Alpha Drive Leak

[PayCheck]

I replaced the Alpha One Gen 1 outdrive (upper and lower) earlier this year with a new Merc replacement part off eBay -$1250. It worked fine, but I blew the water hose from the new impeller water pressure a couple of times before I got a good seal.

The problem is a water leak from inside the drive, that just started and seems intermittent. I'm guessing the gasket between the outdrive and bellhousing and have a replacement kit which includes bearing, seal, bellows, and gasket.

I've pulled the outdrive, and considering replacing the bearing and seal while I'm at it to eliminate the seal as a source, but I'm curious to see if anyone has any advice?

 

[Chris E]

I replaced the Alpha One Gen 1 outdrive (upper and lower) earlier this year with a new Merc replacement part off eBay -$1250. It worked fine, but I blew the water hose from the new impeller water pressure a couple of times before I got a good seal.

The problem is a water leak from inside the drive, that just started and seems intermittent. I'm guessing the gasket between the outdrive and bellhousing and have a replacement kit which includes bearing, seal, bellows, and gasket.

I've pulled the outdrive, and considering replacing the bearing and seal while I'm at it to eliminate the seal as a source, but I'm curious to see if anyone has any advice?

you have either a leaky bellows or a leaky water hose. my bet is the shift bellows is shot. this is where they usually leak. have a look at the gimbel housing and you'll see. the u-joint bellows could also be the culprit, if one is shot replace them all. as far as the gimbel bearing goes, if it isn't making noise - leave it alone. it's probably fine, as long as they get grease they last a long time.

if you need any diagrams, i have the merc service manual for that drive - let me know and i will scan them for you - however, i just packed that book away, as i am moving my office in the next week.

 

[Magnum Thunder]

Alpha Leak

Is it a genuine Mercruiser part? If it is a SE drive (Non Mercruiser on the net)you will have lots of problems. Use genuine Mercruiser part(s). The extra cost alliviates alot of headaches. Is this drive under any warranty?

 

[vinny p.]

I am sorry but I am not following on exactly what is leaking? Are you saying there is water leaking into the bilge? Or is water leaking into the drive oil?

You blew a water hose off? Which one? A new impeller shouldnt be able to blow a hose off, unless there is something strange going on.

 

[PayCheck]

I am sorry but I am not following on exactly what is leaking? Are you saying there is water leaking into the bilge? Or is water leaking into the drive oil?

You blew a water hose off? Which one? A new impeller shouldnt be able to blow a hose off, unless there is something strange going on.

The new Mercruiser outdrive (NIB Genuine Mercruiser Alpha 1 1.62 to 1 PN 5-01662017R) is just fine. In fact, the water pressure from the new pump was so good it blew a hole in the original (1974) water hose from the transom fitting to the circulating pump...I cleaned up the ends and after a couple of runs had the clamps tight enough to hold the pressure.

Then it started as a dribble from what appeared to be inside the drive coupler. I've taken it for a half a dozen runs since leak discovery and it has gotten progressively worse, but it's very difficult to identify exactly where it's coming from. The last run of the season I had to stop and pump for a bit after 8-10 miles to empty the bilge.

So, I've pulled it off and plan to replace both bellows, gasket, and "O" rings, and was wondering whether the gimbal bearing and seal should be done while I'm at it. It looks ok and isn't making any noise.....is there a puller available to make it a slick re + re?

 

[vinny p.]

Now I inderstand!! Yes, your most likely culprit is the driveshaft bellows. Not so easy to do. There is not much room in there to work. Merc manual will tell you to pull the helmet off by removing the trim senders and tilt pins. Then you can let it hamg to the side and work easily. Dont forget to clean the areas where the bellows seals to the gimbal and helmet. Use bellows adhesive when reassembling. Definitely replace the gimbal bearing. You will need a good sized automotive type bearing puller ( slap hammer ) and an installer tool. I made a bearing installer from a steel pipe and solid shaft. Then you have to re-align the gimbal bearing to the coupler..

Goodluck.

 

[PayCheck]

I have two bravos to do as well so I will have some used bearings for sale...thanks for the advice.

 

[Lakeside Restorations]

Now I inderstand!! Yes, your most likely culprit is the driveshaft bellows. Not so easy to do. There is not much room in there to work. Merc manual will tell you to pull the helmet off by removing the trim senders and tilt pins. Then you can let it hamg to the side and work easily. Dont forget to clean the areas where the bellows seals to the gimbal and helmet. Use bellows adhesive when reassembling. Definitely replace the gimbal bearing. You will need a good sized automotive type bearing puller ( slap hammer ) and an installer tool. I made a bearing installer from a steel pipe and solid shaft. Then you have to re-align the gimbal bearing to the coupler..

Goodluck.

Vinny is right.. Also if you want to do the whole 9 yards you may want to do the water hose as well.

There is a kit from merc for replacing the boots, bearing & hose from merc. I can get it for you if you would like.

One other word of advice is if the boat has a good ammount of time on it I would think of replacing the shift cable & trim senders while you are in there. If you are going that far in you might as well spend a little more time to do this so you dont have to do it again 6 mos from now.. We usually do this on all of our boot replacments on the Merc i/o's unless the trim senders & cable are really mint. For example a boat 1 year old just has a torn boot for what ever reason then we probably would not do it, otherwise it usually gets done as preventative maint....

It has been our experience that if the boat is a few years old & has some time on it that the senders & shift cable are usually not far off from needing service & sometimes the boot replacement procedure is just enough to push them over the edge, only to put the whole thing back together & find that now your trim gauge doesnt work, or your shift cable is not adjusting or shifting properly..

Hope this helps.. Feel free to call me if you need any parts..

Jamie / lakeside

.

 

[PayCheck]

Thanks Jamie, and yes, I'll replace the original (1974) water hose next season when i buy new ones for the Bravos. I have the Merc "transom repair kit" for the Alpha, with bellows, bearing, seals, o rings and gasket - picked it up off eBay for $75.00.

 

[Lakeside Restorations]

Thanks Jamie, and yes, I'll replace the original (1974) water hose next season when i buy new ones for the Bravos. I have the Merc "transom repair kit" for the Alpha, with bellows, bearing, seals, o rings and gasket - picked it up off eBay for $75.00.

No problem.. Glad I could help.. Also as I mentioned earlier you may want to replace the trim senders on the gimble ring if yours is so equiped along with the shift cable while you are there..

Happy holidays.. Jamie / Lakeside


.

 

[SneakyPete]

What would you estimate a bellows job, trim sender and shift cable job to go for? I would like to do this to mine, and I have no problem building the motor, but for some reason (irrational or not) I am terrified of getting into the drive...

 

[Chris E]

What would you estimate a bellows job, trim sender and shift cable job to go for? I would like to do this to mine, and I have no problem building the motor, but for some reason (irrational or not) I am terrified of getting into the drive...

probably 3 hours maybe 4, if you can do engine work - this job is a peice of cake - buy a sevice manual and be done with it.