘0390 6 1110 ae [58° 2165 88 3465 10.45 7656 ia’ ‘oan 1130 33 |sse Zar % ‘3460 s hes Jer ‘o<00 oo j2e na 86 2205, 8a “Seo i988 7812 ‘oat 9 160 2 2210 2 | 90 3503 jz00 a74 ios oa 30° ne 37° Pas =. 3580 1 [e028 "7969 1% ‘9020 58 1200 ai }875 ‘2263 94, 3683 j205. ‘ov (0830 57 {34° 112720 ‘2280 1 | aia sea se laos4 ‘8125 se ti) 235 318 1250 % 58 2283 92. 3622 lao e269 115 0482 32 11260 59 2323 925 ‘36a i204 718 =e ‘ees se [225 11279 "2380 a | 33° ‘ace. laras Bag? Bie Lid 0469 4 1285 30/898 234d ie ‘3580 vu is. ‘Bees 12 ‘oarz 33° “209, 80 2382 34 3701 fars3 [3504 = 125 ‘oa2 3a 338 ‘a0 8 | 3s sro lz20. ‘ees 13° osi2 1360 zo [ei 2aor 953 3760 % —... |2z.20 e760 1% (520 ss [35° 1378 2an c * 377 Wis’ ‘gece 135 0513 1408 ve [62 daar 38 37e0 2262 8906 “0550 sa [367 [1408 se 625 2060 > | a7 3a [23.0 9058 ia) “ogst 36 at 63 as 975 3638 [2502 ‘9062 =e 1450570 tao za sas 2500 « oe | 98 ‘358 l2s42 ‘979 su 15 0601 3711457 64 2520 = "3860 w {ss 9252 0895 83 1470 26 [65 2559 ‘3a “3e30 jee: 9375 ie 155 ‘0610 378 1476 s 2870 & | 992 3006 aa.0 gaa 153 0525 1495, 2s |é6° 2508 100° 3037 lan2r 9531 ete 16 0529 3a 1496 2610 6 ‘3970 x [2e5 ‘soa6 0635 82 1520 x |67° 2538 00 Y [eas ‘9687 ose ies bea 38° s5 675 2657 io.52 ‘2062 1% l250 ‘saa 170669 1540 23 |675 2657 “4130 2 [e503 ‘seaa o 0670 st |se7_"1562_ vs 2860 wo [ids aise 25.4 1.0000 1 oR2946-2NG vormene 1.13Symbols Certain symbols or combinations of symbols may appear on your Volvo Penta Sterdrive or accessory. Itis very important that you understand their meeing r purpose. If any symbol is not clearly uynderstood, see you Volvo Penta Dealer. “Safety Warning” Symbols 2. ® Risk of serious injury =< * Be Careful Polsondus * Follow instructions Fire Hazard Contents Under Pressure “Position Indicator” Symbols Shift Positions NEUTRAL FORWARD REVERSE "Condition" Symbols * Voltmeter Hour Meter * Ammeter Tachometer Ej Voltmeter és Oil Filter & “Instructional” Symbols Fuel Filter * Use gasoline “=~ Read Operator's Manural a * Gasoline is present yp before operating product Oil FillSection 2 Transom Bracket Assembly Table of Contents ‘Anode Replacement . Gimbal Housing Assembly .......0..0+ Cleaning and Inspection Disassembly : Installation Removal Gimbat Ring ‘Assembly . Disassembly = Installation see BAL Removal Pivot Housing Assombly . Cleaning and Inspection Disassembly Installation Removal Service Chart... 22... Specifications . TrinvTitt Cylinders Installation Removal Trim Sender Installation Removal 2-14 and 2.20 29nd 2-14 A Safety Warnings Before working on any part of the transom bracket assembly, read the sec- tion called Safety at the end of this manual. When replacement parts are required, use genuine Volvo Penta parts or parts with equivalent characteristics including type, strength and material. Failure to do so may result in product malfunction and pos- sible injury to the operator and/or passengers. Some screw holes have special Heli-Coif inserts that provide a thread- locking feature. Do not clean Heli-Coil ® holes with a thread tap. This will damage the Heli-Coil® inserts and force their replacement. 24Volvo Penta Special Tools PIN Description '9850608-5 «+++ Retaining Ring Pliers 3850609-3, «Drive Handle (3854349-2 .. «. «Insert Too! 3854350-0 <2... 2. Socket Removal Tool 3854351-8 Rod 9854352-6 6.000.0..1112.1! Slide Hammer 3854353-4 Bearing Puller Jaws 3854355-9 2000000000.121) Removerlinstaler 13854356-7 Driver 3854357-5 “Gimbal Housing Seal Installer 3854358-3 “ Removeriinstaller (3854359-1 ..... ...... Upper Steering Bearing Installer 3854360-9, 211.11 Removeriinstaler 3854361-7 22... Steoring Arm Puller Owatonna Service Tools OEM 4184 Slide Hammer Order From: OTC Division of SPX Corporation 55 Elsenhower Drive (Owatonna, Minnesota 55080 USA ‘Toll free order line: 1-800-533-5338 or 1-800-533- age Sealants, Lubricants and Adhesives Cleaning Solvent Gasket Sealing Compound Loctite Primer Loctite Thread Locking Compound Volvo Penta Grease 3M Adhesive Wheel bearing Grease ‘9M Scotch Grip Rubber Adhesive 1300 ae SterndieeRemave the sterndrive following the procedure in Sterndrive Removal and Installation section in this manual. Ifthe complete transom bracket assembly isbeing rebuilt or replaced, remove engine following procedure in Engine ser- vice manual Trim/Tilt Cylinder Removal \ co not remave wit hydraulic tines oF pla uns hyerauie pres- Sure is released from the tril system, Follow steps below to release hy- Graule pressure. Have a drain pan reagy to catch ful ha wit dain rom tho disconnected lines 7] 1. Futy extend sim eylinder rams. [21 A\ 2. wear satety alasses: Cover the fill plug ® with a shop cloth, and slowly remove it Thore willbe high pressure in the reservolr that could spray hydraulic flui 2] A\ 2. cover the hydraulic lines with a shop cloth. There may be ‘anaueet brite ime aout gues pderepremmepens: Loceancrstc} the lines ® to the pump assembly. Place a pan under the line to catch fluid as. the system drains 4. Remove serew, round wire and retainer ftom the frontal the cylinder. [A15. unscrew pivot pin cap © and litt off titi line cover ©. [B.6. remove screw and retainer © at top of cylinder. Cover fitings with a shop cloth, and disconnect trnvtit lines. 7. Remove and discard timtittine Oxings ®. 7] 8. Unscrew the pivot pin locknut @ and remove the flat washer ®. Pull pivot pin out of cylinder, gimbal ring, and cylinder on opposite side. Remove bushing from forward end of trim cylinder and replace if necessary. Remove cylinder and set aside to drain sma 2a9, Repeat steps 4 thru 8 for the remaining cylinder. Trim/Tilt Cylinder Installation [711 ciamp the pivot pin in a softjaw vise and remove the remaining locknut and washer. Clean the pivot pin, then coat itwith Volvo Penta grease. 2, Replace the cylinder’s bushings if they're damaged, then slide the pivot pin through the cylinders and gimbal ring. [21 3. center the pivot pin, then lightly coat the threaded ends with Gaskat ‘Sealing Compound. instal both washers and two new locknuts. Tighten each locknut until equal amounts of threads are exposed on both ends of the pivot pin, Tighten both locknuts to 120-144 in. Ibs. (14-18 Nem). [B14, Place a new O-ring on the trinvtit cylinder line ftings and attach lines to cylinder. Tighten lin fitings to 64-108 in bs. (9,5-12,2 Nem). Install il line retainer ® and secure with screw. 21s. insta trimtit ine cover ® and pivot pin cap ©. [B16. attach retainer and ground wire to front of trimfit cylinder. Tighten screw securely Note | to fil and bieed the trim cylinders and trim motor reservoir, see Fill- ing and Bleeding Dry System in Trim/Titt Hydraulic System section ofthis, manwal. 24ivot Housing Removal Remove the sterndrive following the procedure in Sterndrive Removal and Installation section in this manual. [B] 1. Turn vertical drive to port. Loosen anchor clamp screw © and slide Clamp to starboard disengaging the remote control shift cable (Ze. Remove shift cable from the pivot and gimbal housing. Remove the ‘small and targe seals © From inside of boat, pull shift cable out of the sleeve and connector assembly. 81]. Disengage the U-joint boot from the lp ofthe pivothousing and push itinside, [BAN «wear satety glasses. Use Volvo Penta Retaining Ring Pliors, P/N 3850608-5, to remove the retainer trom inside of the exhaust boot, then push the boot inside the housing. . Unscrew the nut securing the water hose nipple, and push the nipple through the housing as far as possible. [14] 6. urn gimbal ring to the starboard and remove the ground strap © 12} 7. Use a ¥ in. hex drive wrench or socket and remove both pivot pins. 25Pivot Housing Disassembly [11:. Remove and discard the cooling passage O-ting. [2]2. Unscrew the water drain plug and discard the O-ring, [3] 5. inspect the nyion friction washer on the pivot bosses. Peel off and discard if damaged. Remove and inspect the thrust washer @ underneath. Cleaning and Inspection Clean housing in solvent and dry thoroughly. Remove sealer and/or adhesive from the cooling passage opening, Ujoint bellows opening, and pivot bosses. Note | clean screw holes with solvent only. Athread tap would damage the Heli-Coil inserts and force their replacement. + Drain Hole - Clean thoroughly to allow complete water drainage. + O-ring Seal Groove - Check for sharp edges that would prevent O-ring sealing water passage. + Mounting Studs - Look for damaged threads and loose- ness. + Ground Wire - Check wire ends for frayed or loose con- nections. Repair or replace all suspect components. Pivot Housing Assembly [A] 1. coata new O-ring with Gasket Sealing Compound and place it onthe Grain screw. install the sorew and tighten ito 50-60 i, Ibs. (6-7 Nem), 26[B12 Apply a1 Aahesive sealant to the groove around the water passage, and instal a new O-ring seal. E15. tr the old pivot boss friction washers were removed, make sure a thrust washer @ coated with Volvo Penta grease is installed in each pivot instal two new fiction washers and coat them with Volvo Penta grease. Pivot Housing Installation 1. Position the pivot housing in the gimbal ring. Guide the water tube nipple through the housing, and position the bellows behind their respective open- ings. 212. Align one gimbal ring pivot pin hole with the hole inthe pivot housing. Look inside to see ifthe thrust washer is stil position and not blocking the hole. Screw inthe pivot pin until it seats, do not tighten It at this tkme. [B1s. align and instal the other pivot pin. Tit the housing up and down to See it it moves freely. Use a Ys n, hex socket and tighten the pivot screws to 405-120 ft. Ibs. (142-163 Nem). Note | Hold pivot housing to keep housing from over rotating and damaging bellows and water hose while tightening pivot screws. '9.] 4. The drain hole in the nipple must face down when installed in the pivot housing. [0] 5. Put the water tube through the pivot housing as far as itwill go. Screw ‘on the water nipple nut. Ifthe nipple turns with the nut, or if the nipple end does not protrude through the nut when it's seated, then the square nipple collar is not located properly behind the housing. Loosen the nut and rotate the nipple to reposition it. Make sure the drain hole in the nipple faces down, Tighten the nut to 96-120 in. Ibs. (11-14 Nem).6. To seal the U:-joint bellows against water entry. Apply Gasket Sealing Compound around the complete inner V-shaped lip of the pivot housing, 21317. pur the u-joint beiows through the opening and seat the lip in the groove. Bellows must seal the entre circular opering any fat spot on the lip indicates the bolows has not engaged the V-groove [41 2. pul top of exhaust bellows through the pivot housing, Tit the pivot housing and push the bottom of exhaust bellows through the pivot housing seating the bellows channel around the lip of the pivot housing opening. Any flat spot on the bellows indicates the bellows has not engaged the ip. 5] AN . wear safety glasses, Insert the retaining ting inside the bel lows. Poston the opening upward as shown for socure attachment 6] 10. Attach the pivot housing ground wire to the upper threaded hole on the pont side of gimbal ring. AN sotaty Rotated 28 —Remove trimftilt cylinders and pivot housing following instructions else- where in this section. 7] 1 Turn the gimbal to port and remove the two screws holding the trim sender. Do not attempt to pull out the sender as its leads are secured to the transom bracket. 8] [2] 2. Remove the three screws and lock washers holding the lower steering support bracket @ and pull the bracket of. if i's tight, use a dat punch © and mallet to tap on alternating sides of the bracket utilis free. HO] 3. Remove cotter pin © and steering arm pin ©. Remove ground strap © trom stesring arm. [11] 4, Remove two screws and the plastic gimbal housing cover. 12] 5, Remove two screws and the steering cavity cap. Peel off and discard the foam gasket. [13] 5, Remove the four locknuts and retaining plate from the top othe steer- Ing arm. Unscrew the center steering arm bolt ©(7117, Rest VoWwo Penta Steering Arm Puller, PIN 38543617, on top of the two alignment dowels inside the stering arm, and instal the center bot. Tighten the bott 1 remove the steering arm, Be ready to catch the gimbal ing when the arm comes tree, [2]. Remove the steering arm from inside the boat. Remove thrust washer @ trom the gimbal housing Gimbal Ring Disassembly 1, Remove and discard the O-ring around the upper steering post [3]2. Face the large diameter end © of Volvo Penta Removeriinstaller, P/N '9854985-9, toward the gimbal ring. insert the tool into either tit bearing and. rive it out. Remove the other tit bearing in a similar manner. 4} 3, Remove both trimitilt nylon pivot pin bushings. Use Volvo Penta ‘Two-Jaw Puller, P/N 3854353-4, and Volvo Penta Slide Hammer, P/N 3854355- 9. 5] 4, insert small end of Volvo Penta Remover/installer, P/N 3854355-9, into bearing, and drive out bearing, Gimbal Ring Assembly [611. Light oil the outside of a new lower pivot bearing © and place it in the bote. Use Volvo Penta Installer, PIN 9854958-3 ®, to seat the beating into the bottom ofthe gimbal rng Z]2. Apply Volvo Penta grease tothe outside of two new trim nylon pivot Bin bushings. Use Volvo Penta Installer, PIN 3854358.3, o seat them in the gimbal ring@ 3. Apply Volvo Penta grease tothe inside of both trimvtitnyion bushings: [91].4. Lightly oi the outside of two new tit bearings. Insert a bearing into the ‘gimbat ring from the outside. Insert the blunt end of Volvo Penta Installer, P/N '9854358-3 ®, into bearing. Using a soft face hammer, seat bearing flush to 0.010 in, (0.254 mm) below inner surface of gimbal ring. Repeat procedure for installation of the other bearing. [H)s. tr bushing © around upper steering post is damaged, it can be re- moved by spliting it down one side with a sharp too. Note] when replacing steering post bushing, check upper bearing inside ‘gimbal housing to see if also needs replacement. [1] «. upper steering post Bushing ® was removed, ubricae inside diam- eter ofa new bushing with Volvo Perta grease, and piace bushing ontop of steering post. Install steering arm and center bol. Tighten centr bolt uni bushing seats, then remove center bolt and stering arm Gimbal Ring Installation [10):. coat a new O-ring © with Volvo Penta grease and place it around the base of the upper steering post 21Le. coat the thrust washer ® with Volvo Penta grease and setit over the upper pivot bearing inside the top ofthe gimbal housing. From inside of boat, position steering arm © over the thrust washer. L212. Guide gimbat ring steering post up engaging steering arm and install ccenter bolt finger tight Note | when the gimbal ring is properly centered in the upper bearing, the gimbal studs must be flush or above the top of the steering arm when the bott is finger tight. Ifthe studs are not atthe position described, the upper bearing will be damaged when the center bolt is tightened. 3] 4, Tighten the contor bot o 64-72 bs. (88-98 Nem). [2s . Piace the washer on top of the steering arm, Install four new locknuts and tighten them to 19-15 Ibs. (18:20 Nem) 5] 6, instal a now foam seal on tho undersige ofthe steering cally cap. Caretly align the seal notches with those inthe cap.8] 7, install cap and tighten two mounting screws to 60-84 in. Ibs. (7-9 Nem). Align dowels © of cover with gimbal housing holes © and set the gimbal housing cover in place. Install wo mounting screws and fighten them to 60-84 in. Ibs. (7-8 Nem) 8. Attach ground wire to steering arm inside transom. [7]. apply Volvo Penta grease tothe nylon trust washer and lower pivot post. Sige nylon washer © between gimbal ing ane gimbal housing, Align Pivot post hole of the gimbal ring, gimbal housing, and thrust washer, then Side pvot pest through the gimbal ng and gimbal housing untl tis seated [8] +o, insta the lower steering support bracket. Seat i with a mallet if necessary. Apply upward pressure to gimbal ring and support bracket. Use lower trust washers as a gauge to determine how many wil ft space © between upper surface of support bracket and lower surface of gimbal ring. Note | the support bracket has a protruding lip on its upper surface where itfits over the pivot pin. When checking fit, washer insertion must be done at this point only, otherwise too many shims will be measured and installed, ‘These washers will preload gimbal ring. After determining number, add one extra, then install them in position © Use 2 minimum of one but no more than five washers to shim gimbal ring, [B1 11. attach tne trim cynder ground wites tothe two forward screws @, then instal the lock washers. Screw in all three mounting screws and tighten them to 18-20 ft. Ibs. (24-27 Nem). 9142. Route the trim cylinder ground wire between the cylinder lines and the gimbal ring, Side the ground wire onto the greund screw, then instal the lock washer. Atach the screw tothe port side @ of the gimbal rng anc tighten itsecurely. Trim Sender Installation [10] +. connect an ohm meter to the sending unit connector D. Turn the sending uni convel nut © unt the meter reads 11 7 ohm(12. with tower edge of pivot housing pushed in towards the gimbal housing, insert sending unit control nut into pivot bolt head @. install two trim sender mounting serews @ finger tight [2]. with the pivot housing pushed in towards the gimbal housing, check adjustment of sending unit between pins “A” and °C’. Rotate sending unit to oblain a 11 = 1 ohmreading on the meter, then tighten mounting screws to 18- 24 in. Ibs. (2,0-2,7 Nem) Install trimvtilt cylinders and pivot housing followin where In this section. Gimbal Housing Disassembly Remove trimtilt cylinders, pivot housing, and gimbal ring following i structions elsewhere in this section. Water Hose and Bellows Removal 4] 1.Unscrew clamps © and pull off the U joint and exhaust bellows. [E12 Loosen clamp © on upper end of water intet hose and remove hose from water tube Anode Replacement [Note] the sacrificial zine anode need not be removed unless itis more than Yedoleriorated 51] 1. Remove the two screws, lock washers, flat washers, and the anode. 6 ] 2. clean the mounting surtace, then install the new anode and the attach- ing hardware. Tighten the screws to 12-141 Ibs. (16-19 Nem). ‘Sender Removal 7] 1. Disconnect rubber connector at wiring harness on engine. Record the position of the sending unit wires before removing. Use Volvo Penta Socket Removal Tool P/N 3854350-0 to push terminals out of rubber plug.Note} The use of alcohol or Cleaning Solvent will make socket installation into the rubber plug easier. 812. Remove the retaining clip from the grommet ©. 9}5. Push the grommet out with a screwdriver. Pull the wires through the gr ah hole, cut tie straps securing wites to the trim/tlt lines, and remove the trim sender. Water Tube Removal 10] 1. Remove the two screws © from the water tube retainer. Pull the water tube and grommet out of the gimbal housing. if the grommet sticks, go to the outside of the transom and push it through, 2. If the grommet needs to be replaced, slide it off the water tube. it can be reused if undamaged. Hydraulic Lines and Manifold Removal 11] 1. Remove the two clamps © that secure the lines to each side of the gimbal housing. 12] 2. Unscrew all four lines and remove them from the mani-fold. Remove {and discard te fiting O-rings, Removal ofthe grease extension tune @® may make the servicing ofthe starboard sidelines easier. Clamp ave grip pliers Close to the beering bore (1 and rotate the tube to loosen it. Pry against the plier head to force the tube out ofthe housing 73] [74] s, Remove the tocknut and washer @ that attach the manifold to tne housing, Since the manifold is sealed by an O-ing, use a small dit @ to chive it out ofthe housing from the inside ofthe boat.11s. pul the manitold and fines through the hole 2s far as possible, Tag cone ine @ for reference and note ther rection of routing 5. Unsorew both lines, then discard the fitting O-rings. Remove the manifold O-ring and discard it ‘Steering Bearing, Gimbal Bearing and Seal Removal Note] Do not remove the gimbal bearing or upper steering bearing unless they need to be replaced. Removal of the gimbal bearing and seal do not require disassembly of the transom bracket. Access can be gained by going through the U:joint bellows on an assembled transom bracket. 2111 Use a tie-jaw puller such as Owatonna Too, PIN OEM-£184, to pul out the gimbal housing bearing. Spread the tol jaws between the bearing and inner seal, and expand them tghty behind the beating. Remove and card the bearing 2. Pull the inner seal out in a similar manner and discard it. LBs. Remove the thrust washer from around the top of the upper steering bearing. Use Volvo Penta Installer, P/N 3854360-9 ©), and Volvo Penta Driver, PIN 3854356-7 ©, to remove the bearing, Insert the driver into the installer ‘and position the tool underneath the bearing as shown. Drive the bearing up and out of the bracket 2.16Gimbal Housing Cleaning and Inspection Clean grease and sealer from bearing cavity, seal seat, and manifold cavity ‘Check inner bore diameter for scoring or discoloration that indicates a spin- ning bearing, + Pivot Bearing - Inspect Tefion surface for wear or corro- sion. + Gimbal Bearing - Rollers must spin freely and hub must pivot in all directions; inner diameter must be free of corro- sion. + Hydraulic Manifold - O-ring groove must be free of nicks and burrs; all fluid passages must be clear. + Hydraulic Lines - Lines must be clear and fitings undamn- aged. + Grease Fitting and Tube - must be unobstructed. + Mounting Studs - must be tight and have no thread damage. + Seal Grooves - Check for corrosion, burrs and damaged edges. + Anode - Check amount of deterioration, Clean parts in solvent and dry thoroughly. AN some sctow holes have special Hell-Coi! inserts that provide a thread-locking feature. Do not clean Heli-Coil holes with a thread tap. ‘This will damage the Heli-Coif inserts and force their replacement. Lock- ing Hell-Coils are available only from Volo Penta Parts Department. See your parts catalog, Gimbal Housing Assembly Steering Bearing, Gimbal Bearing and Seal Installation 1] 1. Face tne open end of a now gimtal housing seal toward Volvo Penta Installer, PIN 98543675, anc place it onthe projecting nose ofthe too. Lightly coat the meta! case with Gasket Sealing Compound. 5 | 2. screw the installer onto Volvo Penta Drive Handle, P/N 3850809-3 Drive the seal into the housing until it seats. Coat the seal lip with Volvo Penta grease. oan AN satery Rotates 2174] 3. To ensure adequate lubrication of the gimbal bearing, it must be cor rectly postioned prior to installation. Rotate the outer band untiits slot aligns with the lubrication hole. Scribe a reference mark at this point on the bearing case. [21] 4. screw the seal installation side ® of Volvo Penta Installer, P/N 38549575, onto Volvo Penta Drive Handle, P/N 3850608-9. il the exterior of tne bearing case. Place the Dearing withthe reference mark @ facing the extension tube opening, onto the instal. Drive the bearing int tne housing Unt it seats, Lubricate the bearing with Marine EP Whoa! Bearing Grease through the grease iting onthe starboard sige ofthe housing [B1s. ro instal the upper steering bearing, slide Volvo Penta Installer, PIN 5864360-9 ©, onto Volvo Penta Roc, PIN 2854951-8 ©, then place a now bearing © on the instaler. Lion ol the outside ofthe bearing B16. vovo Penta installer, PIN 9854359-1 ®, will act as a stop to seat the bearing. When postioned inside the steering arm cavity, the recessed side of the tol must face the bearing as shown 417. Face recessed side of Volvo Penta Installer, P/N 3854359-1, down and insertitinto the steering arm cavity from inside the boat. Screw puller rod into the installer unti i's flush with the top of the installer. Hold the rod and. tighten the nut until the bearing seats, Hydraulic Lines and Manifold Installation TB). coat a new o-ving with Gasket Seating Compound and place it on the mano. 2. Lubricate two new O-rings with hydraulic fluid and place them on the hy- © Loctite? or equivalent 13-15 ft Ibs. a \ et int it i 18-20 Ni -84 in. Ibs. ® Loctite® or equivalent i m™ f Sr ? 120-144 in. Ibs. (14-16 Nem) meg} So 108-132 in. Ibs. ssn Cen E LER © P ror (62-71 N-my 7 Nar SP 9 a Fe, 84-108 in, tbs. Lo “ a Nn) 20-25 ft. Ibs. © (27-34 N-m) Ky 105-120 ft. Ibs. (142-163 Nem) @ 6 aerate 18 fi) ‘ feu 18-20 ft. Ibs. 4 (24-27 N-m) \i824 in, ibs, 12,0-2.7 Nem} 84-108 in. Ibs. (9,5-12,2 Nem} 50-60 in. Ibé. (67 Nem) 96-120 in. Ibs. (11-14 Nem) 120-144 in, tbs. ®. (1416Nm) © “@) 2:28Section 3 Upper Gear Housing All Models Table of Contents Cleaning and Inspection . Gear Lash Checking, Correcting Pinion Bearing Carrier Assembly . Disassembly. Service Chart ..- Shift Actuator Housing Assembly .. sees Disassembly. Installation . Disassembly. Shimming Lower Output Gear Pinion Bearing Carrier : : Shift Actuator Housing Special Tools Specifications U-Joint Replacement . Uppor Gear Housing ‘Assembly Disassembly. Oll Sereen.. Stud Replacement Upper and Lower Output Gear Assembly Disassembly Vertical Drive Assembly .. Disassembly .33 Filling 3-36 Romova.... 33 Prossure and Vacuum Check. 3-35 Water Passage Plate Service . Thrust Plates eos Top Cover Upper Output Gear Vertical Movement Gf Upper Drveshatts.... 3.24 A Safety Warnings Before begi end of this manual. ing work in this section, read Safety chapter at Proper installation is important for the safe, reliable operation of all mechanical products. The procedures we recommend and describe in these instructions are effective methods to be followed when installing Volvo Penta sterndrive products. Some of these methods require the use of tools specially designed for the purpose. The special tools should be used when and as recommended. 31Volvo Penta Special Toois | Description PartNo. | ‘Spline Socket 3850598-8 ‘Spanner Wrench 3850604-4 Upper Gear Holder 7 | s886163-5 [Remove rinstaller “| 3860606-9 |Seal Installer - 3860607-7 ‘Shim Too! 3850701-8 [Retaining Ring Pliers 3850608-5 |Ujoint Acaptor Ki 'Fin Adaptor Drift [Deir 'Dritt | 884263-6 884266-8 "Drift Assembly Too! 'Disassembly Too! © 884933-3 {Disassembly Tool _ £84933-3_| ‘Sleeve 284938-2 |Standard Shaft ~9991801-3 Owatonna Service Tools ‘OMC 4835 Ujjoint Toot OEM 4184. Slide Hammer Order From: OTC Division of SPX Corporation 656 Eisenhower Drive ‘Owatonna, Minnesota 55060 USA Toll free order line: 1-800-533-5338 or 1-800-533-0492 32 Sealants, Lubricants and Adhesives Varso! Cleaning Solvent DuraPlus™ GLS Synthetic gear lubricant Volvo Penta Gasket Sealing Compound Loctite Primer Loctite Thread Locking Compound Volvo Penta Grease 3M Adhesive Marine EP Wheel bearing Grease 3M Scotch Grip Rubber Adhesive 1300 Helf-Coit@ Thread insertsSterndrive Removal ‘Toservice components of the upper gear housing, remove vertical drive from transom bracket. Follow the procedure in Sterndrive Removal and installa- tion section in this manval Sterndrive Disassembly 4] 1. Mount the vertical drive assembly in a suitable holding fixture and ‘clamp it securely. Unscrew the lifting eye ®, if one was used, or the dipstick. Discard the O-ting on the dipstick. [4 2] 2. remove the rear plastic cover ©, if it hasn't been removed. Remove the ol level plug © 80 the o reservoir vents when draining. Discard the O-ring 3]. Place a 4 quart drain pan under the lower gearcase. Remove the lower drain plug ©, discard the O-ring, and let the vertical drive drain completely. [Ba remove six sorews, two on either side ©, and two aft (3. Remove the upper gearhousing Upper Gear Housing Disassembly [5] +. Remove the water tube © and grommet @ from the upper housing, Discard the grommet 3-31} 2. Attach Spline Socket, P/N 3850598 @, to the Upper Gear Housing Holder, P/N 3850605 ©. Tighten the set screw © se- curely. 213. Mount the upper gear housing on the holding fixture. Loosen locking screw ®. Rotate and lift fixture shaft © to engage housing upper driveshaft splines. Install and securely tighten the four mounting screws @. Shift Actuator Housing Removal 3] 1. Remove cotter pin @ and clevis pin @ retaining shift link @ to eccentric piston arm @. Move shift link out of the way. 4} 2. Remove four screws ® securing shift actuator housing. Remove the housing from the upper gear housing. 5] 3. Note the position of the shift shoe © during removal. It must be properly positioned during installation or the shift system will not function correctly. 34Pinion Bearing Carrier Removal 6] 1. Remove the four screws @ securing the pi carrier to the upper housing. n bearing 7] 2. Remove the pinion bearing carrier using two screwdri ers. Be careful not to damage the upper housing or the bearing carrier mounting surfaces. 8} 3. Seve any undamaged plastic shims, as they may be reused. Remove and discard the O-ring @. Output Gear Removal 911. Remove the four screws © securing the upper gear housing top cover. Remove the cover. 10} 2. Save any undamaged shims under the cover as they may be reused. Remove and discard the cover seal ®. 11] 3. Push the holding fixture shaft up to engage the upper driveshaft splines. Align the flat on the fixture shaft with the locking screw ®. Tighten the locking screw to prevent the upper gear housing shaft from turning. Remove the LEFT-HAND threaded nut @ on top of the shaft with a 30 mm socket. voraere 35CD 4. Litt upper gear and bearing assembly out of the housing. Remove needle bearings @ from center of bearing assembly after noting bearing orientation (top-to-bottom). Remove and save shims @. They can be reused if they are not damaged Note] Do not mix needle bearings with those of the lower gear and bearing assembly. Premature failure will result if they are intermixed. Bearings should be reinstalled in the same top-to- ‘bottom orientation as they were removed for longevity. 215, Remove cone clutch © and spring ©. Note the word “TOP” © on the top side of the cone clutch. This must face up during reassembly. [31 [41 6. Use spanner Wrench, PIN 3850604, to unscrew the bearing retainer ring that holds the lower gear and bearing assembly in place. Insert the tool into the housing. Use two upper ‘gear housing cover screws to secure the spring loaded arm to the top of the gear housing. As the screws are turned down, alternate between the two screws every two turns. Seat the screws ‘completely, then tighten them securely. [Note] Tighten the holding fixture securely. The bearing retainer ring is tightened to 145-166 ft. Ibs. (197-224 N-m).. [4} [51] 7. attach a % in. breaker bar to the spanner tool and break the retainer ring free. After it turns easily, detach the spring-loaded arm from the top of the housing. Unscrew the er ring and lift it out. Be careful removing the screws. The arm is under tension. [51 8. Remove the tower bearing and shaft assembly. Remove the shims ® at the bottom of the housing. The shims can be reused if undamaged. 361] 9. Turn the lower bearing and shaft assembly over. Push up on shaft to disengage upper driveshaft C-clips @ from ring spacer @ [8] 10. Remove the upper driveshatt C-clips @ and ring spacer @from the shaft 9111. Remove lower gear and bearing assembly. Remove needle bearings @ from the assembly after noting bearing orientation (top-to-bottom). Do not mix needle bearings with those of the upper gear and bearing assembly. Premature failure will result if they are intermixed. Bearings should be reinstalled in the same top-to- bottom orientation as they were removed for longevity. Upper and Lower Output Gear Disassembly 10] 1. Place Remover/Installer, P/N 3850606 @, large diameter end up, in a press. Place the upper gear and bearing assembly (has extra ring ® around bearing) into the tool with the gear facing up. Press the ring off the bearing using Drift, P/N 884263 (. 11] 2, Place Sleeve, P/N 884938 @, large diameter end up, in a press, Place the upper bearing assembly into the tool with the gear facing down. Press the gear from the bearing using Drift, P/N 884263 ©. 3. Follow the procedures in the previous step and remove the lower gear from the bearing. 12] A\ 4. Wear eye protection. The upper driveshaft may be disassembled if needed, by removing the spring C-clip @ and spring spacer ©. vonney ZN Safety Related 37U-Joint Replacement Note} Both U-joints can be repiaced without removing the pinion bearing carrier from the upper gear housing, Removal 11 AN 1. wear eye protection. On the inside of each Usoint arm is a retaining ring. Use a small drift and mallet to remove all eight retaining rings. Discard the old retaining rings and replace them with new ones. 2] 2. Remove the Ujoints requiring replacement. Press out the U-joints with Owatonna Tool, PIN OMC 4635 @, or equivalent. Plot the Dearing cap ‘with open adaptor © from Volvo Penta U-joint Kit, PIN 3850528-3. Follow the instructions provided by the tool manufacturer. [3] [Note] s. bo not press any bearing cap completely through its yoke. When the pressure-side cap is almost through the yoke, remove the U-oint shaf from the tool and pul off the exposed cap with pliers. Rotate the U-joit 180° and press the cross bar inthe opposite dection to remove the rema ing cap. 2] 4. Remove the remaining caps and other Uoint using the Owatonna toolas previously deserved Pay special altrtion othe postion ofthe grease fting in elation to the Ujoint abes. Instaltation Note | Remove all bearing caps from a new U-Joint. Use grease fitting and lubricate U-joint wth Marine EP Whee! Bearing Grease until grease appears a end of all four lobes. This ensures each lobe will receive equal volumes of grease after assembly. [4] 1. inser ujointtobes into center coupler of driveshaft. Make sure grease filing is postioned at a 45° angle to any two lobes, otherwise fitings cannot be reached for lubrication [B12 instait both bearing caps by hend. Slide Usoint back ane forth be- tween caps to be sure they're aligned. 5.]3. Press bearing caps on with Owatonna Tool, PIN OMC 4635, or equiva- lent. Place open adaptor from Volvo Penta Ujoint Kit, PIN 3850628-3, in tool and tighten too! unt! retaining ring groove of one cap completely clears the inside of the coupler. [5] AN 4. wear eye protection. niscard ol retaining rings and replace them with new ones, Attach to cap with pliers or hammer. aA Safety Related 3-86, Remove U-joint from tool and rotate it 180°. Press in opposite cap until the retaining ring of the first cap seats against the yoke, Face the open end of the ring toward the driveshaft and attach it to the cap. If necessary, use @ punch and hammer to seat the ring in the groove. 6. Repeat steps 1 thru above for all remaining bearing caps. Lubricate the Joints with Marine EP Whee! Bearing Grease. 7. Check the U-joint for freedom of movement. Drive the end caps outward against the clips as necessary to ensure freedom of movement. Pinion Bearing Carrier Disassembly 6} 4. Make a U-joint Support © by cutting a 1 in. diameter pipe 27/6 in. long. Slide the support through both yokes, [712 Rest the pinion bearing carrier on top of a vise and clamp the yoke securely B13. Remove the pinion gear retainer screw © using a FTX-600 Torx bit. Discard the screw. Remove the pinion gear retainer © [81]4, Remove the pinion bearing carrier from the U-jint shat [101 AN 5. wear eye protection. Remove the seal C-cip from the pinion bearing carrie by using Volvo Penta Retaining Ring Pliers, PIN 3860608-6. [ic Piace sieeve, P/N 884938-2 ©, in a press with the large diameter up Place a ag inside the tool to protect the gear during disassembly. Place pin- ion bearing carrer into the tool, gear side down, Press out the input gear using Dri, PIN 8842688 © A Safety Related 39 10)[17- Remove the crush sleeve from the input gear shaft and discard it Crush sleeves must not be reused. Proper roling torque cannot be achieved with @ used crush sleeve L216. clamp the input gear and bearing in @ bearing separator, placing the Curved side ofthe jaws behind the bearing. Remove the gear from the bearing using Drift, PIN 684266-8 @) Note } Do not remove the bearing from the input gear unless itis damaged Removal will destroy the bearing. When replacing any tapered roller bearing, the corresponding bearing race must also be replaced, [3]. Piace pinion tearing carer in a press withthe seal facing down Press out the seal and roller bearing using Drift, PIN #84263 © 4} [51 10. instat Disassembly Tool, P/N 884933-3 ©, on tothe end of ‘Shaft, P/N 9991801-3 ©. Place the pinion bearing carrier in a press large diameter down. Press out the small bearing rac. [B1}11. Place sieeve, Pin 884936-2 ©, ina press. Tum the pinion bearing carrier over and place it on the tool. Press the large bearing out using the tools inthe previous step. Upper Hou! 9 Stud Replacement DP-S Models Only 41. Remove the stud to be replaced. L212. Appiy Loctite Frimer'o the threads onthe shortend ofthe stud ® and let air dry. Apply Loctite to the threads. Screw the stud into the housing until 1.140-1.144 in, (28,95-29,05 mm) remains exposed @. 3-10Upper Gear Housing Oil Screen 8} Remove the oil screen @ from the upper housing. Clean and replace as necessary. install the oil screen into the oil passage in the housing. Make sure the screen is secure. Shimming Thrust Plates 31] 1, Remove the upper gear housing from the holding fixture. Check the width across the thrust plates with a Vernier Caliper. Make sure all space between the shims and the thrust plates are removed. This is a shimmed dimension that should be greater than 5.007 inches (12,72 cm), but not exceed 5.036 inches (12,79 em). Note] Do not remove the thrust plates unless the dimension is incorrect. If the dimension is less than 5.007 inches (12,72 cm), add one shim to each side. If more than 5.036 inches (12,79 cm), subtract one shim from each side, [10] 2. To reset the width, pry off four retaining rings and remove the thrust plates. The retaining rings can be reused unless they are broken, Notice that the concave side of each ring faces inside the housing. 11] 3. Underneath each plate is one or more shims. Each shim is the same size .015 in. (0,38 mm). Shims must always be installed in pairs, one on each side of the housing. There must always be a minimum of one shim per side, but no more than four per side. If more than four per side are needed, replace both thrust plates and check the dimension again 4, To determine if shimming is necessary, compare your mea- surement with 5.036 (12,79 cm). 5.036 in. required width -5.012 in. measured width 0.024 in, difference In this example, no shims are required. Since shims are added in pairs, the difference would have to exceed .030 in. (.015 in. x 2) before shims would be needed. Note] Do not exceed’ §.036 in. {12,79 cm) when adding shims. Excessive width will cause interference between the upper gear housing and the transom bracket. 12] 5, Place correct shims on the thrust plates and insert the plates into the housing. Face the concave side of each retaining ring toward the inside of the housing. Push the ring onto the plate stud. Hold the ring with a % in. box-end wrench. Tap the thrust plate with a soft face hammer until the ring seats against the housing. vorBens anShift Linkage Disassembly [41] +. Pisce a fiat biade screwcrver inthe slotted end of the bellorank pin Remove and discard cotter pin ® [2]2. eurout the pin and remove belicrank assembly © and two fat wash- es © [3] s. Remove and discard cotter pin ® securing shift ink © to belicrank assembly ©, Remove flat washer @ then the shift fink. Unscrew the shift fork @ from the end ofthe link. 44, Remove and discard the cotter pin D securing the cube to the bellcrank @. Remove flat washer ® then the cube. Water Passage Plate Service LB this pate is a water passage plate and is not removed for normal ser- vice: If the unit nas a restricted water flow cooling system problem, the plate may be removed to look for debris. A new gasket coated with Gasket Seating Compound must be used for reassembly. Tighten the four screws © to 60-84 in. ths. (6.8-9,5 Nem) Cleaning and Inspection Clean the housing in solvent to remove all sealer from screw holes, gasket surfaces, and O-ring bores. Dry the housing thoroughly Note] Most threaded holes in the upper gear housing have Heli-Coil in- serts. Do not use a thread tap to clean screw holes. Tap will damage the Hell-Coll insert and make replacement necessary. Do not replace with stan- dard non-locking Heli-Coiis; use only those shown in the appropriate Volvo Penta Sterndrive parts catalog + Lock Ring Threads - lock ring must turn freely for full septn. 342+ Cooling Passages - chack for corrosion build-up that would restrict water circulation. inion Bearing Carrier Bore - remove all sharp edges that ‘would cut O-ring + Model ILD. Plate - transfer piate to new gear housing when replacing old housing. + Gears, Shafts and Bearings - inspect gear teeth for ‘cracks and chips or discoloration. If any gear is damaged all must be replaced. They are reptaced as a set. Screw threads on end of shafts must be undamaged. Replace shaft if lock patch is excessively wom. Check for pitting, corrosion and discoloration + Cone Glutch and Shift Shoe - replace if any signs of excessive wear is found Shift Linkage Assembly 1 AN +. Apr votvo Penta grease to the cube shaft ®. Install the cube onthe belciank arm wth the sted hole. Secure wth fat washer and cotler pin @. Bend the ends of the cotter pin for a secure attachment. 7 AN 2. scrow tne shit fork ® onto the shit ink ©. Acjus the shi fork {0.51548 in, (150,8 mm) 3 %tumn © measured from ine centorof tne hole © in the shit fork to the centerline ofthe shift ink end ©. Apply Vol Penta Grease tothe 90° bend ofthe shiflink Determine ifthe stercrive is avighl or feft hand rotation drive. The lnk is installeg on the lft side of the eccentric piston arm for righthand rotation and on te right side ofthe eccentrc piston frmforlefthand rotation. instal te nk. Secure wih a fal washer and coter pin ©. Bend the ends of the cotter pin for a secure attachment. A Safety Related 3-134] 3. apply Voivo Penta grease to the bellorank pin. Place the bellcrank assembly @ inside the housing, Insert the pin into the housing from the star- board side. [Note] the screweriver sot must face away from the housing Z1 AN 4. place two nat weshers ® on the pin between the housing and the starboard side ofthe bellcrank Push the belcrank pin all the way trough the bellrank and int the por side of the upper gear nousing Install a cotter pin © into the pvotpin between the wo washers. Bend the ends ofthe cotter pin fora secure altachment Pinion Bearing Carrier Assembly 3] 1, Ptace he pinion bearing carr ina press wih the large opening up Lighly oi the ouside ameter ofthe small bearing race wih DuraPtus™ GLE Synthetic gear lubricant and settin the cater. Press the race in until seats using Assembly Tool, P/N 884932-5 ©), large diameter up, and Shaft, P/N 0918013 © 4] 2, Turn the pinion bearing carier over and sett inthe press. Lighly oil the oulside ofthe large bearing race with DuraPlus™ GL5 Synthetic gear lubricant and setitin the cartier. Assemble the special ols used inthe previ ‘us step withthe large diameter of Assembly Tool, PIN 864932-6 ©, facing down, Press the race in unt i seats. 5] 3. Coat the pinion gear © shaft with DuraPlus™ GLE Synthetic gear lubricant and setit in the press. Protect the gearteeth, Using dri PIN 884263- 5 @, position the large tapered roller bearing on the input gear and press it until it seats A satety rotates a16 ]4 Place a new crush sleeve @ on the input shait. Note] 4 new crush sleeve must be used to achieve proper rolling torque. TILE) s. of the irge and small roller bearings with DuraPlus™ GLS Syn- thetio gear lubricant. Place the pinion bearing carer on top ofthe input gear Pace the small bearing on top of the input Bearing shaft [216 Press the small bearing onto the shaft using Drift, PiN 824263-5 . tnt there is about 040-060 in (7,0-1.5 mem) bearing carrer end play Note | this is the starting point for determining rolling torque of the pinion bearing carrier. Use caution. Do not press the bearing en too far. Ifthe crush sleeve is distorted by pressing the bearing on too far, proper roling torque cannot be achieved, The carrier will have fo be disassembled and the crush sleeve must be replaced [19] 7. coat the outside surtace of a new seal with Gasket Sealing Compound. Piace the protruding lip @ of the seal into the recess of Seal Installer, PIN 38506077. 12] 8. Press the seal into the pinion bearing carrier untit it seats. 315[1AM 2, wear eye protection. install sea! C-cip into ts groove in the pinion bearing carer using Volvo Penta Retaining Ring Plies, PIN 3850508 5. Make sure the retaining rng seats completely. [21 10. coat he seal lips with Volvo Penta grease [31 [4] 11. piace the u-joint yoke support ® used during disassembly through both yokes and place it in a vise. Carefully insert the U-joint shaft through the seal and engage the splines ofthe input gear 51] 12. Spray the threads of the U-joint shaft and a new pinion gear retainer screw with Loctite Primor N and allow to air dry. [113.piace the pinion gear retainer © onto the top of the input gear. Apply Loctite thread locking compound to the screw threads 7] 14. install the screw and tighten a litle at a time using a Torx Bit FTX500, ‘Turn the pinion bearing carrier while tightening the screw to seat the bearings. Frequently remove the assembly from the vise to check the roling torque Stop when the rolling torque reaches 9-14 in. Ibs. (1,0-1,6 Nem) Note] ifthe rotting torque is exceeded, the pinion bearing carrier will have to be disassembied and a new crush sleeve installed. AN satetynetatea a6Upper and Lower Output Gear Assembly 4. Place the lower gear in a press. Protect the gear face. Lightly oll the inside diameter ofthe bearing with DuraPlus™ GL8 Synthetic gear lbricant. [212 Piace the bearing, numbered side facing up, on the top of: the gear. Press the bearing in place untl it seats, using Dri, PIN 8841686 ©. 3. Repeat the above procedures to assemble the upper bearing assembly LO] 4, Place sieeve, P/N 884938-2 ©, large dlameter end up, in 2 press. Lightly oil the inside diameter of the adaptor ring © with DuraPius™ GL5 ‘Synthetic gear lubricant. Place it ontop ofthe sleeve, flange side up [Els piace the upper bearing ®, gear side down, on top of the adaptor ring © Press the bearing into the edaptor ring untiit seats using Removeriinstaller, PIN 3850605-9 @, and a suitable piece of stee! flat stock. Siero 317Note] The following procedures will set gear position for the input, lower and upper output gears. Record all measurements for future reference. Lower Output Gear Shimming 1} 1. Place the lower gear and bearing assembly, gear side down, on a suitable work surface. Place Shim Tool, P/N 3850701 @, on the assembly as shown. Take a feeler gauge measurement at the outer edge @ of the bearing. Record this measurement. 2] 2. Add or subtract the shimming allowance © on the gear from the measurement taken in Step 1. This is the amount of shims required to properly position the lower output gear in the upper gear housing, [1] [2] [Rete] Because of the location of shims in relation to the gear, use the following information when adding or subtract- ing the etched allowance figure from the measurement in Step 1. © If the etched number is +5, you would SUBTRACT .005 in. from the feeler gauge measurement taken in Step 1. © If the etched number is -5, you would AOD .005 in. to the feeler gauge measurement taken in Step 1. © If the etched number is zero (0), you ADD or SUBTRACT nothing toifrom the feeler gauge measurement taken in Step 1 (EERE Aca / Subtract @ - Feeler Gauge Measurement + © - Shimming Allowance Etched On Gear Amount Of Shims Required Note] Ail mating, thrust and bearing faces must be clean. Shims to be used during assembly must be clean and undamaged. No less than one shim but no more than four shims should be used. Shims to be used must be clean and undamaged. 3418Upper Output Gear Shimming 3] 1. Place the upper gear and bearing assembly, gear side down on a suitable work surface. Place Shim Tool, P/N 3850701 @ on the assembly as shown. Take a feeler gauge measurement at the lower edge © of the adaptor ring. Record this measure- ment. 41 2. add or subtract the shimming allowance © on the gear. from the measurement taken in Step 1. This is the amount of shims required to properly position the upper output gear in the upper gear housing. 3] [4] [Note] Because of the location of shims in relation to the gear, use the following information when adding or subtract- ing the etched allowance figure from the measurement in Step 1. © If the etched number is +5, you would ADD .005 in. to the feeler gauge measurement taken in Step 1. © If the etched number is -5, you would SUBTRACT .005 in. from the feeler gauge measurement in Step 1. © If the etched number is zero (0), you ADD or SUBTRACT nothing to‘from the feeler gauge measurement taken in Step 1. Add / Subtract @ - Feeler Gauge Measurement + © - Shimming Allowance Etched On Gear Amount Of Shims Required Note] qj) mating, thrust and bearing faces must be clean. Shims to be used during assembly must be clean and undamaged. No less than one shim but no more than four shims should be used. Shims to be used must be clean and undamaged. worm 3.19Pinion Bearing Carrier Shimming 1711. Position shim Fixture PIN 3850600 @ on top of the pinion gear, re- cessed side facing up. Using a verner caliper or depth micrometer, measure the actual dimension @ from the top of the tocl to the surface ofthe pinion bearing carter Measure in several laces, then take an average, Stay way from the bolt holes to get an accurate reading. Subtract 600 in frem tis measurement Subtract 2.489 in. Dimension © 500 in. Thickness of Shim Fixture 1,989 in, Actual Dimension L212 a shimming allowance figure © is etched on the pinion (input) gear Addor subtract he shimming allowance rom the actual dimension n Step 1 Note Because of the location of shims in relation to the gear, use the {ellowing information when adding or subtracting the etched allowance figure from the dimension found in Step 1 © Ifthe etched number is +5, you would ADD .008 in. to the dimension found in Step 1 © Ifthe etched number is -8, you would SUBRACT .005 in. from the dimension found in Step 1 © Ifthe etched number is zero (0), you ADD or SUBTRACT nothing to/from the dimension found in Step 4 Add / Subtract 1,989 in. - Dimension found in Step 1 =.002 in. - Shimming Allowance Etched On Gear 1,987 in. - Total 2, Subtract the nominal figure 1.898 from the Total of Step 2 fort.97-1 and. 2.18 ratios ONLY. Subtract the nominal figure 1.971 from Total of Step 2 for ALL OTHER ratios. This figure is the amount of shims required to property position the pinion gear in the upper gearhousing BEDI suptract 4.987 in. - Total Of Step 2 + 1.971 in. - Nominal Figure 016 in. - Amount Of Shims Required 3-204 Note] shims are to be placed between the bearing carrier and the upper {gear housing. No less than one shim but no more than five shims should bbe used. Shims to be used must be clean and undamaged, Upper Gear Housing Assembly Lower Output Gear and Shaft Assembly [3] 1. instat the spring spacer © onto the splined ond of the [upper driveshait with the recessed side facing the helix ®. Install e spring C-clip © on the recess next to the helix. [4] 2. Piace the uoper driveshaft through the lower output gear assembly. The groove @ must be on the same side as the ‘bearing. [5] 3. Lighty oit the lower needle bearings @ with OuraPus™ GLS Syn- thetic gear lubricant. Install the needle bearings onto the upper driveshaft with the same top-to-bottom orientation as when disassembled to ensure longevity. New bearings can be installed with either end up. Push the bearing all The way into the gear and bearing assembly. [B14 Place the cing spacer D on tothe upper diveshelt with the Recess Diacing up [Z}TB15. Piace the two upper diveshatt C-tips ® into the Groove on the driveshait. Move the driveshaft down to capture the C-clips in the recess of the ing spacer. 3:21Lower Output Gear Installation 4][2]1. piace the required amount of shims @ determined in a previous stop into the upper gear housing. Rest the shims on the ledge at the bottom of, the bore as shown, Bz. Pisce the lower output gear assembly into the upper gear housing and restiton the shims. Do Not let the driveshaft drop down into the housing [As Loosen the locking screw ® and adjust the height of the fixture shaft toengage the upper driveshaft. This willnow suppor the upper driveshaft and retain te C-clips Note] Faire to support the driveshaft wit allow the C-clips to fall out. Re- ‘moval of the output gear assembly will be required to reinstall the C-cips. CITB 4. cichty othe bearing retainer ring © with DuraPlus™ BLS Syn- thetic gear lbricant. Installthe ringin the upper gear housing. Thread the ing all the way in by hand until it seats. 5. When fully seated, the bearing retainer ring will be below the bottom edge of the pinion bearing carrier opening. 3.226. Install Spanner Wrench, P/N 3850604 @ and secure the tension arm ®with two upper gear housing top cover screws ©. Tighten the cover screws down evenly, alternating every two turns. Tighten the screws securely. 217. Tighten the bearing retainer ring to 145-165 ft. Ibs. (197-224 N-m). Remove the two retaining screws then remove the wrench. Note] Use caution when removing the retai arm is under spring tension. ing screws as the Cone Clutch Installation 10] 1. Place the cone clutch spring @ around the upper driveshaft. Slide the spring down into the housing until it rests on the spring spacer. 11] 2. identify the end of the cone clutch that is marked with the word “TOP” @. 12] 3. install the cone clutch with the word “TOP” facing UP, onto the upper driveshaft. Slowly let the cone clutch spin down the driveshaft helix until it rests on the spring Upper Output Gear Installation 13] 1. Place the predetermined amount of shims @ to locate the upper output gear into position on top of the upper gear housing. vores 3-23[7112 Place the upper output gear ® on top of the housing and seat the assembly. Be careful not o distur the shims when installing the bearing as- ‘sembly. Note | You may have to loosen the four screws that secure the upper hous- ing to the holding fixture, to center the housing and shaft. This will make in- staliation of the upper output bearing assembly easier [2]. Place the upper needle bearing ® on top of the upper driveshaft. Maintain the same top-to-bottom orientation as during disassembly to ensure longevity, New bearings can be Installed with ether end up, Push the beating allthe way info the gear and bearing assembly Shimming Vertical Movement Of Upper Driveshaft In order to obtain the correct vertical clearance (up and down movement of the upper driveshaft), there are four upper driveshaft nuts with shoulders of different thicknesses. 3)1. Apaty ourapius™ G15 Synthetic gearlubricantto the upper driveshaft threads to prevent galing, Select an upper driveshaft nut © and instalit on the upper driveshaft Note} Nut has a left-hand thread [2 )2. Tighten the nutto 96-110. Ibs, 130-149 N.m. [B12 Push up on the holding fixture shaft to remove the end play in the upper driveshaft. Measure the clearance between the upper driveshaft nut ‘andthe upper output gear bearing ©) The vertical clearance shoul be 0,002 0.010 in. (0,05-0.25 mm). I the clearance is high, install a thicker nut. If the clearance is low, instal a thinner nut The thickness of the nut can be deter- mined by the number onthe top ofthe nut 3-24 at snare0 000 in. 3852301 2 008 in. 3852302 4 016 in. 3852303 6 024 in. 3852375 4. Retighten the nut to the specified torque and measure the clearance again. Note] If the proper clearance is not obtainable with any of the nuts, make sure the upper gear, bearing and bearing support ring are correctly assembled. If the components are correctly assem- bled, the bearing is defective and must be replaced. Pinion Bearing Carrier Installation 6 gear O-ring at this time. Note] Plastic shims will only fit on the align with the carrier bolt holes in one direction. Misalignment of the holes will destroy the shims and possibly cause the gear to be out of position. [21 2. instal the pinion bearing carrier into the upper gear housing and secure with four screws ®. Tighten the screws to 12-14 ft Ibs. (16-19 Nem}. Top Cover Shimming [81 1. Place .040 in. of shims @ (or any other amount) on top of the upper bearing, and record this figure. This will raise the cover enough to make a feeler gauge measurement. 912. Being careful not to displace the shims, install the top cover and push down lightly. Take several feeler gauge readings to determine an average clearance. Record this figure. 3. The specified top cover clearance is .002-.004 in. (0,05-0,10 mm). Take the midpoint of this range (.003 in. - 0,075 mm) and add it to the initial amount of shims. Initial Amount of Shims (Step 1) Midpoint Of Specified Clearance .043 in. - Total vorteg 3-254, Subtract the dimension determined in Step 2 from the total of Step 3. The resulting figure will be the shims needed to set top cover clearance to the specified range. 043 i 027 in. - Total of Step 3 - Clearance Measurement (Step 2) 016 in, - Amount Of Shims To Be Placed Under Top Cover [Note] Use at least one shim, but no more than four shims. 1 5, Place the correct amount of shims on top of the upper bearing. Being careful not to displace the shims, install the top cover and secure with four screws. Tighten the screws to 16-18 ft. Ibs. (22-24 Nem). Checking Gear Lash This procedure will check the relative clearance between the pinion gear and the upper and lower output gears. Lower Gear 2][3] 1. attach a dial indicator to the upper gear housing. Place the indicator tip at the vertical/horizontal midpoint @ of a lower gear tooth. Proper indicator placement is important for an accurate reading. 3] 2. Zero the indicator. With your finger, gently rotate the gear first in one direction until tooth contact is felt, then in the other direction. Do not turn the gear far enough to rotate the U-joint, just far enough to contact the pinion gear in both directions. Correct gear lash is 0.006-0.011 in. (0,15-0,28 mm). Record your measurements. Upper Gear [2] [41 1. Reposition the dial indicator to contact the vertical! horizontal midpoint of an upper gear tooth. [4] 2. zero the indicator. With your finger, gently rotate the gear first in one direction until tooth contact is felt, then in the other direction. Do not turn the gear far enough to rotate the U-joint, just far enough to contact the pinion gear in both directions. Correct gear lash is 0.006-0.011 in. (0,18-0,28 mm). Record your measurements. 3-26Correcting Gear Lash 5] ifboth readings are different, yet within each gear’s specified Tange, gear lash is correct, Gear lash measurements that are incorrect will fall into one of the categories below. Refer to chert and drawing when determining how to change gear lash. Make all shim changes at Position @ first, then at @, ©, © and @ in that order. Determine amount of change by either subtracting range mi point from reading, or by subtracting reading from range mi point. Note] A change to shim © affects gear lash of both upper and lower output gears. A change to shim @ affects gear lash of upper output gear only. A change to shim @) affects gear lash of lower output gear only. One Gear Correct, One Gear Requires Change Positions Requi 5 | Add or subtract same amount of shims at each location indicated, 19 Shim Change Condition ® © © © Lower gear less than range min. Subtract . , * — Reshim Upper gear within range Lower gear greater than range max. Add 7 . * — Reshim Upper gear within range Upper gear less than range min. 7 Add Reshim + Reshim Lower gear within range Upper gear greater than range max. . Subtract * — Reshim Lower gear within range * No Change Required voraeg 3:27Both Gears Incorrect By Same Amount 1 (1) add or subtract same amount of shims at each location indicated. Positions Requiring Shim Change Condition ® © ® © Upper gear greater than range max. Subtract Subtract Reshim =~ —_—Reshim Lower gear less than range min. Lower gear greater than range max. Add Add = Reshim =~ ~—Reshim Upper gear less than range min. Lower gear less than range min. : = * Add * Upper gear less than range min. Lower gear greater than range max. Upper gear greater than range max. * Subtract + * No Change Required 3-28Both Gears Incorrect By Different Amounts 7 2 21] Add or subtract different amounts of shims as required at each location indicated. 9 Shim Change Condition © © © Upper gear greater than range max. Subtract Subtract. Reshim + Reshim Lower gear less than range min. Lower gear greater than range max. Add Add Reshim + Reshim Upper gear less than range min. Lower gear less than range min. Subtract. Add —_Reshim * Reshim Upper gear less than range min, Lower gear greater than range max. Add Subtract Reshim = * _—-Reshim Upper gear greater than range max. * No Change Required vortens 3.29Final Assembly of Upper Gear Housing 1, Remove the pinion bearing carrier and top cover from the upper gear hous- ing, 4]2. Coat the surface of a new top cover gasket with Gasket Sealing Com- pound. Place the gaskel around the upper output gear assembly. Orient the tab ® with the hole init over the oil circulating passage ® as shown. Check the position ofthe shims © to make sure they are in position fer cover instal- lation [2]}s.instatttne top cover and secure with four screws Uncoated with Volvo Penta Gasket Sealing Compound, Tighten the sorews to 16-18. Ibs. 122-24 Nm, [31 4. coat a new O-ring © with DuraPlus™ GLE Synthetic gear lubricant and place itn the O-ring graove inthe pinion bearing carr. Check the posi- tion athe plastic shims © to make sure they are in postion for carrier insta- lation 45. installthe pinion bearing carrier and secure with four screws © coated with Gasket Sealing Compound. Tighten the screws to 12-14 ft. Ibs. (16-19 Nem) 6. Install U-oints following instructions found elsewhere in this section. Shift Actuator Housing Disassembly 1511. Remove shift shoe @ and spring © from the shift actuator hot Note the position of the shift shoe for reassembly. 3:30[5] 2. Remove and discard the shift actuator housing O-ring. 3. Drive the tension pin @ into the eccentric piston until the eccentric piston pin ® can be removed. [8] 4. Remove the eccentric piston pin ® with a pair of pliers. [31 5. Note the eccentric piston’s orientation then remove the piston from the housing. 6. Turn the piston over and tap out the tension pin @. Note] The tension pin must be removed before installation. Do not install a new tension pin without removing the old one from the eccentric piston. Having two pins in the hole will make removal of the new one almost impossible. [14] 7. Remove the shift actuator seal by inserting a screwdriver behind the seal. Twist the screwdriver and remove the seal. Discard the seal. 8, Clean all parts in solvent and dry with air. Inspect all parts for wear. Replace any defective components. voters 331[T1121 coat the outsce case of a new seal with Gasket Sealing Com- pound. Identty the side of the seal that has the larger space @ between the case and lip. This side must face outwards during installation 3112. piace tne shit actuator housing in a press with the seal cavity facing up. Place the seal in the cavity wth the large space @ facing up. Press the seal in place with Orit, PIN 684259-3 ®, large diameter down, untl the too! seats on the Rousing [B. coat the seal tips with Volvo Penta grease B14. install the eccentric piston through the seal and bushing. Orient the piston withthe offset screw © towards the side ofthe housing wth the notch © Align hole © in the eccentric piston pin with the hole © in the eccen- trie piston. Insert the piston pin into the piston until the two holes align. 3-32[81s install the tension pin @. Drive the pin in unti its fush with the top of the piston, 9] [10] 7. instatl the shift shoe spring @ into the hole in the eccentric piston. Install the shift shoe @ on top ofthe spring. Orient the shift shoe as ‘shown with the long edge toward starbord. Note] nike sure the shift shoe is installed correctly as shown, The shift ‘mechanism will not operate propery ifthe shift shoe is installed in any other position [iis coat a new o-ring @ with DuraPlus™ GLS Synthetic gear lubricant and instal tin the O-ring groove on the shift housing Installation [22 1. set the ecceniric piston pin ® on one of the flat areas © on either side ofthe neutral detent ® 3:33To. tnstat the shift actuator housing into the upper gear unit and secure wi four screws @. Tighten the screws to 60-84 in bs. (6,6-9.5 Nem) Shimming Shift Actuator Housing 214. support the eccentric piston arm and remove the shimming screw ©. Remove all shims © form the shift shift shoe stop screw T3171 2. reinciatt ne shit shoe stop screw ®, without shims, Position the eocentre piston pin on one ofthe lat areas either side of the neutral detent. The eccentric piston arm wil be positioned sighlly high or low of hor- zontal, While turning the vetical shaft by hand, finger tighten the stop screw untilits ne longer possible to turn the vertical shaft by hand. Loosen the stop screw until the vertical shaft tums freely again 41}3, using a teeier gauge, measure the distance between the housing and the siop screw. [514. remove the stop serew. Add enough shims to equal the feeler gauge measurement plus one move shimto the screw. Shims come in ene size only Coat the screw threads with Pipe Sealant with Tetfon. Note] No tess than one shim but no more than four shims should be used. [B11 s. insta the stop screw. Support the eccentric piston arm and tighten the stop screw to 10-12 f Ibs. 14-16 Nem). Insure the vertical shaft turns frealy by hand. If not, repeat sleps 1-5 unll proper adjustment is achieved, [71 AN. tach the shittink fork © tothe eccentric pston arm. The hole © on the starboard side is for LEFT-HAND rotation propellers, The hole © on the port side is for RIGHT-HAND rotation propellers. Secure with pin © and cotter pin ®. Bond the ends of the cotter pin for a secure attach- ment. A Safety Related 334Assembly of Sterndrive [1 1. tnstat splined sieeve © with the groove @ facing upward, onto the verlical shaft [21 0) 2. tnstatt and position water grommet ® and supply tube © into upper gear housing. Check ol iter @ for proper instalation [Note] care mustbe used on reassembly of gearcase. lf machined surface is damaged, leakage may occur. 11] 3. Chack to soe if the pivot pin ground spring ® is in position. Service can be done by screwing the spring out or in as needed, [22] 4. attach upper gear housing to the lower gearcase. Engage vertical shatt D splines and water supply tube ©. t [3] s. apply Gasket Sealing Compound to the lower gear case mounting screws, install four hort screws, two on etter ste © of the gearcase, and {i two longer seraws © att Tighten 98-8 screws to 22-24 ft bs. (30-39 Nem) and 7/16-14 screws to 32-40 ft, Ibs, (43-54 Nm) Pressure and Vacuum Testing Sterndrive Before fling drive with gearcase cil, it must be pressure and vacuum tested to verify proper sealing during assembly. Install magnetic drain plug on side of gearcase skeg and oil level gauge at top of drive. Remove the oil level plug at the back of the gearcase. 3-35Pressure Testing 7111. attach a pressure tester (such as a Stevens S-34) toil level hole, and pressurize drive to 3-5 PSI (20,7-34,5 kPa). Rotate propeller shaft and U-joint Shaft to check sealing. If pressure oss is indicated. use a soapy water sole fion or submerge drive in watar to find source. Make necessary repairs then repeat test. 1] 2. It pressure loss is not indicated, increase pressure to 16-18 PSI (110-124 kPa). Again, use a soapy water solution or submerge in water to find source if drive looses pressure. Make repairs as necessary and repeat test Drive must hold pressure before making vacuum test, and must not loose more than 1 PSI (6, kPa) in 3 minutes. Vacuum Testing 1}. Attach a vacuum tester (such as a Stevens V-34) to oil level hole, and pull vacuum to 3-5 inches of mercury (10-16,8 kPa). Rotate propeller and U- joint shat to check sealing, If drive does not hold vacuum, apply aheavy oil to seal and gasket surfaces to find source. Make necessary repairs then repeat test. No loss of vacuum should occur on tow test. To. 1 vacuum oss s not Inccated increase vacuum to 14-16 inches Hg, (47-54 kPa) Again, apply heavy ail fo find eouoe i dive witnot hold vacuum. Maks tonsiraacoca-eauy avtropoetoel Die eet iethocsenorsthen 7 Inch of mercury (8.4 KPa) in minutes. Sterndrive 9 [Note | Do not fill sterndrive with oil unti it passes both pressure and vacuurn tesis, Drives that fal either test will allow water entry when in use and cause subsequent damage to intemal parts 213] 1 Place ctve ina vertical position. Remove the rear plastic cover to allow access to the cil evel plug. Remove the oil evel plug @®. Also remove the dipstick ® at top of dive to help vent the oil reservoir Discard the plug and dipstick seal, Replace them with new ones. 4] 2. Sx Models Only: Remove magnetic drain screw on side of skeg. Discard screw seal and replace with anew one 5 ]3, DP-S Models Only: Remove drain screw at the back of the gearcase. Discard screw O-ring and replace with a new one. Install Fill Adaptor, P/N 3855932-4 ©. 3-362) (6) 7] « Fit drive with OuraPtus GLS Synthetic gear lubricant (meet- ing or exceeding MIL-L-2105C or D, AP! GL-4 or 5) from drain hole. Fill slowly to purge trapped air. Stop filing when the oil level reaches the bottom of the oil level ©, Do not overfill! Note | Fitting drive too quickly may form air pockets that will cause an inaccurate oil level reading. Running drive with improper oll level can result in immediate internal damage. [2131 s. an modets: when oil reaches proper level, stop filing and screw in the level plug and dipstick. This will create an airlock to prevent excessive cil loss while drain plug is installed ‘416. Sx Models Only: Apply Gasket Sealing Compoundto the drain plug, and tighten to 60-84 in. Ibs. (6,8-9,5 Nem). Apply Gasket Sealing Compound {othe level plug and auge. Tighten them to 48-72 in. Ibs. (5.4-8,1 Nem). [8]. pp-s models Only: Apply OuraPius™ GL5 Synthetic gear lubricant to the drain plug O-ring, ostall and tighten drain plug © to 10-15 ft Ibs. (14-20 Nem). 8. Install the sterndrive and adjust the shift system following the instructions under Sterndrive Removal and Installation, [21s Irthe stemdrive is not to be installed, install the shift linkage access cover and secure with three screws ®. Tighten the screws to 108-122 in. Ibs. (12-18 Nem) [10] to. atter drive has been run briefly, racheck oil lovel. Add make-up oil through dipstic opening to Bring oll up tothe proper level somewhere in the range © onthe dipstick 3-37 StaveSpeciica ss Description English Metric | Bera Ten05k vaaane ‘Upper drive shaft nut 96-110 ft b, 130-149 Nm | Draing screw -DP-S 1045 Rb 14.20 Nm | Tower to upper gon | 20-16 22.24% b 30-33 Nm | mi64 32408 43-54 Nm Dipstek and ol level plug 48-72 in b 5.481 Nm | Pirion bearing carder w2aake 16-19 Nm | Shift ackator housing 60-84 in b. 68-95 Nm | Shiflinkage cover 108-132 in b. 4248 Nm | ‘Shimmring screw 1042 8b 14-46 Nm | Top cover 16-18 Rb | 22-24 Nm ee Gasket Sealing Compound Loctite Primer N + Pinion gear retaining screw Loctite + Pinion gear retaining screw Volvo Penta Grease + Seal lips + Shift linkage pivot points DuraPlus Synthetic GL5 Gear Lubricant + Threads, upper gear vertical shaft + Orring, pinion bearing carrier + O-ring, shift actuator housing 3.38 + Dipstick and olf level plug + Gasket, top cover + Screws, water passage plate + Screws, pinion bearing housing + Screw, drain + Screws, lower to upper gearcase + Screws, shift acuator housing + Screws, shit linkage access cover + Screws, top cover Pipe Sealant with Teflon® + Shimming screw + 0.0. all metal case sealsService Chart - Sealants, Lubricants, Adhesives and Torque ValucS <> ® Volvo Penta Grease 96-110 ft. Ibs. ® Gasket Sealing Compound (130-149 N-m) © Teflor® Pipe Sealant © Synthetic GL5 gear oil © Lootite® or equivalent © 3M adhesive or equivalent @ Wheel Bearing Grease SXSterndrive Oil Capacity ©: 71 oz. (2100cc) DP-SStemdrive Oil Capacity ©: 81 02. (2400 cc) 16-18 ft. Ibs. \y 48-72 in. Ibs. ZT (22-24N-m) 15 4.8,1 Nem) sms0- © Le sei be a ee ee eC) re ay ce 4 Ss (B) ®@ © L— 60-84 in, tbs. (416 Nem) (6,8-9,5 N-m) © ® 12-14 ft. Ibs, a ZA list a ® 3-39NOTES 3.40 wreSection 4 Lower Gearcase SX Models Table of Contents Anodes Installation . * 448 Removal ...... Lad Testing and Replacement. 1424 Gear Lash 1445 Lower Gearcase Disassembly .. Installation . Assembly Removal Pinion Shimming Pressure and Vacuum Testing . Propshaft Bearing Housing Initial Shimming .........- Thine sa ai Final Shimming Rolling Torque Setting Final. Setting Initial . Sealants, Lubricants and Adhesives Specifications . Upper Gear Housing Oil Screen. Vertical Drive Filling . : A Safety Warnings Before beginning work in this section, read Safety chapter at end of this manual Proper installation is important for the safe, reliable operation of all mechanical products. The procedures we recommend and describe in these instructions are effective methods to be follawed when installing Volvo Penta sterndrive products, Some of these methods require the use of tools specially designed for the pur- pose, The special tools should be used when and as recommended. a4Volvo Penta Special Tools PIN Description 2850598-8 Spline Socket 3850599-6 Sess. Pinion Shim Fixture 3850600-2 feces Shim Fixture 3850601-0, « Spanner Wrench 3850602-8 0 20.02.0200.200 0001 Gear Lash Extension 38506036 : Retainer Instaltion Too! 3850609-3 Drive Handle 38506101 2.2... Drive Handle 3850611-9 =. Pullor Bridge 38506127 - Puller Jaws, 3850613-5 - Alignment Plate 3850614-3 © + Support 38508168 Remover 3850817-6 Propshatt Bearing Installer 3850818-4 Spline Socket 3850619-2 Guide Piate 3850620-0 . Pinion Installer 3850621-8 - Bearing Cup Installer 3850622-6 Pinion Bearing Remover 3850823-4 Rod 9850824.2 .° Removerinstallor 3850625-9 . Bearing Remover 3850626-7 2 + Shimming Ring 3850827-5 a TIT Seal Installer 3850707-5 *..2.2 Propshait Bearing Housing Remove/Installer 3854864.0 inion Nut Holder 38550984 6222. Pinion Shimsming Fixture 3855859-9 62020000 200020022 Remover Tip 38558607 62.2... Rod, Nut, and Washer Sealants, Lubricants and Adhesives Volvo Penta Sealing Compound PIN 1141570-0 Volvo Penta Grease 828250-1 Loctite Primer N"™ or equivalent Loctite 242™ or equivalent ‘3M adhesive or equivalent DuraPlus™ GL-5 Synthetic Gear Lubricant GM Gear Marking Compound, P/N 1052351 42Lower Gearcase Removal 1] 1. With the vertical drive in the full tilt down position, place a 4 quart oil drain pan under the gearcase. 2 | 2. Remove the cil level dipstick so the oil reservoir can vent while draining. 3] 3. Remove lower oil fill/drain plug. Clean off magnet and let vertical drive drain completely before removing the lower gear- case. 4 | 4, Use the trimttilt system to raise vertical drive to the full tilt up position. A\ Be prepared to support the lower gearcase. When the last, screw retaining the lower gearcase to the upper gear housing is removed, the lower gearcase will be free to drop down. 41[5)} 5, Remove six screws, two on either side @ and two aft ©. Pull off lower gearcase assembly and mount it into a suitable holding fixture. 5] 6. Mark the location of the trim tab (if one is used) with a felt-tipped marker for future reference. Remove the trim tab screw © and trim tab. Lower Gearcase Disassembly Propshaft Bearing Housing Removal 6] 1. Remove screw @ and retainer ©. ner propshaft beai 19 housing [7] 2. Remove propshaft bearing housing set screw © using a Torx 7-27 bit. muy thy Safety Related a3Anode Removal (7121s. remove anode retainer screws @ and retainer ©. Use a Torx 20 bit for the small screw, and a Torx T-40 bit fer the two larger screws. Remove anode © and inspect it if anode is Ya its orginal size (14 deterio- rated), replace it 3114. Using Volvo Penta Propshaft Bearing Housing Remover/installer, P/N 3850707-5, unscrew Propshaft bearing housing counter-clockwise. Note } care must be used to prevent damaging the Propshaft bearing hous- ing threads. Damaged bearing housing threads can damage the internal gearcase threads. 415. Remove, clean and inspect shim © It may be reused if t's not dam- aged. Discard O-ring ©. Propshaft Bearing Housing - Seal and Bearing Removal [511 Use a punch and hammer to remove Propshaf seal from housing Seal will be damaged during removal and must be replaced. [E12. attach threaded rod © (from Volvo Penta Drive Handle, PIN 3850611- )%0 Volvo Penta Two Jaw Puller, PIN 38506 12-7 ©. Slide Volvo Penta Guide Plate, PIN 3850613-5 @D, stepped side facing up, anfo threaded rod. Insert Puller into housing. expand jaws tightly behind beering cup, and pullout cup. Propshaft Bearing Housing - Seal and Bearing Installation (71EB1 1 clean and inspect Propshaft bearing housing. Assemble Volvo Penta Pusher/Puler. PIN 3850623-4 (, Guide Plate, PIN 3850813-5 @ and Seal Installer, PIN 3850627-5 ®, as shown. Face lp of seal toward too and slide seal onto instaler. Apply Gasket Sealing Compound to metal cas- ing of seal Press seal into bearing housing unt it seats. Apply Volvo Penta Grease to the sea lipLSI LE1 2 Appi a tignt coat of DuraPlus™ GL-5 Synthatic Gear Lubricant tothe bearing cup. Using Volvo Penta Pusher/Puller, P/N 3850623-4 (0, Guide Plate, P/N 3850613-5 (I), and Bearing Cup Installer, P/N 914703 (0, press bearing cup into housing until it seats, Propshaft Bearing Removal [40] 1. Pull out and inspect propshatt. [Et] 2. To remove propshatt bearing, screw propeller nut onto shaft to pre- vent thread damage. Support bearing and press propshatt down and out of bearing. Be ready to catch shaft when bearing comes free Propshaft Bearing Installation [2] acpy a tight coat of OuraPtus™ GL-5 Synthetic Gear Lubricant to the \D. ofthe bearing, Side bearing onto propshaft with taper facing the treaded propeller nut end. Rest Volvo Penta Bearing Installer, PIN 3880617-6 ©, on the open jaws of a press support. Position raised lip of installer up; it must contact nose of bearing. To prevent spline damage, slide Volvo Penta Spline Socket, PIN 9850618-4 @®, onto propshaft Insert propshaft into Installer and press propshatt into bearing untl it seats. Intermediate Driveshaft and Water Tube Guide Removal 13] 1. Remove intermediate driveshaft and inspect splines. If damaged, re- place driveshaft Remove inlet water tube ® and grommet ©. Discard grom- met. 4] 2, Remove anode ® and inspec if anode is % is original size (% deteriorated), replace seanane 453, Remove infet water tube seal ® and retainer ©. If seal or retainer are damaged, replace them, (B14, Remove and replace oil passage O-ring © Driveshaft Retainer Removal Using Spanner Wrench, P/N 3850601-0 ©, unscrew retainer and O-ring ©. Discard O-ring. Driveshaft and Gear Removal [)1. screw Votvo Penta Pinion Nut Holder, PIN 3864864.0 ®, onto Volvo Penta Handle, P/N 3850609-3 @. Slide Volvo Penta Alignment Plate, P/N 3850613-5 ®, onto handle B1].2. Insert pinion nut holder pilot into crive gear while turning driveshatt to align pinion nut with holder. Skde Spline Socket, PIN 3860588-8 ©, onto driveshaft. 46“E12, To remove pinion nt. tum driveshaft countr-clockwise TZ 4. Remove and retain pinion nut and pinion. B] [3] 5. it out arivesnatt assembly, then remove propeller shaft gear assembly. The 19 pinion roller bearings may fall out ofthe retainer; remove and retain the roller Bearings. Propshaft Gear - Bearing Cup Removal FI] 1. use 2 tree-jaw puller such as Owatonna Too! PIN OEM-4184, 10 remove the bearing cup and shims Note] the shims will be dariaged during removal and must be replaced on reassembly. FT] 2 bo not remove propshaft gear bearing unless you intend to re- place it. Removal process may damage bearing. Use a bearing separator tp suppor the bearing. insert Volvo Penta Bearing Remover, PIN 2660625-9 @, and Volvo Penta Handle, PIN 3650610-1 ®, into gear, then press gear out of bearing, [22]. do not remove ol slinger trom gear unless you intend to replace It Remove process may damage cil slinger. Use a besring separator to sup- por the ol slinger. and press gear out of oil singer 47Pinion Bearing Removal 2111. acsembte volvo Penta Remover Tip, PIN 3855859-0 ®, Rod ®, Nut © and Washer ©, P/N 3855860-7 and Guide Plate, P/N 3850613-5 ©. Place the remaver tip into the drveshatt cavity under the ip of the lower diveshatt bearing race ©. [212 tiohten the nut © and remove the lower criveshaft bearing race © and shims ©. The shims may be damaged during bearing race removal and should be veplaced [31212 To remove pinion bearing, apply grease to the bearing rollers and place them in the bearing case. Use Volvo Penta PusheriPuler, P/N 3860623-4 @, Guide Plate, P/N 3850613-5 ©, and Remover, PIN ® LEIA\ 4 wear satety Glasses install remover into pinion bearing. Using a hammer, drive pinion bearing down and out of gearcase. Clean and inspect gearcase. Driveshaft Bearing Removal and Installation Note } po not remove driveshaft bearings unless you intend to replace them. Removal process may damage bearings. (B11. Note size, position, and direction of taper of the driveshaft bearings for reinstallation. Using a bearing separator and press, remove bearings AN satety Rotated 4812, Apply a light coat of DuraPlus™ GL-5 Synthetic Gear Lubricant to the .D. of the small bearing. Protect threads of driveshatt by instaling, a pinion nut @ onto driveshaft. Slide bearing onto driveshaft with taper facing the pinion end. Rest Volvo Penta Bearing Installer, PIN 3850617-6 ®, on open jaws of press support. Position raised lip of Installer up; it must contact backside of bearing. Insert driveshaft into Installer, and press driveshatt into bearing unti it seats. 8]. Apply a ight coat of DuraPlus™ GL-5 Synthetic Gear Lubricant to the I'D, of the large bearings. Slide bearing © onto driveshatt with taper facing ‘away from small bearing. Rest Volvo Penta Bearing Installer, P/N 3850617-6 ® on open jaws ofa press support. Position raised lip of installer up; It must contact nose of bearing. Insert driveshaft into Installer, and press driveshaft into bearings unti it seats Pinion Shimming Note] this procedure determines the amount of shims required to property positon the pinion in relation to the propshatt gear. Record the following shimming measurement for the final gear lash check. [2] +. clamp spine Socket, PIN 3850598-8 @, into a vice and slide drveshafinto socket Install small bearing, cup ® onto bearing, Side Pinion Shim Fiture, PIN 3855088.8 ©, onto driveshaft withthe three slots © fac- ing threaded end of ériveshatt 10] 2 install pinion and pinion nut. Tighten pinion nutto 150-160 ft. Ibs. (203-217 Nem). Rotate shim fixture to seat bearing for shimming purposes TH] 3. Check ait three slots with feeler gauge and record each readin’y Average the three recorded eeler Nudge readin, = by addin*y them together, then dividing by three Example: Slot no. 1 = 011 in 028 in. = 3 =.0098 in Slot no. 2 = .008 in (Round off to 009 in.) Slot no, 3 = .008 in, Total 028 in. ag 10 114, Remove pinion gear and discar¢ the nut. 7115, add or subtract the shimming allowance number etched on the gear from the number found in Step 3 the number i etched +5, you would add 006 into the number. the etched number is 6, you would subtract 005 in from the number. If the number is zero (0), do not add or subtract anything trom the number. Example: AdarSubtrac (008 in. figure from Step 3 +.005 in. figure etched on gear 014 in, shims required 6. Record dimension (example: .014 in.) for the pinion bearing shim. Note No less than one shim but no more than five shims should be used to obtain the average recorded shim thickness. Upper Gear Housing Oil Screen 21] Remove the o screen @ from the upper gear housing, Clean and re: place as necessary. instal the oll screen into the oll passage in the upper gear housing, Make sure the screen Is secure. Lower Gearcase Assembly 3] 1. The selected pinion shims @ are installed into the gearcase under the lower small bearing cup 4) [5]. Appiy a light coat of DuraPlus™ GL-S Synthetic Gear Lubricant to the small bearing cup. Install bearing cup © on top of shims with cup taper facing up. Use Voivo Penta Pusher/Puller, P/N 3850823-4 ©, Guide Piate, P/ N3850613-5 ©, and Bearing Cup installer, P/N 3860621-8 ©, to install bear- ing cup. Place Cup Installer on cup, then seat Guide Plate © onto gearcase. Wear Satety Glasses. Use 2 hammer to seat bearing cup.Propshaft Gear - Bearing Installation Note | this procedure determines the amount of shims required to properly position the Propshaft gear in relation to the pinion, Record the following shimming measurement for the final gear lash check. [611 Appiy a light coat of OuraPlus™ GL-6 Synthetic Gear Lubricant to the Propshaf gear and oil slinger. Align the pins © cof ol slinger with the holes of the Propshatt gear. Use Volvo Penta earing Instaler, P/N 3850617-6 ®, and Volvo Penta Propshaft Bearing Instaler, PIN 385017-6 CD, to press oi slinger onto gear unt seated. [7] 2. Apaiy alight coat of DuraPius™ GL-5 Synthetic Gear Lubricant to the bearing, Side new bearing onto Propshalt gear wih taper facing away from gear. Poston nose of Volvo Penta Removerinstaler, PIN 2850624-2 ©, onto bearing, and press bearing onto gear unt itis seated Propshaft Gear Shimming B] 1. Place gear and bearing ® on a fiat surface, Place the bearing race © ontop of the bearing, Rotate the race to seat the bearings. Positon Shim Finture, PIN 3850800-2 @, on top of the gear and bearing assembly, r€- cessed side facing down [2]2. using a depth micrometer, measure the distance from the top of the shim fixture ED to the end of the gear shaft. Subtract .500 in. from this mea- surement. Example: Gibime) 597 in. measurement to end of gear shaft ~ .500 in. thickness of shim fixture 097 in, actual dimension 2. Add or subtract the shimming allowance number etched on the gear ‘rom the actual dimension in Step 2. If the etched number is -5, you would SUBTRACT .005 in. from the actual dimension in Step 2. If the etched num- ber is +5, you would ADD .005 in. to the actual dimension in Step 2. Ifthe fetched number is zero (0), you add or subtract nothing from the actual di mension in Step 2. Example: AdaiSubirs 097 in, actual dimension in Step 2 1000 in, etched number (0) on gear 097 in, Total an 10)44. Subtract the total figure in Step 3 from a nominal dimension of 106 in. This ew total is the number of shims required to position the propshaft gear. (Subtract) 4106 in. nominal dimension 097 in: total from Step 3 009 in. total shims required Propshaft Gear - Bearing Cup Installation (11. setect the correct number of shims to equal your recorded measure- ment. Place shims into recass of bearing cup bore Note] No less then one shim but no more then three shims should be used. [2] 2. Aoply a tignt coat of DuraPus™ GL-5 Synthetic Gear Lubricantto the bearing cup. Place bearing cup on top of shims in lower gearcase. Screw Volvo Penta Bearing Cup installer P/N 3850621-8 ® onto Volvo Penta Handle PIN 3850608-3 ©. Slide Volvo Penta Alignment Plate PN 3850613-5 © onto handle. 3. Use wooden 2x¢ or 2x6 to cushion forward gearcase edge. Drive bear- ing cup in until seated Pinion Bearing Installation 1. Apply Volvo Penta grease to the roller bearings and install bearings into pinion bearing race, [2)2. Api light coat of DuraPlus™ GLS Synthetic oar lubricant to pin- ion bearing. Install pinion bearing © onto Volvo Penta Pinion Installer P/N 385620-0 ©. Slide Volvo Penta Guide Plate P/N 3850610-2 onto Red ©, Nut @, and Washer , P/N 3855860-7. Insert rod into gearcase and screw into installer © [3]. turn nut @ until pinion bearing is seated, then unscrew and remove to's 412[Note] irinstatertunsin bearing, screw Volvo Penta Pion Nut Holder, PIN 3854864-0 ©, onto Volvo Penta Handle PIN 3850609-3 ®. Side Volvo Pena Alignment Disc, PIN 3850013-5 ©, onto handle, Insert into gearcase and hold pinion installer. Driveshaft and Gear Installation [7] [8] +. insta propshat gear and bearing assembly ® into gearcase Position pinion above propshaft geer in gearcase pinion pocket. Engage pi ion teeth ® with propshatt gear teeth. Install diveshatt © into gearcase and engage pinion splines. Note] insert driveshaft carefully so pinion bearing rollers aren't dislodged. 3112, Apply alight coat of DuraPlus™ Gt-6 Synthetic Gear Lubricant to the upper bearing cup. Place cup in housing, and push down untl it seats on driveshaft bearing Driveshaft Retainer Installation 0], screw in driveshaft etainer ® using Spanner Wrench, P/N 3850601- 0 @, and seat upper criveshaft bearing cup. FT] 2. Apply Loctite Primer No the threads onthe dive shaft and let air ry Apply Loctite 242™ adhesive to the threads. Install a new pinion nut onto driveshaft. Screw Volvo Penta Pinion Nut Holder, P/N 3854864-0 ©, onto Handle, PIN 3850609-2 ©. Slide Volvo Penta Aignment Disc, PIN 3850513- 5 ©, onto handle, then inset into propeller shaft gear. 3. Install Spline Socket, P/N 3850598-8 ®, onto driveshaft and tighten pir ion nut to 150-160 ft bs. (203-217 Nem). Setting Initial Rolling Torque Note] this procedure will ensure bearing life by setting the driveshaft roll- ing torque. Turn gearcase so that propshaft bore is vertical. This will en- ‘sure the propshaft gear will not interfere with the pinion rolling torque mea- surement. Record the following shimming measurement for the final roll- ing torque setting.1. Tum driveshaft several times to ensure bearing is seated before each torque reading T]a Tighion driveshaft retainer @ to achieve a driveshaft rolling torque of 24 in. Ibs. (0,22-0,45 Nem). Record rolling torque setting. Initial Propshaft Bearing Housing Shimming Note} this procedure determines the amount of shims required to preload the propshaft bearings, and also ensures bearing life by setting the driveshaft’ propshaft rolling torque. [211 Appiy DuraPtus™ GL-5 Synthetic Gear Lubricantto the threads of the propshaft bearing housing, Use Volvo Penta grease to hold Shim Ring ( 160 in), P/N 3850626-7 © and place Shim Ring on housing. Do not install O-ring at this time. 3] 2, screw in propshatt bearing housing. Attach torque wrench to Volvo Penta propshaft bearing housing Removerinstaller, PIN 3850707-5 ©, at a 90° angle, an tighten housing to 80 ft Ibs. (108.5 Nem). Note] Record the following shimming measurement for the final gear lash check. 4], Determine depth of propshaft bearing housing. Measure from gearcase hub edge © to top of each bearing housing rib ©. Stay away from the bolt holes, Record and average the measurements. Example: Gag) Rib no. 1 = 403 in. 1.208 in. + 3 = .4026 in, Rib no. 2 = 407 in Rib no. 3= 398 in, Total 1.208 in. 4, Round off division figure (example: 403 in.), and add .160 in. (Shim Ring, PIN 3850626-7} to rounded off number (example: 403 in, +160 in, = .863 in). This result will be used later to determine the amount of shims required for the propshatt bearing housing, 2] 5. unscrew propshaft bearing housing and remave Shim Ring, P/N 3850626-7 ©Setting Final Rolling Torque Install propshaft and bearing housing. Use Volvo Penta propshaft bearing hous- ing Remover/instaiter, P/N 3850707-5 ©, and Spline Socket, P/N 3850598-2 ©, to turn driveshaft and tighten bearing housing, This will set final rolling torque for the lower gearcase. Setroliing torque 19-23 in. Ibs (1.58-2,60 Nem for 1.49:1, 1.51:1 and 1.60:1 gear ratio stemdrives and 11-18 in. Ibs. (1,24-2,03 Nem) for 1.66:1, 1.85:1 and 1.95:1 gear ratio sterndrives. Gear Lash Checking [6] 1. The propeller must not turn when checking gear lash. If final roling torque is high enough to make the propeller shaft hard to turn by hand, no additional steps are necessary. If the propeller shaft turns freely, install a Volvo Penta propeller without the thrust washer. Install the brass spacer and prop nut. Tighten the prop nut by hand until the propshatt does not rotate freely. Te. siide Gear Lash Extension, PN 3850602-8 @ onto driveshalt splines, 7 }3. Clamp or hold base of dial indicator onto machined surface of gearcase. Position dial indicator perpendicular to flat surface of gauge arm. Dial indica tor must contact groove ® on gauge arm for an accurate reading. Rotate gauge arm and dial indicator should read between ,005-,012 in. (0,13-0,30 mm). Ifa teading between .005-.012 in, (0,13-0,80 mm) is obtained, remove propeller and continue to page 4-17 Final Propshaft Bearing Housing Shim- ming. Correcting 4. If dial indicator reading is less than .008 in. (0,13 mm) or more than .012 in (0,30 mm}, all shimming operations must be remeasured. If corrections are made in the rechecking of the shimming operations, and a gear lash of 005-.012 in. (0,13-0,30 mm) is obtained, continue to page 4-17 Final Propshaft Bearing Housing Shimming.2. If all rechecked shimming operations are the same as the original recorded shimming operations, and the recorded gear Jash js still less then .008 in. (0,13 mm) or more then .012 in. (0,30 mm), continue with the following procedure: DOES Eee? Subtract the gear lash measurement from .0085 in. (optimum. gear lash measurement), and divide by two. .0085 in. Optimum gear lash measurement -.003 in. Gear lash measurement 0055 in. Result .0055 in. + 2 = .00276 in. correction needed Round off to nearest thousandths of an inch (i.e. .003 in.) if needed. This example requires the addition of .003in. shim under the lower driveshaft bearing cup, and .003 in. shim removed from behind the propeller gear bearing cup. The optimum gear lash measurement is .0085 in.. CES a) Subtract .0085 in. (optimum gear lash measurement) from the incorrect gear lash measurement, and divide by two. (Example Only) .015_ in. Gear lash measurement =.0085 in. Optimum gear lash measurement 0065 in. Result .0066 in. + 2 = .00328 in. correction needed Round off to nearest thousandths of an inch (i.e. .003 in.) if needed. This example requires the removal of .003 in. shim from under the lower driveshaft bearing cup, and .003 in. added behind the propeller gear bearing race. The optimum gear lash measur ment is .0085 in. 416 voresFinal Propshaft Housing Shimming E1 1. Determine depth of propshaft bearing housing. Measure from gearcase bub edge ~ to top of each bearing housing rib A. Stay away from the bolt holes. Record and average the measurements. Example: Rib no. 1 = 443 in. 4.835 in. + 3 = 445 in, Rib no. 2=.447 in Rib no, 3 =_445 in Total 1.336 in. Subtract this figure from first recorded measurement (example: .563 in. - 445 in. =.118 in.). The resutt will be the amount of shims required for the propshaft bearing housing, A 118 in, shims required for the propshaft bearing housing in this example, 2} 2 Apply DuraPlus™ GL-5 Synthetic Gear Lubricant to O-ring © and threads of propshaft bearing housing, Apply Volvo Penta grease to the se- lected shim ring to help hold it in place, then attach shim © to bearing hous- ing. Install assembly into gearcase. 3] 5, instal torque wrench at a 90" angle to Volvo Penta propshaf bearing housing Removeriinstaller, P/N 3850707-5 ©. Tighten bearing housing to 200-226 ft. Ibs. (271-305 N-m). Recheck final total rolling torque to make sure it hasnt changed Note} if final roling torque is too high (more than 23 in. Ibs. (2,6 N.m) for 1.43.1.51 and 1.60 gear ratio vertical drives and 18 in. Ibs (2,03 N.m) for 1.66, 1.85 and 1.97:1 gear ratio vertical drives), remove the propshaft bear- ing housing shim ring and install the next size larger shim ring, Recheck final rolling torque. final rolling torque is too low (less than 19 in. Ib. [1,88 Nem] for 1.43:1, 1.81:4 and 1.60:1 gear ratio vertical drives and 11 in. Ib. [1,24 Nem] for 1.66:1, 1.85:1 and 1.97:1 gear ratio vertical drives), remove the propshaft bearing housing shim ring and install the next size smaller shim ring, Recheck final rolling torque. Propshaft Bearing Housing - Retainer Installation 1. Apply Loctite Primer N to the set screw, let dry, then apply Loctite™ 242. Tighten set screw no more than 42-60 in. Ibs. (4,8-6,8 Nem). Note} gearing housing lip will be distorted or broken if set screw is tight- ened more than recommended. 47