Workshop Manual

Group 40

130S-A, 130SR-A, 130S-B, 130SR-B

130S-C, 130SR-C, 130S-D, 130SR-D

150S-A, 150SR-A, 150S-B, 150SR-B

150S-C, 150SR-C, 150S-D, 150SR-D
 Table of Content

General Information
00-0 General ............................................................................................. 2

Specifications
03-4 Specifications, Power Transmission ............................................ 6

Safety and Other Instructions

05-1 Safety Instructions .......................................................................... 8

Special tools
08-2 Special Service Tools ................................................................... 14

Marine Propulsion
44-4 Drive, Inboard ................................................................................ 18
Upper and Lower Gear Housing, Disassembly ............................... 18
Upper and Lower Gear Housing, Assembly .................................... 41
Miscellaneous .................................................................................. 111
Index ......................................................................................................... 119
References to Service Bulletins ............................................................ 121

7742984 02-2021 © AB VOLVO PENTA 1

00-0 General
General Information

About this Service Manual

This manual contains instructions for standard
versions of sailboat drivelines. The workshop manual
has been produced primarily for use in Volvo Penta
workshops and by Volvo's trained service technicians.
Therefore, users of the manual shall possess basic
knowledge of marine drive systems and be able to
perform the mechanical or electrical tasks associated
with the profession. Volvo Penta is constantly
improving its products and we reserve the right to make
changes without notice. All of the information in the
manual is based on product data available when the
manual was published. All necessary changes and
modifications to the product or changes in service
methods that are added after the manual is printed are
issued in the form of service bulletins.

Spare parts
Spare parts for electrical and fuel systems are subject
to various national safety requirements, such as U.S.
safety regulations. Coast Guard. Original Volvo Penta
spare parts meet these specifications. All types of
damage resulting from the use of spare parts that are
not original Volvo Penta parts for the product in
question are not covered by any warranty given by AB
Volvo Penta.

2 7742984 02-2021 © AB VOLVO PENTA


General information
This Service Manual contains technical data,
descriptions and maintenance and repair instructions
for standard model Volvo Penta products. A list of
these products may be found in the section
Specifications.
The product designation and the serial number and
specification is indicated on the engine decal or type
plate. This information must be included in all
correspondence regarding the product.
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified
personnel. It is assumed that any person using the
Service Manual has a fundamental knowledge of the
product and is able to carry out mechanical and
electrical work to trade standard.
Volvo Penta continually develops its products; we
therefore reserve the right to make changes. All
information in this manual is based on product data
which was available up to the date on which the
manual was printed. New working methods and
significant changes introduced to the product after
this date are communicated in the form of Service
bulletins.
Spare Parts
Spare parts for the electrical and fuel systems are
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts
not approved by Volvo Penta will be compensated by
any warranty undertaking.
7742984 02-2021 © AB VOLVO PENTA
00-0 General
About this Workshop manual
Certified engines
When carrying out service and repair on
emission-certified engines, it is important to be
aware of the following:
Certification means that an engine type has been
inspected and approved by the relevant authority.
The engine manufacturer guarantees that all engines
of the same type are manufactured to correspond to
the certified engine.
This places special demands on service and repair
work, namely:
• Maintenance and service intervals
recommended by Volvo Penta must be
complied with.
• Only spare parts approved by Volvo Penta may
be used.
• Service on injection pumps, pump settings and
injectors must always be carried out by an
authorized Volvo Penta workshop.
• The engine must not be converted or modified,
except with accessories and service kits which
Volvo Penta has approved for the engine.
• No changes to the exhaust pipe and engine air
inlet duct installations may be made.
• No warranty seals (where present on the
product) may be broken by unauthorized
persons.
The general instructions in the Operator's Manual
concerning operation, service and maintenance
apply.
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.
Volvo Penta accepts no responsibility for damage or
costs arising as a result of failure to follow the above
mentioned standards.
3
00-0 General
Introduction
The working methods described in this manual are
based on a workshop scenario where the product is
mounted in a workholding fixture. Maintenance work
is often carried out in situ, in which case - if nothing
else is indicated - using the same working methods
as the workshop.
Warning symbols that occur in the service manual.
For significance, refer to Safety Information.
DANGER!
WARNING!
CAUTION!
IMPORTANT!, NOTE!
are by no means comprehensive since not everything
can be foreseen as service work is carried out in the
most varied of circumstances. We call attention to
risks that may occur due to incorrect handling during
work in a well-equipped workshop using working
methods and tools tried and tested by us.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta
Special Tools are designed to ensure the safest and
most rational working methods possible. It is
therefore the responsibility of anyone using tools or
working methods other than those we recommend to
ensure that no risk of personal injury or mechanical
damage is present, or that malfunction can result.
In some cases, special safety regulations and user
instructions may be in force for the tools and
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no
special instructions about this in the workshop
manual.
By following these basic recommendations and using
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean
product will eliminate many risks of personal injury
and malfunction.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.
4 7742984 02-2021 © AB VOLVO PENTA
Repair instructions
Our Mutual Responsibility
Each product comprises a large number of interacting
systems and components. A deviation from the
technical specification may dramatically increase the
environmental impact of an otherwise reliable
system. It is therefore critical that the stated wear
tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Original Parts are used. The intervals in the care and
maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
special expertise and test equipment. A number of
components are factory-sealed, for among other
things environmental reasons. Warranty-sealed
components may not be worked on without
authorization to perform such work.
Remember that most chemical products, incorrectly
used, are harmful to the environment. Volvo Penta
recommends the use of biodegradable degreasers
whenever components are cleaned, unless otherwise
specified in the Service Manual. When working
outdoors, take especial care to ensure that oils and
wash residues etc. are correctly properly for
destruction.
Tightening torque
Tightening torques for vital fasteners that must be
applied using a torque wrench are indicated in the
Service Manual, chapter Tightening torques and in
the Manual's work descriptions. All torque indications
apply to clean threads, bolt heads and mating faces.
Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
required for fasteners, the correct type will be
indicated in the job description.
Torque, angle tightening
When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
continues through a pre-determined angle.
Example: For 90° angle tightening, the fastener is
turned an additional 1/4 turn in one sequence, after
the specified tightening torque has been achieved.

Lock nuts
Removed lock nuts may not be re-used; they must be
replaced by new ones, as locking properties are
impaired or lost with re-use.
In the case of lock nuts with plastic inserts, the
tightening torque indicated must be reduced if the nut
has the same nut height as a standard, all-metal
hexagonal nut.
Reduce the torque by 25% for bolt sizes of 8 mm or
larger.
In the case of lock nuts with plastic inserts with a high
nut-height (where the all-metal thread is as high as a
standard hexagonal nut), the indicated torque
applies.
Strength Classes
Nuts and bolts are grouped into different strength
classes. Their classification is shown by a marking on
the bolt head. Markings of a higher number indicate
stronger material. For example, a bolt marked 10-9 is
stronger than one marked 8-8.
For this reason, it is important that when bolted joints
are removed they are returned to their original
locations on re-assembly. When replacing bolts,
check the applicable Spare parts catalog to ensure
the correct bolt is used.
Sealing compounds etc.
To ensure service work is correctly carried out, it is
important that the correct type of sealants and locking
fluids are used on joints where such are required.
In each service manual section concerned, the
sealants used in product manufacture are indicated.
The same sealants, or sealants with equivalent
properties, must be used for maintenance work.
A service technician should have a basic knowledge
of how sealing compounds are handled, and are able
to assess the condition of existing seals.
Make sure that mating surfaces are dry and free from
oil, grease, paint and anti-corrosion agent before
applying sealant or locking fluid. Always follow the
manufacturer's instructions regarding applicable
temperatures, hardening times and such.
Two basic types of compound are used:
RTV preparations (Room Temperature
Vulcanizing).
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV
sealants are completely visible when the part has
been removed. Old RTV sealant must be removed
before the component is sealed again. Use
denatured alcohol.
7742984 02-2021 © AB VOLVO PENTA
00-0 General
Anaerobic agents.
These agents cure in the absence of air. These
preparations are used when two solid components,
e.g. two cast components, are fitted together without
a gasket. Common uses are also to lock and seal
plugs, stud threads, taps, oil pressure monitors etc.
Hardened anaerobic preparations are vitreous and
for this reason, the preparations are colored to make
them visible. Hardened anaerobic preparations are
highly resistant to solvents, and old compound
cannot be removed. On re-assembly, it is important
to carefully degrease and wipe dry components first,
before applying new sealant in accordance with the
instructions.
Safety regulations for fluorocarbon
rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings, for example.
When fluorocarbon rubber is exposed to high
temperatures (above 300°C/572°F), hydrofluoric acid
can form. This is highly corrosive. Contact with the
skin can result in severe chemical burns. Splashes in
your eyes can result in corrosive wounds. If you
breathe in the fumes, your lungs can be permanently
damaged.
WARNING!
Seals must never be cut with a torch, or be burnt
afterwards in an uncontrolled manner. Risk for
poisonous gases.
WARNING!
Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles. Handle the
removed seal in the same way as corrosive acid. All
residue, including ash, can be highly corrosive. Never
use compressed air to blow clean.
Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
water before removing them.
The following seals are most probably made from
fluorocarbon rubber:
Seal rings for the crankshaft, camshaft, idler shafts.
O-rings, regardless of where they are installed. O-
rings for cylinder liner sealing are almost always
made of fluorocarbon rubber.
Please note that seals which have not been
exposed to high temperature can be handled
normally.
5
03-4 Specifications, Power Transmission

03-4 Specifications, Power Transmission

General Tightening Torques
M6 standard bolt 10 Nm
M8 standard bolt 24 Nm
M10 standard bolt 48 Nm
M12 standard bolt 85 Nm
M14 standard bolt 140 Nm
M16 standard bolt 220 Nm

IMPORTANT!
Check bolts that will be re-installed. Damaged bolts with e.g.
shear marks under the heads, must be scrapped.

Technical Data
General Data

Type Designation 130S-A, 130SR-A, 130S-B, 130SR-B, 130S-C, 130SR-C, 130S-D, 130SR-
D
150S-A, 150SR-A, 150S-B, 150SR-B, 150S-C, 150SR-C, 150S-D, 150SR-
D

Weight
130S 26.5 kg
150S 27 kg

Cog flank play

Lower gear,
pinion drive - gear wheel 0.10 – 0.20 mm
Upper gear
input front drive - output gear wheel 0.12 – 0.27 mm
input rear drive - output gear wheel 0.12 – 0.27 mm

Preload (turning resistance)

Input shaft
new bearings 1.0 – 1.4 Nm
used bearings 1.0 – 1.4 Nm
Output shaft (upper gear)
new bearings 0.1 – 0.5 Nm
used bearings 0.1 – 0.5 Nm
Propeller shaft
new bearings 0.3 – 1.6 Nm
used bearings 0.3 – 1.6 Nm

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 03-4 Specifications, Power Transmission

Lubrication system
Oil grade and viscosity SAE 15W-40
Oil volume, approx.
130S, 150S approx 3 liters

Special tightening torques

Upper gear housing, split plane 22 Nm
Gear shift mechanism 20 Nm
Clamp screw, gear shift arm 22 ± 1 Nm
Rear cover 14 Nm
Bolt, input shaft 50 Nm
Nut, output shaft 50 Nm
Upper gear housing - intermediate plate 22 ± 1 Nm
Upper gear housing - lower gear housing 22 ± 1 Nm
Nut, vertical shaft 50 Nm

Pinion nut
130S, 130SR 110 Nm
150S, 150SR 240 Nm
Propeller bearing housing 28 Nm
Oil drain plug 10 Nm

7742984 02-2021 © AB VOLVO PENTA 7

05-1 Safety Instructions

05-1 Safety Instructions

Safety Information
This workshop manual contains repair instructions,
descriptions and technical data for products or product
designs from Volvo Penta. Check that you have the
correct workshop manual.

Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.

!
This symbol is used in the service manual and on the product to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:

DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.

CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.

IMPORTANT!
Is used to make you aware of something that may cause minor damage or a minor
malfunction to the product or property.

NOTICE! Is used to make you aware of important information that will facilitate the work
or operation in progress.

8 7742984 02-2021 © AB VOLVO PENTA

 05-1 Safety Instructions

This symbol is used on certain functions to indicate the following: Performance of this operation requires prior
theoretical and/or instructor-led training. Contact your local training organization for further information.

This symbol is used when VODIA computers must be used for fault tracing or programming.

This symbol is used on certain functions when there is a requirement for further instructions before work is
begun.

A compilation of safety precautions that must be taken and risks which you must be aware of is presented
in the following pages.

7742984 02-2021 © AB VOLVO PENTA 9

05-1 Safety Instructions
Immobilize the engine by turning off the power
! supply with the main switch(es) and lock it
(them) in the off position before work is begun.
Place a warning notice at the main switch.
As a general rule, all service operations must be
! carried out with the motor stopped. However,
some work, such as adjustments, will require
the engine to be running. Approaching a
running engine is a safety risk. Remember that
loose clothing and long hair can fasten in
rotating parts and cause serious personal
injury.
Beware of hot surfaces (exhaust pipes,
! turbocharger, loading air pipe, pre-heaters,
etc.) and hot liquids in supply lines and hoses
on engines that are running or have just
stopped).
A careless movement or a dropped tool may, in
the worst case, result in personal injury when
working in the vicinity of a running engine.
Make sure that all warning and information
! decals on the product are always visible.
Replace decals that have been damaged or
painted over.
Avoid getting oil on the skin! Protracted or
! repeated exposure to oil can cause skin to
become dry. Irritation, dryness, eczema and
other skin problems may then result. Used oil is
more dangerous than fresh oil from a health
aspect. Use protective gloves and avoid oil-
soaked clothes and rags. Wash regularly,
especially before eating. Use suitable
protective creams to counteract skin dryness
and to aid dirt removal.
Stop the engine and disconnect the power at the
! main switch(es) before working on the electrical
system.
10
Avoid opening the coolant filling cap when the
! engine is hot. Steam or hot coolant may spray
out and the system can lose pressure. Open the
filler cap slowly, and release the pressure in the
cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed while the engine is hot,
Hot oil can cause burn injuries. Avoid getting hot
! oil on the skin. Make sure that the lubrication
system is not under pressure before any work
is begun. Never start or run an engine without
the oil filler cap in place. Hot oil under pressure
can spray out.
Never start an engine without the air filter in
! place. The rotating compressor turbine in the
turbocharger can cause severe injury. Foreign
objects entering the intake ducts can also cause
mechanical damage. Install all protective
covers before starting the engine.
Only start the engine if the surrounding
! ventilation is satisfactory. When operating in a
confined space, exhaust fumes and crankcase
gases must be led away from the engine
compartment or workshop area.
The majority of chemicals, e.g. engine and
! transmission oils, glycol, gasoline, and diesel
oil, together with chemicals for workshop use
such as degreasing agents, paints and
solvents, are health hazards. Carefully read the
instructions on the product packaging! Always
follow the product's safety instructions e.g. the
use of protective masks, goggles, gloves etc.
Make sure other personnel are not exposed to
substances that are harmful to health. Ensure
good ventilation. Handle used and leftover
chemicals in the prescribed manner.
Connection adjustments must be made with the
! engine stopped.
7742984 02-2021 © AB VOLVO PENTA

Always use protective goggles when carrying
! out work where a risk of splinters, grinding
sparks, splashes from acid or other chemicals
is present. Your eyes are extremely sensitive;
injury may cause blindness!
Never use start gas or similar products as a
! starting aid. They may cause an explosion in the
inlet manifold.
All fuels, and many chemicals, are flammable.
! Never allow open flames or electrical sparks in
the their vicinity. Gasoline, certain solvents and
hydrogen from batteries are extremely
flammable and explosive in the right
concentration in air. No smoking! Ensure the
work area is well ventilated and take the
necessary safety precautions before welding or
grinding work is begun. Always ensure that
there are fire extinguishers close at hand in the
work area.
Batteries must never be exposed to open
! flames or electrical sparks. Never smoke in the
vicinity of the batteries. When charging, they
generate hydrogen gas, which is explosive
when mixed with air. This gas mixture is very
easily ignited and highly explosive. A spark,
which can be caused by incorrect battery
connection, is enough to cause the battery to
explode and cause serious damage.
Do not touch the connections during a starting
attempt. Spark hazard! Do not lean over
batteries.
Never mistake the positive (+) for the negative
! (-) battery post when installing batteries.
Incorrect pole connections can result in serious
damage to electrical equipment. Refer to the
wiring diagram.
Always wear protective goggles when charging
or handling the batteries. The battery electrolyte
contains sulfuric acid, which is highly corrosive.
Rinse immediately with plenty of water and
soap if battery electrolyte comes into contact
with unprotected skin. If you get battery acid in
your eyes, flush at once with a generous
amount of water, and get medical assistance at
once.
7742984 02-2021 © AB VOLVO PENTA
05-1 Safety Instructions
Never start the engine with the valve cover
! removed. There is a risk of personal injury.
Stop the engine before working on the cooling
! system. Marine engines: Close the seacock/
cooling water inlet valve before starting work on
the cooling system.
Ensure that rags soaked in oil or fuel and used
! fuel and oil filters are stored safely. Oil-soaked
rags may ignite spontaneously in certain
conditions. Used fuel and oil filters are
environmentally hazardous waste and must be
taken to an approved waste management
facility for correct handling, as must any used
lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Never work alone when installing heavy
! components, even when using lifting equipment
such as lockable blocks. Two people are usually
required when using a lifting device; one to
operate the lifting device and the other to make
sure the components do not collide with objects
and suffer damage during the hoist.
Use the loops on the engine when lifting it.
! Always check that the hoisting equipment is in
good condition and has the capacity to lift the
engine (engine weight including gearbox and
any auxiliary equipment installed). The engine
must be lifted with a properly adjusted lifting
boom to ensure safe handling and avoid
damage to components fitted to the top of the
engine. All chains or wires must run parallel to
each other and as perpendicular to the engine
as possible. If the engine has equipment fitted
that alters its center of gravity, special lifting
devices may be necessary to achieve the
correct balance for safe handling. Never carry
out any work on an engine that is only
suspended by lifting equipment.
11
05-1 Safety Instructions
The components in the electrical and fuel
! systems on Volvo Penta products are designed
and manufactured to minimize the risk of fire
and explosion. The engine must not be
operated in areas where there are explosive
materials or gases.
Only use fuels and lubricating oils as
! recommended by Volvo Penta. Refer to the
operator's manual for the product concerned.
Using fuels that are of a lower grade may
damage the engine, the injection pump and the
injectors. In the case of diesel engines, low-
quality fuel may cause the control rod to stick
and the engine to overrev with the risk of engine
damage and personal injury as a result. Low-
quality fuel and oils may lead to higher service,
maintenance and repair costs.
Under no circumstances may fuel pipes be bent
! or straightened. Cracks may occur. Damaged
pipes must be replaced.
12
Take extreme care when searching for fuel
! system leaks and testing fuel injector nozzles.
Wear safety goggles. The jet from a nozzle is
under very high pressure and has great
penetration power. Fuel can penetrate deep
into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).
Never use a high-pressure washer to clean the
! engine.
Pay attention to the following when using a high-
pressure washer on components other than the
actual engine: Never aim the water jet at seals,
rubber hoses or electrical components.
When overhauling an engine, perform leakage
! and function checks as necessary.
7742984 02-2021 © AB VOLVO PENTA
 05-1 Safety Instructions

7742984 02-2021 © AB VOLVO PENTA 13

08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on
the drive. The special tools can be ordered from AB
Volvo Penta by specifying the tool number concerned.

P0001805

P0001806

884143 Handle 884161 Slide hammer 884265 Drift 884359 Drift

884611 Adapter 884721 Extractor 884723 Counterhold 884726 Expander ring

884752 Drift 884753 Plate 884754 Drift 884760 Puller

884830 Splined socket

884777 Drift (small) 884833 Drift 884959 Drift
Splined socket 130S

14 7742984 02-2021 © AB VOLVO PENTA

 08-2 Special Service Tools

P0001812

885178 Circlip pliers

885370 Drift 885377 Press tool 885474 Fixture
(small)

885475 Fixture 885479 Counterhold 885480 Fixture 885481 Plate

P0001816

885523 Measurement
885560 Sleeve 885568 Adapter plate 885571 Fixture
fixture

P0009017

885572 Measurement 885849 Counterhold 885850 Counterhold 885851 Puller

fixture Only 130S Only 130S

885852 Puller 885853 Counterhold 885854 Drift 885870 Alignment tool

7742984 02-2021 © AB VOLVO PENTA 15

08-2 Special Service Tools

P0001857

3850617 Mounting tool

9991801 Standard handle 9992584 Counterhold 9995028 Drift
Only 130S

22563001 Drift (two-piece) 88820004 Puller 88820005 Splined socket (small) 88820007 Fixture

88820012 Measurement fixture

Only 130S
88820009 Drift 88820010 Fixture 88820014 Press tool
88820013 Measurement fixture
Only 150S

16 7742984 02-2021 © AB VOLVO PENTA

 08-2 Special Service Tools

Other Equipment
The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number
indicated.

P0002938
P0002937

P0006821

885511 Roller 885516 885531 9985472

Gasket scraper Pressure testing kit Depth micrometer

P0001880 P0001877
P0001879 P0001875

9985472 9998081 9999696 Magnetic 9989876

Depth micrometer Torque wrench stand Dial indicator

P0001882
P0001876 P0001870

88820006
9992520 Stand 3807716 Marking dye Dial gauge
(long tip)

7742984 02-2021 © AB VOLVO PENTA 17

44-4 Drive, Inboard

44-4 Drive, Inboard

Upper and Lower Gear

Housing, Disassembly
Upper and Lower Gear Housing,
Disassembly
Tools:
9992520 Stand
88820010 Fixture
1 Fit the attachment.
Attach it to the frame.

P0026568

2 Clean the outside of the upper and lower gear

housings.
Remove the drain plug and drain the oil.
Discard the O-ring.

P0026569

18 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

3 Remove all screws on the underside of the drive's

dividing plane.

P0026570

4 Split the drive.

Save the shims (1) and note the thickness of the
shims.
Lift away the splined socket (2). Discard the
gasket

P0026571

5 Remove the intermediate plate and remove the

rubber seal.
Check the rubber seal for cracks and wear.

WARNING!

The rubber seal should be changed every seven

years, or earlier if defects are found.
Discard the O-rings.

P0026572

7742984 02-2021 © AB VOLVO PENTA 19

44-4 Drive, Inboard

Upper Gear, Overhaul

Disassembly
IMPORTANT:

Mark the components when disassembled, to avoid

mixing them up.
Note the thickness and position of all the shims in the
gear housing when you are working. There is a
template for this at the end of the manual.

Tools:
884830 Splined socket (small)
885178 Circlip pliers (small)
885377 Press tool
885474 Fixture
885481 Plate
885560 Sleeve
885849 Counterhold
3850617 Mounting tool
9991801 Standard handle
9992520 Stand
9995028 Drift
22296432 Counterhold
1 Install the fixture on the gear case.
Install the fixture in the stand.

P0026573

20 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

2 Lift off the rear cover. Discard the gasket. Keep

the shims in a safe place.
Put the gear selector in neutral and remove the
gear mechanism.

P0026574

3 Remove the upper part of the gear housing. Tap

the input shaft with a plastic-faced mallet to break
the adhesive joint between the housing halves.

P0026575

7742984 02-2021 © AB VOLVO PENTA 21

44-4 Drive, Inboard

4 Remove the plug and slide the selector fork shaft

out.

P0026576

5 Lift the input shaft out.

Discard the seal ring.
Save the shims and note the thickness of the
shims.
Remove the outer bearing races.

P0026577

22 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

6 Place the splined socket in a vice. Put the input

shaft in the splined socket.
Remove the screws and washer and shims. Note
the thickness of the shims.
Clean all traces of locking fluid off the threads.

P0026578

7 Put the input shaft in a press, with the splines

facing down.

P0026579

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44-4 Drive, Inboard

8 Press off, in one and the same operation:

• tapered roller bearing
• sintered washer
• needle roller bearing
• spacer sleeve
• needle roller bearing
• spacer ring
• shims
• rear gear wheel unit
• rear friction plate unit
• clutch unit
• front friction plate unit
• front gear wheel unit
P0026584
Use drift 9995028.
Save the shims and note the thickness of the
shims.
9 Remove the wedge from the shaft.

P0026585

24 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

10 Lift off the shims, spacer ring and needle roller

bearing.
Save the shims and note the thickness of the
shims.

P0026586

11 Press off:
• the needle roller bearing race
• the spacer
• the needle roller bearing with needle roller
bearing race
• sintered washer
• tapered roller bearing
Use the drift and abutments.

P0026587

7742984 02-2021 © AB VOLVO PENTA 25

44-4 Drive, Inboard

12

P0026588

13 Remove the front and rear gear wheels from their

respective flange drives as follows:
Press the sintered washer down with a press tool.
Remove the circlip with circlip pliers.

P0026589

26 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

14 Lift away:
• the sintered washer
• the two disc springs
• the washer.
Remove the retainer ring.
Lift away:
• the spacer
• the shims
Save the shims and note the thickness of the
shims.

P0026590

15 Tap the gear off the flange with a plastic faced

hammer.
Save the shims and note the thickness of the
shims.

P0026591

7742984 02-2021 © AB VOLVO PENTA 27

44-4 Drive, Inboard

16 Remove the three springs (1) and the two holders

(2) and (3) from the clutch unit. Be careful to save
the balls, three in each holder.

P0026592

NOTE! Place the hub (4) with the clutch plate (5)
in a cloth or similar before separating them, to
prevent pins and springs from flying away.
Carefully separate the hub and clutch plate.
Save the pins and springs.
17 Lock the slotted nut with abutment 885 849
(130S-A/B).
For the remaining models use abutment
22296432. Do not screw the screws in all the way,
the abutment must be able to move axially.
Undo the nut by turning the shaft clockwise with
the splined socket.

P0026598

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 44-4 Drive, Inboard

18 Remove the abutment and slotted nut.

Press out the shaft, using a drift.

P0026593

19 Remove the lower bearing, shims and spacer

sleeve.
Save the shims and note the thickness of the
shims.

P0026594

7742984 02-2021 © AB VOLVO PENTA 29

44-4 Drive, Inboard

20 Press out the upper bearing race with plate and

standard shaft.
Save the shims and note the thickness of the
shims.

P0026595

21 Turn the gear housing over and press the lower

bearing race out.

P0026596

30 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

22 If the upper bearing needs to be replaced, remove

the bearing with a knife puller.

P0026597

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44-4 Drive, Inboard

Upper gear, inspection

1 Check all bearings and gear wheels.

P0026599

2 If the sailboat drive is to be fully renovated, it is

recommended that the front and rear friction plate
packages and the four thrust washers should be
replaced.

P0026600

32 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

3 Measure the wear on the sliding surfaces of the

gear selector fork.
Max permissible wear 0.2 mm.

P0026601

4 Check the wear on the cam of the gear

mechanism, see Shift mechanism,
overhaul, page 34.

P0026602

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44-4 Drive, Inboard

Shift mechanism, overhaul

Disassembly

Tools:
885523 Measurement fixture
88820009 Drift
1 Undo the clamping screw and remove the
selector arm.
Clean any paint residue off the shaft and then
separate the shaft/cam from the housing.

P0026603

2 Carefully prise out the seal ring with a

screwdriver.

P0026604

34 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

3 Check the wear on the cam, using the

measurement fixture.
Thread the fixture onto the cam. Tighten the
socket cap screw slightly, to eliminate any
clearance between the fixture and the cam.

P0026605

4 Measure as shown, if the play exceeds 0.6 mm

change the cam.

P0026606

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44-4 Drive, Inboard

Assembly
5 Put the gear change mechanism on two plates
(separated slightly so that the tension pin is free)
and press the seal in with a drift. Turn the seal as
shown.
Align the drift as shown in the illustration, and
press until the drift bottoms against the plates.

P0026607

6 Grease the bore and the seal ring liberally with

grease, part no: 828 250.
Install the cam and the selector arm.
Angle the selector arm as in one of the two
alternatives in the illustration (depending on what
the boat installation looks like) and make sure that
the clearance between the arm and the housing
is at least 0.5 mm.
IMPORTANT:

Tighten the clamping screw.

Tightening torque: 22 Nm

P0026608

36 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Gear shift mechanism, adjustment

1 Check that the clutch plate is in neutral.
Install the gear mechanism as shown in the
illustration. Roughly adjust the position by
centering in the screw holes. Tighten the nuts to
about 10 Nm (it should be possible to fine adjust
the position of the gear mechanism by lightly
tapping it with a plastic-faced mallet).
IMPORTANT:

The position of the gear mechanism must be fine

adjusted as in the points below, to reduce wear
on the selector fork and clutch plate.

P0026661

2 Attach measurement fixture 885 870. The fixture

can be installed along or across the reverse gear,
depending on how the gear shift arm is installed.

P0026662

7742984 02-2021 © AB VOLVO PENTA 37

44-4 Drive, Inboard

3 Put the gear shift mechanism in the neutral

position.
Find the gear shift arm “neutral position” by
turning the mechanism carefully in each direction
(without engaging a gear). Mark up the end
positions as in the illustration.
NOTE! If you put masking tape on the measuring
fixture, the markings will be more easily visible.

P0026663

4 Take the end positions of the gear arm with the

gear engaged by engaging the gear and gently
turning the gear arm back until contact is obtained
with the clutch plate. Mark this position and repeat
the procedure with the opposite gear position.

P0026664

5 Measure the distances between A and B as

shown in the illustration.
The permissible values of the A and B dimensions
are not more than 24 mm.
In addition, the difference between the two
dimensions must not exceed 3 mm.
Example:
A = 23.1 mm
B = 22.3 mm
A - B = 23.1 - 22.3 = 0.8 mm

P0026665

38 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

6 If the values are outside the specified maximum

dimensions, adjust the gear shift mechanism by
carefully tapping it in the direction where the
smallest value was measured.
Repeat the measurements and adjustments until
you end up between the specified dimensions. If
the specified dimensions are not achieved, the
reverse gear must be replaced.

P0026666

7 When the correct position has been found,

remove the measurement fixture and install the
bracket for the control cable.

P0026667

7742984 02-2021 © AB VOLVO PENTA 39

44-4 Drive, Inboard

8 Install the dipstick with a new O-ring.

P0026668

40 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Upper and Lower Gear

Housing, Assembly
Upper and Lower Gear Housing,
Assembly
Tools:
884265 Drift
9985472 Micrometer 0-25 mm
9999701 Micrometer 0-25 mm
1 Align the rubber sleeve on the upper gear.

WARNING!

The rubber cuff should be inserted dry. No kind of

grease, silicone sealant or other sealant may be
used.

P0026722

2 Put the four O-rings on the intermediate plate.

Affix them with some grease.
Install the intermediate plate on the upper gear.

P0026723

7742984 02-2021 © AB VOLVO PENTA 41

44-4 Drive, Inboard

3 NOTE! Align the plate to fit the relevant drive type.

Depending on whether the drive should be
located in front of or behind the engine, align the
plate (and the lower gear) as shown in the
illustration.
Apply grease, part no. 828 250 to the bolts.
Tightening torque: 20 Nm.

P0026724

4 Check that there is no end play vertically.

If necessary, tap the upper bearing housing down
with a drift.

P0026725

42 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

5 Measure the depth (C) of the lower gear housing

with depth micrometer 998 5472.
Example: C = 13.97 mm

P0026726

6 Measure the thickness (G) of a new gasket with

a micrometer 999 9701.
Example: G = 0.37 mm

P0026727

7742984 02-2021 © AB VOLVO PENTA 43

44-4 Drive, Inboard

7 Measure the height (X) of the intermediate plate

depth micrometer 998 5472.
Example: X = 12.36 mm

P0026728

8 In order to determine the play between the

bearing race and the upper gear case it is
necessary to add gasket thickness (G) to
measurement (C) and then subtract the
measurement (X).
Example:
Play = C + G - X = 13.97 + 0.37 - 12.36 = 1.98
mm
Shims must then be added between the bearing
race and the upper bearing housing to obtain the
recommended pre-load of 0.00-0.05 mm.
The example above leads to a shim thickness of
2.00 mm, which gives a bearing preload of 0.02
mm.
P0026729

44 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

9 Put the calculated thickness of shims (1) in the

lower gear housing.
Put a new gasket (2) on the lower gear housing.
Turn the gasket over.
Install the splined sleeve (3) on the vertical shaft.
Carefully lift the upper gear housing/intermediate
plate into place.
Apply grease, part no. 828 250 to the bolts.

P0026730

10 Tighten the bolts according to the tightening

schedule by 20 Nm.

P0026731

7742984 02-2021 © AB VOLVO PENTA 45

44-4 Drive, Inboard

Upper gear, assembly

Output shaft

Tools:
884754 Drift
884830 Splined socket (small)
885370 Drift
885377 Press tool
885475 Fixture
885479 Counterhold
885480 Fixture
885560 Sleeve
885571 Fixture
885747 Drift
9998081 Torque wrench
9999696 Magnetic stand
22296432 Counterhold
88820005 Splined socket (small)
88820006 Dial indicator (long probe)
1 Place shims for the upper bearing race in the gear
housing as follows:
• If the original drive kit and bearings are to be
used, use the original quantity of shims
• if the drive kit and/or bearing has been
replaced, use 0.60 mm as a rule of thumb.
Press in the bearing race.

P0026609

46 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

2 Turn the gear housing over and press the lower

bearing race in.

P0026610

3 Press the bearing onto the output shaft.

Remember to protect the gearwheel teeth.

P0026611

7742984 02-2021 © AB VOLVO PENTA 47

44-4 Drive, Inboard

4 Put the spacer sleeve (1) on the output shaft.

Put the original shim thickness in the shaft. If this
value is not known, use 0.90 mm as a rule of
thumb.
Put the output shaft in the gear housing and press
the lower bearing on with the drift. Press the
bearing until it bottoms against the shim.
IMPORTANT:

Check that the bearings do not lock against each

other, by turning the gear housing over during the
press operation. Abandon the operation in this
case, press the output shaft out and increase the
shim thickness slightly.

P0026612

5 Check the rotational torque with the torque

wrench and splined socket.
Correct values:
New bearings 0.1–0.5 Nm
Run-in bearings 0.1–0.5 Nm
If there is play, press the output shaft out and
reduce the shim thickness. If the turning torque is
too high, the shim thickness should be increased.

P0026613

48 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

6 When the correct value has been obtained, screw

the slotted nut on.

NOTICE! Turn the nut to face as illustrated.

Fix the nut with an abutment. Tighten the nut by

turning the shaft anti-clockwise with the splined
socket.
Tightening torque: 50 Nm.

P0026614

7 Place the following components in the

measurement fixture:
• tapered roller bearing
• sintered washer
• needle roller bearing
• spacer sleeve
• needle roller bearing
• spacer ring
• shims (original thickness, if this is unknown
use a value of 0.50 mm as a rule of thumb)
• front carrier
• hub
• shims (original thickness, if this is unknown
use a value of 0.50 mm as a rule of thumb)
• spacer ring
• needle roller bearing
• spacer sleeve
• needle roller bearing
• rear carrier
• sintered washer
• tapered roller bearing
• washer
• screw
P0026615
Tighten the screw lightly, approx 10 Nm.

7742984 02-2021 © AB VOLVO PENTA 49

44-4 Drive, Inboard

8 Measure the play between the hub and both

flanges with a feeler gage.
The play shall be equal on both sides.
130S : 0.50-0.55 mm
150S : 0.35-0.40 mm
Correct the shim thickness if necessary, to give
the correct play.

P0026616

9 Slide the carriers apart and measure distance (A).

(This measurement indicates how far apart the
front and rear gears will be positioned)
Example: A = 109.80 mm

P0026617

10 The gear wheels are made to be located 107.60

(2x53.8) mm away from each other.
This distance (B) shall however be corrected by
the deviations in the gear wheels. The deviation
in mm is engraved on the gear wheel, for example
“0.15”. The value is always positive.
Read the deviation on the gear wheel and correct
dimension B.
Example: B = 107.60 + 0.20 + 0.21 = 108.01

P0026618

50 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

11 Deduct the distance (B) (which we want between

the gears) from the distance (A) (which is the
current distance between the carriers) and halve
that amount, to obtain the shim thickness that
needs to be laid between each carrier and gear.
Example: Shim thickness = (A - B) x 0.5 = (109.80
- 108.01) x 0.5 = 0.895
Round off the value to 10/100 mm, which in this
example gives us a shim thickness of 0.90 mm.
When the shim calculation is completed, remove
all components from the measurement fixture.

P0026619

Input shaft, assembly

12 Place the calculated thickness of shims on each
carrier.
Install each gear wheel on its carrier. Tap them
together with a plastic faced mallet. Be careful to
ensure that the carrier bottoms properly.

P0026620

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44-4 Drive, Inboard

13 Put the original shim thickness and spacer ring on

the carrier. Install the new locking ring. Make sure
the locking ring bottoms properly.
Check that there is no play between the circlip
and the spacer ring. Increase the shim thickness
in this case.

P0026621

14 Place the washer (1), the two cup springs (2) and
the sintered washer (3) on the appropriate carrier.
Align the components as shown in the illustration.
Compress the disc springs using the press tool
and fit the new locking ring. Make sure that the
locking ring is seated properly in its groove before
the cup springs are unloaded.

P0026622

15 Install the springs (1), pin (2) and (3) in the hub.

P0026623

52 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

16 Place the hub in the clutch plate. Align the

components as shown in the illustration.
Press the pin in at the same time as the hub is
pressed down into the clutch plate. Make sure
that the pin engages in the groove for neutral
gear.

P0026624

17 IMPORTANT! Note the appearance of the holder

(A) as shown (A). Put the holder (A) on the bench.
Install:
• the balls
• assembled hub
IMPORTANT! Make sure that the inner part of the
hub is aligned so that the balls are seated as
shown in the illustration (B).
• the balls
• holder (C)
IMPORTANT! Note the appearance of the holder
(C) as shown (C).
Install the springs, facing as shown in the
P0026625 illustration.

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44-4 Drive, Inboard

18 Press:
• bearing
• sintered washer (as shown in the illustration)
• needle roller bearing
• spacer
• needle roller race
on the input shaft. Make sure that the
components are seated securely.

P0026626

19 Place the input shaft in the splined socket.

Thread on:
• needle roller bearing
• spacer ring
• shim (thickness as in point 8)
• front gear wheel unit
on the input shaft.

P0026627

54 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

20 Install the two wedges.

Install the front friction plate package. Put the
steel plate at the bottom, and then alternate with
coated friction plates. There is a total of three of
each for the 130S, and four of each for the 150S.

P0026628

21 Thread the clutch hub onto the shaft. Align the

steel clutch plate tags so that they enter the
cutouts in the hub.
IMPORTANT:

Make sure that the groove in the inner part of the

hub is aligned as shown in the illustration.

P0026629

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44-4 Drive, Inboard

22 Thread on:
• shim (thickness as in point 8)
• spacer ring
on the input shaft.

P0026630

23 Press on:
• needle roller bearing
• spacer
• needle roller race
on the input shaft.

P0026631

56 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

24 Thread the needle roller bearing on.

Install the rear friction plate package. Put a
coated friction plate at the bottom, and alternate
with steel friction plates. There is a total of three
of each for the 130S, and four of each for the
150S.

P0026632

25 Install the rear gear wheel unit. Rock the gear

wheel to center the coated friction plates.
Thread the coated washer on, facing as shown in
the illustration.

P0026633

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44-4 Drive, Inboard

26 Press the bearing on.

P0026634

27 Measure distance (A) between the bearing race

and the shaft with a depth micrometer.
Fill the distance up with shims as follows:
Round off to the nearest 10/100 mm. Then deduct
0.10 mm.

Example:
A = 1.76 (rounded off to 1.80)
Shim thickness = 1.80 – 0.10 = 1.70

P0026635

58 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

28 Put in the calculated thickness of shims.

Apply thread locking fluid, VP part number 114
1053 to the bolt.
Install the washer and bolt. Tightening torque: 50
Nm.

P0026636

Input shaft, turning torque

29 Place the input shaft together with the rear
bearing race (1), the front bearing race (2) and the
original shim thickness (3) in the gear housing.
If the original shim thickness is not available, use
0.50 mm as a rule of thumb.
Fix the shaft with clamps. Align the rear clamp
evenly with the gasket plane and tighten the bolts
lightly, approx 10 Nm.

P0026637

7742984 02-2021 © AB VOLVO PENTA 59

44-4 Drive, Inboard

30 Install the rear cover together with the gasket and

the original shim thickness.
If the original shim thickness is not available, use
0.50 mm as a rule of thumb.
Tighten the bolts, approx 14 Nm while spinning
the shaft. This is to check that the turning torque
is not so high that it “locks” the shaft.

P0026638

31 Measure the turning torque with splined socket

and torque wrench.
The correct turning torque is:
1.0-1.4 Nm (new bearings)
1.0-1.4 Nm (run-in bearings)
If the turning torque is too low, increase the shim
thickness inside the rear cover.
If, on the other hand, the value is too high, reduce
the shim thickness.

P0026639

60 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Cog flank play

32 When the correct turning torque has been
obtained, check the gear flank play.
Mount the fixture on the gear housing. Place the
magnetic stand and dial gauge on the fixture.

P0026640

33 Slide the clutch plate backwards and read off the

gear flank play on the rear gear wheel by carefully
rocking the input gear wheel.
Note the value.

P0026641

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44-4 Drive, Inboard

34 Slide the clutch plate forwards and read off the

gear flank play on the front gear wheel by
carefully rocking the input gear wheel.
Note the value.

P0026642

35 Compare the two values. The play shall be as

equal as possible on both gear wheels.

P0026643

62 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

36 Adjust (center) the input shaft if necessary, by

changing the shim thickness on the outer bearing
races.
NOTE! Remember to remove the same amount
on one side as you add on the other side, to avoid
changing the turning torque.
The correct play after centering shall be 0.12-0.27
mm on both gears.
Always check the gear engagement pattern
before making any adjustment to the clearance.

P0026644

Engagement pattern
37 When the input shaft has been centered (equal
play on each gear wheel) across the output gear
wheel, check the gear engagement pattern.
Paint a thin layer of marking dye 380 7716 on 5-6
teeth of the lower gearwheel.
Slide the clutch plate backwards.
Place the splined socket 888 20005 on the input
shaft and turn clockwise 3-4 turns while the output
shaft is braked with the splined socket 884 830
(130S) and 885 560 (150S) respectively.

P0026645

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44-4 Drive, Inboard

38 It is easiest to check the gear engagement pattern

on the concave outer side of the gear wheel.
The engagement pattern must be located
centrally on the teeth, both longitudinally and
vertically.

P0026646

39 Paint a thin layer of marking dye 380 7716 on 5-6

teeth of the lower gearwheel.
Slide the clutch plate forwards.
Repeat the procedure and check the location of
the gear engagement pattern on the convex side
of the output gear.
The engagement pattern must be located
centrally on the teeth, both longitudinally and
vertically.

P0026647

64 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

40 When it is necessary to adjust gear play in cases

where the engagement pattern is correct:
In most cases, the location of the front and rear
gears is retained and the output gear is moved up
or down.
If the output gear wheel is moved 0.10 mm, the
gear flank clearance is changed about 0.05 mm.

P0026648

41 NOTE! Remember to compensate the shim

thickness between bearings so as to retain the
turning torque..
Put the current shim thickness, gear flank play
and engagement pattern locations in a copy of the
“Shim table, upper gear housing” at the end of the
book. This facilitates work significantly should
there be a need to fine adjust shim thicknesses.

P0026649

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44-4 Drive, Inboard

42 If the engagement pattern must be adjusted

without changing the gear play:
The outgoing gear wheel, rear and front gear
wheel are all moved.
If the output gear is moved e.g. 0.05 mm, the rear
and front gears should be moved twice as much,
i.e. 0.10 mm to maintain gear flank play.
If the engagement pattern is as shown here,
move the output gear wheel up, and the rear and
front gear wheels outwards.

P0026650

43 If the engagement pattern is as shown here,

move the output gear wheel down, and the rear
and front gear wheels inwards.
NOTE! Remember to compensate the shim
thickness between the output shaft bearings so
as to retain the turning torque.
NOTE! Remember to compensate the shim
thickness between the carrier and locking rings..
Record the current shim thickness, gear flank
play and engagement pattern locations in a copy
of the “Shim table, upper gear housing” at the end
of the book. This facilitates work significantly
should there be a need to fine adjust shim
thicknesses.

P0026651

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 44-4 Drive, Inboard

Final assembly

Tools:
885511 Roller
885516 Gasket scraper
1 Apply locking fluid 85145750 on the nut.
Tightening torque 50 Nm.

P0026614

2 Oil the selector fork bearing bush. Put the fork in

position and slide the shaft in.
Apply thread locking fluid, VP part number 116
1053 to the plug.
If the shaft design is as shown in (A), tighten the
plug to 5 Nm.
If the shaft design is as shown in (B), tighten the
plug to 35 Nm.

P0026652

7742984 02-2021 © AB VOLVO PENTA 67

44-4 Drive, Inboard

3 Make sure the play between plug and axle is min

0.5 mm and that the fork can move easily.
If the design of the shaft is according to (A) above,
check that the play between the plug and the axle
is min 0.5 mm and that the fork can move easily.

P0026653

4 IMPORTANT:

Clean all contact surfaces on both gear housing

halves with denatured alcohol and a gasket
scraper.
Old sealant residue must be completely removed,
to promote successful re-sealing.

P0026654

5 Apply a thin layer of sealant (red), part number

840 879, to the oil pump seal surfaces. Use roller.

P0026655

68 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

6 Place the input shaft together with the bearing

races, calculated shim thickness on the input side
and the seal ring in the gear housing. Turn the
seal over.

P0026656

7 Install the upper gear housing half.

NOTE! Make sure that the clutch plate is in
neutral..
NOTE! Make sure that the selector fork engages
on the clutch plate.
NOTE! Align the front of the housing.
Tighten the bolts diagonally to 22 Nm.

P0026657

8 Install the rear cover together with the tested shim

thickness and a new gasket.
Tighten the bolts to 14 Nm.

P0026658

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44-4 Drive, Inboard

9 IMPORTANT:

Clean all contact surfaces on the gear housing

and gear mechanism with denatured alcohol and
a gasket scraper.
Old sealant residue must be completely removed,
to promote successful re-sealing.

P0026659

10 Apply a thin layer of sealant (red), part number

840 879, to the gear mechanism. Use roller.

P0026660

70 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Gear shift mechanism, adjustment

Tools:
885870 Alignment tool
1 Check that the clutch plate is in neutral.
Install the gear mechanism as shown in the
illustration. Roughly adjust the position by
centering in the screw holes. Tighten the nuts to
about 10 Nm (it should be possible to fine adjust
the position of the gear mechanism by lightly
tapping it with a plastic-faced mallet).
IMPORTANT:

The position of the gear mechanism must be fine

adjusted as in the points below, to reduce wear
on the selector fork and clutch plate.

P0026661

2 Attach measurement fixture. The fixture can be

installed along or across the reverse gear,
depending on how the gear shift arm is installed.

P0026662

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44-4 Drive, Inboard

3 Put the gear shift mechanism in the neutral

position.
Find the gear shift arm “neutral position” by
turning the mechanism carefully in each direction
(without engaging a gear). Mark up the end
positions as in the illustration.
NOTE! If you put masking tape on the measuring
fixture, the markings will be more easily visible.

P0026663

4 Take the end positions of the gear arm with the

gear engaged by engaging the gear and gently
turning the gear arm back until contact is obtained
with the clutch plate. Mark this position and repeat
the procedure with the opposite gear position.

P0026664

5 Measure the distances between A and B as

shown in the illustration.
The permissible values of the A and B dimensions
are not more than 24 mm.
In addition, the difference between the two
dimensions must not exceed 3 mm.
Example:
A = 23.1 mm
B = 22.3 mm
A - B = 23.1 - 22.3 = 0.8 mm

P0026665

72 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

6 If the values are outside the specified maximum

dimensions, adjust the gear shift mechanism by
carefully tapping it in the direction where the
smallest value was measured.
Repeat the measurements and adjustments until
you end up between the specified dimensions. If
the specified dimensions are not achieved, the
reverse gear must be replaced.

P0026666

7 When the correct position has been found,

remove the measurement fixture and install the
bracket for the control cable.

P0026667

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44-4 Drive, Inboard

8 Install the dipstick with a new O-ring.

P0026668

74 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Lower Gear, Overhaul

Disassembly

Tools:
884143 Handle
884161 Slide hammer
884611 Adapter
884721 Extractor
884723 Counterhold
884726 Expander ring
884753 Plate
884760 Puller
884830 Splined socket (small)
884833 Drift
885560 Sleeve
885568 Adapter plate
885850 Counterhold
885852 Puller
9992520 Stand
9992584 Counterhold
22518599 Slide hammer
22563001 Drift (two-piece)
88820004 Puller
88820007 Fixture
88820010 Fixture
1 Install the fixture on the gear case
Install the fixture in the stand.

P0026669

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44-4 Drive, Inboard

2 NOTE! Remove the oil drain plug.

Remove the zinc anode.

P0026670

3 Remove the bolts for the propeller bearing

housing.
Remove the propeller shaft and bearing box.
Discard the O-rings.

P0026671

4 Fix the upper nut for the vertical shaft with fixture.
Undo the nut by turning the vertical shaft
clockwise, with the splined socket.

P0026672

76 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

5 Fit the pinion nut. Use a clean rag to protect the

gear case.
Undo the nut by turning the vertical shaft anti-
clockwise with the splined socket.

P0026673

6 Pull up the vertical shaft using puller and drift.

Catch the pinion gear.

P0026674

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44-4 Drive, Inboard

7 Pull the bearing race up with the puller.

Save the shims and note the thickness of the
shims.

P0026675

8 Remove the needle bearing.

P0026676

78 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

9 Pull out the bearing race for the front propeller

shaft bearing. Use the puller.
Save the shims and note the thickness of the
shims.

P0026677

10 Tap the seal rings out of the propeller bearing

box, with the aid of a screwdriver.

P0026678

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44-4 Drive, Inboard

11 Press the bearing race out with an expander and

standard shaft. Use a ring as an abutment.
Save the shims and note the thickness of the
shims.

P0026679

12 Press the bearings off with the puller halves and

the plate.
Save the washer (1).

P0026680

80 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

13 Press the needle roller bearings off with the puller

halves and the plate.

P0026681

14 Press the inner bearing off the propeller shaft.

P0026682

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44-4 Drive, Inboard

15 Press the gear wheel and outer bearing off.

Use the drift as a shim so that the threads on the
shaft are not damaged.

WARNING!

Major pressure required (conical joint). Wear

safety goggles.

P0026683

Assembly
1 NOTE! Brush a thin layer of glycerin on the
conical surface of the gear wheel and the
propeller shaft (only 150).
Press the propeller shaft down onto the gear
wheel. Use the plate as an abutment.
Press until the step bottoms solidly against the
gear wheel.

P0026684

82 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

2 Press the front bearing on. Use a ring as an

abutment.
Use the drift as a shim so that the threads on the
shaft are not damaged.

P0026685

Gears 130S, shims

3 The measuring deviation of the gear (Getched) is
engraved on the gear.

P0026686

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44-4 Drive, Inboard

4 Read the gear deviation (Getched)and insert it into

the "Shim calculation table, intended to be copied
located at the end of the book.

P0026687

5 Read the measuring deviation (Xstamped)and

insert it into "Shim calculation, lower gear housing
130S-A, 130SR-A". The table, intended to be
copied, is at the end of the book.
Only decimals in 1/100 mm are marked.
Example: X12 = 0.12 mm

P0026688

6 Place the propeller shaft on the bearing race as

shown in the illustration.
Press the shaft hard against the bearing race and
measure the distance between the bearing race
and the gear wheel. Make a number of
measurements and prepare an average.
Example:
Gmeasured =
(100.27 + 100.25 + 100.23) = 100.25 mm
3

P0026689

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 44-4 Drive, Inboard

7 Enter the calculated and measured dimensions in

the table and calculate the shim thickness
(Gshim).
Round off to the nearest 5/100 mm.

P0026690

Gears 150S, shims

8 The measuring deviation of the gear (Getched) is
engraved on the gear.

P0027256

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44-4 Drive, Inboard

9 Read the gear deviation (Getched)and insert it into

the "Shim calculation table, intended to be copied
located at the end of the book.

P0026687

10 Read the gear housing measurement deviation

(Xstamped)and insert it into the "Shim calculation
table, intended to be copied located at the end of
the book.
Only decimals in 1/100 mm are marked.
Example: X04: 0.04 mm

P0026688

11 Place the propeller shaft on the bearing race as

shown in the illustration.
Press the shaft hard against the bearing race and
measure the distance between the bearing race
and the gear wheel. Make a number of
measurements and prepare an average.
Example:
Gmeasured =
(111.27 + 111.31 + 111.29) = 111.29 mm
3

P0026689

86 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

12 Enter the calculated and measured dimensions in

the table and calculate the shim thickness
(Gshim).
Round off to the nearest 5/100 mm.
NOTE! If X isstamped with a value close to 100,
e.g. X96, housing nominal = 50.00 mm applies.

P0027257

13 Put the calculated thickness of shims (Gshim) in

the housing. Affix them with some grease.
Install the bearing race.
Turn the lower part of the tool to suit the bearing
race in question.

P0027258

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44-4 Drive, Inboard

14 Press the bearing onto the vertical shaft with ring.

Align the bearings as shown in the illustration.
NOTE! Be careful not to damage the threads for
the pinion nut.

P0026693

15 Turn over the needle layer with the text face down
(toward the tool). Tap up the bearing until it
bottoms.

P0027259

88 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Pinion gear 130S, shim

16 Pinion gear nominal height = 49.70
Lower gear housing nominal dimension = 357

P0027260

17 Read the gear deviation (Getched)and record it

into the "Shim calculation table, intended to be
copied located at the end of the book.

P0027261

18 Fit the splined socket in a vise. Place the vertical

shaft in the splined socket and thread the
measurement fixture.
Install the pinion gear and the old pinion nut.
Tighten the nut to 110 Nm.

P0027262

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44-4 Drive, Inboard

19 Using a feeler gauge, measure the distance

between the tool and the pinion drive. Measure
the three sockets in the measuring fixture and find
the average.
Example:
(1.44 + 1.48 + 1.46) = 1.46 mm
3
Add the measuring fixture’s fixed length of 301.00
mm to arrive at the measurement we call:
Pmeasured = 1.46 + 301.00 = 302.46 mm
Record this dimension into the table below.

P0027263

20 Read off the gear housing deviation Zstamped,

only decimals in 1/100 mm are marked. Record
this dimension into the table below.
Example: Z93 = 0.93 mm

P0027264

21 Enter the calculated and measured dimensions in

the table and calculate the shim thickness Pshim.
Round off to the nearest 5/100 mm.

P0027265

90 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Pinion drive 150S, shim

22 Pinion drive nominal height = 56.00
Lower gear housing nominal dimension = 357

P0027266

23 The pinion drive deviation is engraved on the

pinion drive. The deviation is noted in plain
language.
Example: 0.09 = 0.09 mm
Read the pinion drive deviation (Petched)and
record it into the "Shim calculation table, intended
to be copied located at the end of the book.

P0027261

24 Fit the splined socket in a vise. Place the vertical

shaft in the splined socket and thread the
measurement fixture.
Install the pinion drive and the old pinion nut.
Tighten the nut to 240 Nm.

P0027267

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44-4 Drive, Inboard

25 Using a feeler gauge, measure the distance

between the tool and the pinion drive. Measure
the three sockets in the measuring fixture and find
the average.
Example:
(1.44 + 1.48 + 1.46) = 1.46 mm
3
Add the measuring fixture’s fixed length of 301.00
mm to arrive at the measurement we call:
Pmeasured = 1.46 + 301.00 = 302.46 mm
Record this dimension into the table below.

P0027268

26 Read off the gear housing deviation Zstamped,

only decimals in 1/100 mm are marked. Record
this dimension into the table below.
Example: Z93 = 0.93 mm

P0027264

27 Enter the calculated and measured dimensions in

the table and calculate the shim thickness Pshim.
Round off to the nearest 5/100 mm.

P0027269

92 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

28 Install the calculated shim thickness in the gear

housing and install the bearing race.

P0027270

29 Press the needle roller bearing onto the vertical

shaft with ring.

P0026693

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44-4 Drive, Inboard

30 Place the vertical shaft in the gear housing.

Attach the pinion drive and screw the nut by hand.

P0026694

31 Fit the pinion nut.

Use a clean rag to protect the gear case.
Tighten the nut by turning the vertical shaft with
the splined socket.
Tightening torque 130S: 110 Nm
Tightening torque 150S: 240 Nm

P0026695

94 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

32 Put the original shim thickness in the propeller

bearing box.
(Or adjust the shim thickness with the difference
between the calculated and the original shim
thickness for the front bearing race).
Press in the bearing race. Turn the lower part of
the tool to suit the bearing race in question.

P0026696

33 Press the rear bearing onto the propeller shaft.

Use the plate as an abutment.

P0026697

7742984 02-2021 © AB VOLVO PENTA 95

44-4 Drive, Inboard

34 Lightly oil the bearings.

Place the propeller shaft in the gear housing.
Install the propeller bearing box without O-rings.
Tighten the bolts to 20 Nm.

P0026698

35 Check the turning round torque with adapter nut

and torque wrench.
The correct turning torque is 0.3 Nm – 1.6 Nm
If the turning torque is too low, increase the
thickness of shims under the bearing track in the
propeller bearing housing, and if the turning
torque is too high, reduce the thickness of shims.

P0026699

96 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

36 When the correct turning torque has been

obtained, gear engagement play and gearwheel
engagement pattern must be checked.
Remove the propeller bearing box and propeller
shaft.
Paint a thin layer of marking dye on 5-6 teeth of
the lower gearwheel.

P0026700

37 Place the propeller shaft back in the gear

housing.
Assemble the propeller bearing housing with the
fixture as shown. Tighten the bolts to 20 Nm.

P0026701

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44-4 Drive, Inboard

38 Drive the upper bearing race down with a plastic-

faced mallet and drift.

P0026702

39 The shafts must be braked at the same time as

the propeller shaft is turned, to permit the gear
engagement pattern to be checked.
Attach an adapter nut to the propeller shaft.
Place the splined socket on the vertical shaft and
turn it 3-4 turns clockwise at the same time as the
propeller shaft is braked.

P0026703

98 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

40 Position the fixture, magnetic stand and dial

gage.
Put the measurement tip on the inner marking of
the fixture.

P0026704

41 Fix the vertical shaft in a suitable manner.

Rock the propeller shaft back and forth (avoid
rocking radially) and read off the gear flank play.
The correct value is 0.10 - 0.20 mm.
Note the measured value in the “Shim table, lower
gear”.

P0026705

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44-4 Drive, Inboard

42 Remove all special tools.

Remove the propeller bearing box and lift the
propeller shaft out.

P0026706

43 Check the location of the engagement pattern.

The engagement pattern on the gear wheel
should be displaced slightly towards the “large
end” and slightly towards the tooth tips.
During operation, the propeller forces will press
the gear wheel forwards, which displaces the
engagement pattern and makes it centrally
located in both height and lengthways direction.

P0026707

100 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

44 When it is necessary to adjust gear flank play in

cases where the engagement pattern is correct:
The pinion location is retained (Pshim) in most
cases, and the gearwheel is moved (Fshim).
If the gearwheel is moved 0.05 mm, the gear flank
play measurement changes by approx 0.05 mm.
NOTE! Remember to compensate the thickness
underneath the propeller bearing box
(Preloadshim) to retain turning resistance. The
sum of: Fshim + Pre-loadshim remains unchanged

P0026708

45 Put the current shim thickness, gear flank play,

turning torque and engagement pattern locations
in a copy of the “Shim table, lower gear housing”
at the end of the book. This facilitates work
significantly should there be a need to fine adjust
shim thicknesses.
If the engagement pattern must be adjusted
without changing the gear flank play:
Both the pinion and the gearwheel have to be
moved.
If the gearwheel is moved e.g. 0.05 mm, the
pinion must be moved twice as much, i.e. 0.10
mm, in order to maintain gear flank play.

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44-4 Drive, Inboard

46 When the engagement pattern is as illustrated,

move the gearwheel in (Fshim) and the pinion
upwards (Pshim).

P0026709

47 If the engagement pattern is as illustrated, move

the gearwheel out (Fshim) and the pinion
downwards (Pshim).
NOTE! Remember to compensate the thickness
underneath the propeller bearing box
(Preloadshim) to retain turning resistance. The
sum of:
Fshim + Pre-loadshim remains unchanged

Put the current shim thickness, gear flank play, turning

torque and engagement pattern locations in a copy of
the “Shim table, lower gear housing” at the end of the
book. This facilitates work significantly should there be
a need to fine adjust shim thicknesses.
When correct turning torque, gear flank clearance and
engagement pattern have been obtained, remove the
propeller bearing box and propeller shaft.

P0026710

102 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Final assembly
1 Remove the old pinion nut and discard it.
Apply thread locking fluid, VP part number 116
1053 to the new pinion nut and screw it on by
hand.
NOTE! Turn the nut to face as illustrated.
Fit the pinion nut. Use a clean rag to protect the
gear case.
Tighten the nut by turning the vertical shaft with
the splined socket.

P0026711

2 Thread the washer on.

Apply thread locking fluid, VP part number 116
1053 to the nut and screw it on by hand.
NOTE! Turn the nut to face as illustrated.

P0026712

7742984 02-2021 © AB VOLVO PENTA 103

44-4 Drive, Inboard

3 Fix the nut with a fixture.

Tighten the nut by turning the vertical shaft anti-
clockwise with the splined socket.
Tightening torque 50 Nm.

P0026713

4 Place the propeller shaft in the gear housing.

P0026714

5 Press the bearing race out of the propeller

bearing box with an expander and standard shaft.
Use the ring as an abutment.
Keep the shims in a safe place.

P0026715

104 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

6 130S/150S (A—>C)
Insert the outer sealing ring into the propeller
bearing box. Use a standard shaft and drift.
NOTE! Install the sealing ring dry and turn it so
the spring faces outwards.
Press the stop and hold the pressure force for a
few seconds so that the sealing ring "sits down".

P0026716

7 130S/150S (A—>C)
Insert the inner sealing ring into the propeller
bearing box. Use a standard shaft and drift.
NOTE! Install the sealing ring dry and turn it so
the spring faces inwards.
Press the stop and hold the pressure force for a
few seconds so that the sealing ring "sits down".

P0026717

8 130S/150S (D—>)
H = 4.5 —>9 mm

P0032955

7742984 02-2021 © AB VOLVO PENTA 105

44-4 Drive, Inboard

9 Place the tested shim thickness in the propeller

bearing box.
Press in the bearing race.

P0026718

10 Install new O-rings on the propeller bearing box.

Grease the seal rings and the O-rings liberally
with grease, VP part no. 828250.
Put the propeller bearing box into position. Be
careful to ensure that the splines do not scratch
the seal rings.
Tighten the bolts. Tightening torque 20 Nm.

P0026719

106 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

11 Install a new O-ring on the oil drain plug. Tighten

the plug to 10 Nm.

P0026720

12 Scrape the mating surface clean and install the

zinc anode. Tighten the bolts to 10 Nm.

P0026721

7742984 02-2021 © AB VOLVO PENTA 107

44-4 Drive, Inboard

Pressure Test
Before the drive is filled with oil, it must be pressure
tested to check that the drive is oil-tight after repair.
If a used drive is to be tested, the oil must be drained
first. Note the appearance of the oil. Gray oil indicates
leakage (water entry).

Tools:
885531 Pressure testing kit
1 Remove the drain plug.
Install the nipple and pump from the pressure test
kit.

P0026732

2 Pump the pressure up to 21–35 kPa.

Turn the propeller shaft, gear shift mechanism
and input shaft, and check for leakages. If a
pressure drop is noted, use soapy water or
immerse the drive in water to locate the leak.
Carry out the necessary repairs and repeat the
test.

P0026733

108 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

3 If no pressure drop can be noticed, raise the

pressure to 90–95 kPa. Again, use soapy water
or immerse the drive in water to locate the leak if
a pressure drop occurs. Permissible pressure
drop max. 7 kPa per 3 minutes.

P0026734

7742984 02-2021 © AB VOLVO PENTA 109

44-4 Drive, Inboard

Rubber bushing, change

Tools:
88820014 Press tool
1 130S-A/B, 150S-A/B:
Remove the rubber bush with the press tool.

P0026735

2 130S-A/B, 150S-A/B:
Brush glycerin in the cutout for the bushing in the
gear housing.
Turn the new bushing.
Press it in with the press tool.

P0026736

3 130S-C/D, 150S-C/D:
Tightening torque: 40 Nm

P0026737

110 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Miscellaneous
Painting
IMPORTANT!
Read and carefully follow the instructions and
warnings on the packaging.
1 Remove all marine fouling.
2 Remove all loose paint and corrosion residue by
blasting or sandpaper.
When blasting, the blasting medium must be
An
aluminum oxide with a particle size of between
t if oul in g
0.2 (0.0079") till 0.7 mm (0.0276"). Blow clean
after blasting.
If sandpaper is used, it must be coated with
aluminum oxide. Sand the painted surfaces and
the damaged/corroded raw aluminum surfaces to
be touched up. Then clean with water or a good
cleaning fluid.

IMPORTANT!
Do not use steel wool. Small pieces of steel will
P0008917
become embedded in the aluminum and will cause
severe corrosion damage.

IMPORTANT!
Do not use emery cloth. Small pieces of iron oxide
used in the emery cloth will become embedded in
the aluminum and will cause severe corrosion
damage.
3 In places where the primer coat is thin or the
surface has been repainted, primer must be
applied; use primer VP part number 1141562-7.
The primer solvent must be given time to
evaporate and the primer must harden before the
top coat is applied. Allow 8 to 12 hours drying
time.
4 Apply the top coat. The spare parts catalogue and
the “Volvo Penta accessories” catalogue specify
the part numbers for surface treatment products.

IMPORTANT!
Sacrificial anodes on transom shield and drive
must not be painted.
5 Also apply anti-fouling.

NOTICE! Use the locally recommended anti-

fouling on the drive.

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44-4 Drive, Inboard

112 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Shimming, reference guide

Shim calculation, lower gear housing

130S/SR

Shim calculation, lower gear housing

150S/SR

7742984 02-2021 © AB VOLVO PENTA 113

44-4 Drive, Inboard

Shim table, lower gear housing

114 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Shim table, upper gear housing

7742984 02-2021 © AB VOLVO PENTA 115

44-4 Drive, Inboard

Fault Tracing
In the event of a fault, first check if all the points in the assembly record have been performed and the running
instructions have been followed.
The table below will help you with troubleshooting.

1. Oil leakage

Reason: Pores in castings.

Action: Replace defective components.

Reason: Leaking oil seals.

Action: Replace the defective oil seals.

Reason: Leakage at mating surface.

Action: Check whether the bolts have been tightened to the correct torque. Clean the surfaces and apply new
sealant.

Reason: Leakage by dipstick.

Action: Change the dipstick or the O-ring on the dipstick.

Reason: Oil level too high.

Action: Drain/suck out surplus oil.

2. High oil temperature

Reason: Oil level too high.

Action: Drain/suck out surplus oil.

Reason: Slipping clutch

Action: See point 3.

3. Slipping clutch

Reason: Gear shift arm wrongly adjusted/installed.

Action: Adjust the gear shift arm.

Reason: Worn friction plates.

Action: Disassemble the sailboat drive, change the friction plates.

Reason: Wrong oil quality.

Action: Drain the oil and re-fill with the correct oil quality.

Reason: Water in oil.

Action: Check and replace the propeller shaft seals in the first instance. Then check the O-rings and seal between
the upper and lower gear housings.

4. Noise under load

Reason: Wrongly shimmed gear wheels and roller bearings.

Action: Check shimming and assembly of the sailboat drive.

116 7742984 02-2021 © AB VOLVO PENTA

 44-4 Drive, Inboard

Reason: Defective gear wheels.

Action: Replace the relevant driveline kit (gear wheels are not sold separately).

5. Sailboat drive gear can not be shifted

Reason: Gear shift arm wrongly installed.

Action: Adjust the gear shift arm.

Reason: Flexible clutch defective.

Action: Change the flexible clutch.

Reason: Gear shift arm loose.

Action: Check the gear shift arm and tightening torque of the clamp screw.

Reason: Defective components as below.

Action: Check the cam on the gear mechanism, replace if necessary.
Replace the springs in the clutch package.
Replace the friction disks.
Replace the selector fork.
Adjust the gear mechanism.

6. Hard to shift gear

Reason: Idling speed too high.

Action: Adjust idling speed to the correct level.

7. Output shaft rotates in neutral position

Reason: Distorted clutch plates due to overheating.

Action: Replace friction plates and other damaged components.

Reason: Defective needle roller bearing on input shaft.

Action: Remove the sailboat drive and input shaft, replace the appropriate bearing and other damaged
components.

7742984 02-2021 © AB VOLVO PENTA 117

Index
A
About this Workshop manual..................................... 3
D
Drive, Inboard........................................................... 18
F
Fault Tracing.......................................................... 116
G
Gear shift mechanism, adjustment..................... 37, 71
General....................................................................... 2
General Tightening Torques....................................... 6
L
Lower Gear, Overhaul.............................................. 75
M
Miscellaneous......................................................... 111
O
Other Equipment...................................................... 17
P
Painting.................................................................. 111
Pressure Test......................................................... 108
R
Repair instructions...................................................... 4
Rubber bushing, change........................................ 110
S
Safety Information...................................................... 8
Safety Instructions...................................................... 8
Shift mechanism, overhaul....................................... 34
Shimming, reference guide.................................... 113
Special Service Tools............................................... 14
Specifications, Power Transmission........................... 6
T
Technical Data........................................................... 6
U
Upper and Lower Gear Housing, Assembly............. 41
Upper and Lower Gear Housing, Disassembly........ 18
Upper gear, assembly.............................................. 46
Upper gear, inspection............................................. 32
Upper Gear, Overhaul.............................................. 20

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AB Volvo Penta
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SE-405 08 Gothenburg
Sweden
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