Alpha One Generation II Stern Drive
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Transcript of Alpha One Generation II Stern Drive
2
74243
ALPHA ONE GENERATION IISTERN DRIVE
2 - 0 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Table of ContentsPage
Installation Specifications 1. . . . . . . . . . . . . . . . . . Torque Specifications 1. . . . . . . . . . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives 1. . . . . . . . . . Special Tools 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transom Specifications 1. . . . . . . . . . . . . . . . . . . . .
Installation Procedures 2. . . . . . . . . . . . . . . . . . . . Transom Assembly Installation 2. . . . . . . . . . . . . . Power Steering Control Valve and
Cable Installation 3. . . . . . . . . . . . . . . . . . . . . . Power Steering Hose Connections 4. . . . . . . . . . . Stern Drive Unit Installation 4. . . . . . . . . . . . . . . . . Trim Cylinder Connection 4. . . . . . . . . . . . . . . . . . . Propeller Installation 5. . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft HousingSpecifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 6. . . . . . . . . . . . . . . . . . . . . . . Upper Drive Shaft Bearing Preload 6. . . . . . . . . . . U-joint Bearing Preload 6. . . . . . . . . . . . . . . . . . . . . Gear Shimming Specifications 6. . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives 6. . . . . . . . . . Special Tools 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Housing Exploded Parts View 8. . . . U-Joint and Driven Gear Components 8. . . . . . . . Drive Shaft Components 10. . . . . . . . . . . . . . . . . . .
Drive Shaft Housing Shimming 11. . . . . . . . . . . . Gear Distance, Driven Gear 11. . . . . . . . . . . . . . . . Gear Distance, Drive Gear 11. . . . . . . . . . . . . . . . .
Standard Rotation Gear Housing Specifications 12. . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 12. . . . . . . . . . . . . . . . . . . . . . Shimming Specifications 12. . . . . . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives 12. . . . . . . . . Special Tools 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Rotation Gear Housing Exploded Parts View 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Components 14. . . . . . . . . . . . . . . . . . . Propeller Shaft Components 16. . . . . . . . . . . . . . . .
Page
Standard Rotation Gear Housing AssemblySpecifications 18. . . . . . . . . . . . . . . . . . . . . . . .
Pre-Disassembly Inspection 18. . . . . . . . . . . . . . . . Pinion Gear Height 18. . . . . . . . . . . . . . . . . . . . . . . . Shift Spool End Play 18. . . . . . . . . . . . . . . . . . . . . . Forward Gear Backlash 19. . . . . . . . . . . . . . . . . . . . Reverse Gear Backlash 19. . . . . . . . . . . . . . . . . . . .
Counter-Rotation Gear Housing Specifications 20. . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 20. . . . . . . . . . . . . . . . . . . . . . Shimming Specifications 20. . . . . . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives 20. . . . . . . . . Special Tools 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter-Rotation Gear Housing ExplodedParts View 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Components 22. . . . . . . . . . . . . . . . . . . Propeller Shaft Components 24. . . . . . . . . . . . . . . .
Counter-Rotation Gear Housing AssemblySpecifications 26. . . . . . . . . . . . . . . . . . . . . . . .
Pre-Disassembly Inspection 26. . . . . . . . . . . . . . . . Forward and Reverse Gear Identification 26. . . . . Pinion Gear Height 26. . . . . . . . . . . . . . . . . . . . . . . . Shift Spool End Play 26. . . . . . . . . . . . . . . . . . . . . . Forward Gear Backlash 27. . . . . . . . . . . . . . . . . . . . Reverse Gear Backlash 27. . . . . . . . . . . . . . . . . . . .
Transom Assembly Specifications 29. . . . . . . . . . Torque Specifications 29. . . . . . . . . . . . . . . . . . . . . . Special Tools 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives 29. . . . . . . . .
Alpha One Transom Assembly Exploded View 30. . . . . . . . . . . . . . . . . . . . . . .
Bell Housing Components 30. . . . . . . . . . . . . . . . . . Gimbal Housing Components 32. . . . . . . . . . . . . . . Inner Transom Plate Components 34. . . . . . . . . . . Gimbal Ring and Steering Lever
Components 35. . . . . . . . . . . . . . . . . . . . . . . . . .
ALPHA ONE GEN. II STERN DRIVE 2 - 190-806534960
Installation Specifications
Torque SpecificationsNOTE: Securely tighten all fasteners not listed below.
ITEMTORQUE
ITEMlb. in. lb. ft. N⋅m
Exhaust Pipe to GimbalHousing Screws
23 31
Propeller Nut 1 55 75
Steering Cable Coupler Nut
Tighten Nut Until It Bottoms Out Against FlatWasher, then Loosen 1/2
Turn
Steering Cable Coupler Nut 35 48
Steering system Pivot Bolts 50 68
Transom Assembly Attaching Screws and Nuts
23 31
Power Steering HydraulicH Fi i 23 31
g yHose Fittings 23 31
Stern Drive Unit to BellHousing Attaching Nuts
50 68
1: Amount specified is MINIMUM.
Lubricants, Sealers, and Adhesives
DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubricantwith Teflon
92–825407A12
Quicksilver Special Lubricant 101
92-13872A1
Perfect Seal 92-34227-1
Liquid Neoprene 92-25711--2
Quicksilver Engine Coupler Spline Grease
92-816391A4
Special Tools
DESCRIPTION PART NUMBER
Alignment Tool Assembly
91-805475A1
Transom Specifications
22170
a
e c
d
a
b
b
fa - Transom Thickness-2-2 1/4 in. (51mm-57mm)b - Transom Surfaces-Parallel to within 1/8 in. (3.2 mm)c - Area Covered by Inner Transom Plate - Flat to within 1/8 in.
(3.2 mm)d - Area Covered by Gimbal Housing Assembly - Flat to within
1/16 in. (1.6 mm)e - Transom Angle-10� to 16�f - Keel (if Equipped) - Remove 4 ft. (1.2 m) forward of
transom
2 - 2 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Installation Procedures
Transom Assembly Installation
! CAUTIONSteering lever ground wire MUST be positionedas shown or wire may fatigue.
70012
70015
70011
50632
50632
70005
1
2
4
2
3
2
5
6
7
7
a2
a
a
a
700068
b
1 - Speedometer Tube Pick-up Connection2 - Locknuts and Flat Washers3 - Screw4 - Steering Lever Continuity Wire5 - Trim System Wires6 - Shift Cable7 - Trim Hoses (and MerCathode Wires, if so equipped)8 - Gear Lube Hose Fitting
Torque Specification
a 23 lb. ft. (31 N·m)
b 70-90 lb.in. (8-10 N·m)
ALPHA ONE GEN. II STERN DRIVE 2 - 390-806534960
Power Steering Control Valve and Cable Installation
71901
71903
71906
5 68
7
4
a
12
3b 10
73901
9
5
A
1 - Steering Cable2 - Grease Fitting3 - Cable Coupler Nut4 - Cable Guide Tube5 - Cable End6 - Clevis7 - Clevis Pin8 - Cotter Pin9 - Flats on Guide Tube MUST Be Vertical10- Pivot Bolt
Lubricants, Sealers, and Adhesives
A - Quicksilver Special Lubricant 101 92-13872A1. . . . . . . . . . . .
Torque Specification
a 35 lb. ft. (47 N·m)
b 50 lb. ft. (68 N·m)
2 - 4 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Power Steering Hose Connections
73786
a
Typical Hose Routing
a - Hose Fittings - Torque Both Fittings to 23 lb. ft. (31 N·m).
Stern Drive Unit Installation
USING THE ALIGNMENT TOOL
! CAUTIONForcing the alignment tool into position maydamage the Gimbal Bearing or Engine Coupler.Do not attempt to force the alignment tool!
Raise or lower the engine as necessary until align-ment tool moves freely.
71463
a
a
c
a - Alignment Toolb - Gimbal Bearingc - Engine Coupler
STERN DRIVE TO BELL HOUSING CONNECTION
a b
22062
a - Locknut and Flat Washers - Torque to 50 lb. ft. (68 N·m)b - Locknut and Continuity Circuit Washer - Torque to 50 lb. ft.
(68 N·m)
Trim Cylinder Connection
a
b c
d
e
70027
a - Aft Anchor Pinb - Bushingsc - Flat Washers (2)d - E-ring Clips (2)e - Plastic Caps (2)
ALPHA ONE GEN. II STERN DRIVE 2 - 590-806534960
Propeller Installation
a
b
c
e f
g
d
a - Propeller Shaftb - Forward Thrust Hubc - Propellerd - Continuity Washere - Spline Washerf - Tab Washerg - Propeller Nut-Torque to 55 lb. ft. (75 N·m)
2 - 6 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Drive Shaft HousingSpecifications
Torque SpecificationsNOTE: Securely tighten all fasteners not listed below.
DESCRIPTIONTORQUE
DESCRIPTIONlb. in. lb. ft. N⋅m
Top Cover Screws 17-23 23-31
U-joint Retainer Nut 200 271
Oil Vent Screw 30-50 3.4-5.6
Upper Drive Shaft Bearing Preload
DESCRIPTIONTORQUE
DESCRIPTIONlb. in. N⋅m
New Bearings 6-15 0.7-1.7
Used Bearings* 3-7.5 0.3-0.8
*Bearings are considered used if spun under load once.
U-joint Bearing Preload
DESCRIPTIONTORQUE
DESCRIPTIONlb. in. N⋅m
New Bearings 6-10 0.7-1.1
Used Bearings* 3-7.5 0.3-0.8
*Bearings are considered used if spun under load once.
Gear Shimming Specifications
DESCRIPTIONGEAR LOCATION
DESCRIPTIONinches millimeters
Drive Gear .025 0.64
Driven Gear .025 0.64
Lubricants, Sealers, and Adhesives
DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubricantwith Teflon
92-825407A12
Quicksilver U-Jointand Gimbal BearingGrease
92-828052A2
3M Brand Adhesive 92-25234-1
Quicksilver BellowsAdhesive
92-86166
Quicksilver NeedleBearing Assembly Lubricant
92-825265A1
Quicksilver Perfect Seal 92-34227-1
Permatex Ultra Blue Silicone Sealant
Obtain Locally
Quicksilver Special Lubricant 101
92-13872A1
Quicksilver High Performance GearLube
92-816026A4
Special Tools
DESCRIPTION PART NUMBER
Adaptor 91-38756
Bearing Cup Driver 91-38918
Bearing Driver Cup 91-33493
Driver Cup 91-36577
Driver Rod 91-37323
Driver Tool 91-90774
Oil Seal Driver 91-817570
Shimming Tool(Driven Gear)
91-60526
Shimming Tool(Drive Gear)
91-60523
Slide Hammer Puller 91-34569A1
Torque Wrench (lb. in.) 91-66274
U-joint Bearing RetainerWrench
91-17256
Universal Puller Plate 91-37241
ALPHA ONE GEN. II STERN DRIVE 2 - 790-806534960
TORQUE CONVERSION CHART
Use the following table to torque the u-joint retainerto 200 lb. ft. (271 N·m).
Torque Wrench Lengthin Inches (cm)
Torque Wrench Readingin lb. ft. (N·m) to
Achieve 200 lb. ft.(271 N·m) of Torque
15 (38)16 (41)17 (43)18 (46)19 (48)20 (51)21 (53)22 (56)23 (58)24 (61)25 (64)26 (66)27 (69)28 (71)29 (74)30 (76)31 (79)32 (81)33 (84)34 (86)35 (89)36 (91)
111 (151)114 (155)117 (159)120 (163)123 (167)125 (170)127 (172)129 (175)131 (178)133 (180)135 (183)136 (184)138 (187)140 (190)141 (191)143 (194)144 (195)145 (197)147 (200)148 (201)149 (202)150 (203)
a
26363
a
a - Torque Wrench Length
70690
1
23
4
5
6
7
8
9
10
11
11
12
13
14
15
16
1718
1920
21
19
22
23
2526
23
24
27
2829
b
a
A
A
C
B
B
D
2 - 8 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Drive Shaft Housing Exploded Parts ViewU-Joint and Driven Gear Components
ALPHA ONE GEN. II STERN DRIVE 2 - 990-806534960
1 - Drive Shaft Housing2 - Screw3 - O-ring4 - Spring Assembly5 - Oil Seal6 - Wear Pad7 - Plug8 - Universal Joint9 - Yoke, universal joint - gear end10- Socket, center - universal joint11- Cross and Bearing12- Yoke Assembly, universal
joint - coupling end13- O-ring14- Retainer15- Ring16- O-ring17- Carrier Assembly18- Oil Seal19- Roller Bearing and Cups20- Cup Spacer21- Shim22- Shim23- Drive Gear Assembly24- Roller Bearing and Cup25- Washer26- Nut27- Shims28- Ground Plate29- Screw
Lubricants, Sealers, and Adhesives
A - 2-4-C Marine Lubricantwith Teflon 92-825407A12. . . . . . . . . . . .
B - Quicksilver High PerformanceGear Lube 92-816025A4. . . . . . . . . . . . .
C - Quicksilver Special Lubricant 101 92-13872A1. . . . . . . . . . . .
D - Quicksilver Engine Coupler Spline Grease 92-816391A4. . .
Torque Specification
a 200 lb. ft. (271 N·m) (See Chart on p. 2B-2)
Rolling Preload
b Tighten in Small Increments Until6-10 lb. in. (.07-1.1 N·m) of Rolling Preload
2 - 10 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Drive Shaft Components
74243
a
b
b
A
B
5
1
2
3
4
8
9
10
11
12
13
14
16
15
17
18
1 - Cover, top2 - Bearing and Cup3 - Shim4 - O-ring5 - Screw8 - Drive Shaft, upper9 - Filler Wall10- Washer11 - Nut12- Anodic Plate13- Screw14- Lockwasher15- Screw16- Seal17- Water Tube18- Stuffer Plug
Lubricants, Sealers, and Adhesives
A - Quicksilver 2-4-C MarineLubricant with Teflon 92-825407A12. . .
B - Quicksilver High Performance Gear Lube 92-816026A4.
Torque Specifications
a 20 lb. ft. (27 N·m)
b 35 lb. ft. (47.5 N·m)
ALPHA ONE GEN. II STERN DRIVE 2 - 1190-806534960
Drive Shaft HousingShimming
Gear Distance, Driven Gear
SHIMMING TOOL 91-60526
Overall DriveUnit Gear Ratio
ToolPosition
1.47:11.62:11.81:11.94:12.40:1
ZXYYY
23012
a
.025”(0.64mm
)
a - Feeler Gauge - .025 in. (0.635mm)
Gear Distance, Drive Gear
23012
.025”(0.64mm)
a
23012
SHIMMING TOOL 91-60523
Overall DriveUnit Gear Ratio
ToolPosition
ZYYYY
1.47:11.62:11.81:11.94:12.40:1
a - Feeler Gauge - .025 in. (0.635mm)
2 - 12 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Standard Rotation GearHousing SpecificationsTorque SpecificationsNOTE: Securely tighten all fasteners not listed below.
DESCRIPTIONTORQUE
DESCRIPTIONlb. in. lb. ft. N⋅m
Water Pump Body Screws 60 6.8
Pinion Gear Nut 70 95
Gear Housing to DriveShaft Housing Screws
28 38
Gear Housing to DriveShaft Housing Nuts
35 47
Trim Tab Screw 23 31
Shift Shaft Bushing Screws 60 6.8
Drive Shaft Retainer 100 136
Bear Carrier Retainer 210 285
Oil Fill/Drain Screw 30-50
3.4-5.6
Propeller Nut 1 55 75
1: Amount specified is MINIMUM.
Shimming Specifications
DESCRIPTIONGEAR LOCATION
DESCRIPTIONinches millimeters
Pinion Gear Height .025 0.64
Forward Gear Backlash .017-.028 0.43-0.71
Reverse Gear Backlash .034-.054 0.86-1.37
Lubricants, Sealers, and Adhesives
DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubricant with Teflon
92-825407A12
3M Brand Adhesive 92-25234-1
Quicksilver Bellows Adhesive 92-86166
Quicksilver Needle Bearing As-sembly Lubricant
92-825265A1
Quicksilver Perfect Seal 92-34227-1
Permatex Ultra Blue SiliconeSealant
Obtain Locally
Quicksilver Special Lubricant101
92-13872A1
Loctite 8831 92-823089-1
Quicksilver High PerformanceGear Lube
92-816026A4
ALPHA ONE GEN. II STERN DRIVE 2 - 1390-806534960
Special Tools
DESCRIPTION PART NO.
Backlash Indicator Rod 91-53459Bearing Carrier Retainer Wrench 91-61069Bearing Preload Tool ♠ 91-14311A2*Belleville Washer 12-54048Dial Indicator 91-58222A1Dial Indicator Holding Tool 91-89897Drive Shaft Nut Wrench 91-56775Driver Cup ♦ 91-31106Drive Shaft Bearing Wrench 91-43506Needle Bearing Driver 91-15755Needle Bearing Driver 91-33491Oil Seal Driver 91-31108Oil Seal Driver 91-817569Pinion Gear Shimming Tool 91-56048Pinion Nut Adapter (Includes the following item) 91-61067A3
Drive Shaft Adapter 91-61077Puller Bolt 91-85716Puller Jaws 91-46086A1Slide Hammer Puller 91-34569A1Torque Wrench (inch pound) 91-66274Universal Puller Plate 91-37241Water Pump Alignment Pins 91-821571A1Universal Bearing Removal and Installation Tool (Includes the following items) 91-31229A7
Bearing Adapter 91-15755Bearing Installation Tool 91-38628Collar 91-30366-1Driver Head 91-32336Driver Head 91-36569Driver Head 91-37311Driver Head 91-37312Driver Head 91-52393Driver Head Rod 91-37323Nut 11-24156Pilot Washer 91-36571Pilot Washer 91-37324Pilot Washer 91-37350Puller Plate 91-29310Puller Head 91-36379Puller Head 91-32325Puller Head 91-38628Puller Rod 91-52394Puller Shaft 91-31229Roller Bearing Removal and Installation Tool 91-37292Washer 12-34961
♠ The 91-14311A2 Bearing Preload Tool is also usedon Mercury and Mariner V-6 gear housings.
♦ The 91-31106 Bearing Cup Driver is also used onMercury and Mariner V-6 gear housings and BravoStern Drives.
2 - 14 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Standard Rotation Gear Housing Exploded Parts ViewDrive Shaft Components
74242
28
7
30
2526
29
31
a
f
a
b
A
D
A
A
A(ID)
C
A
B
D
A
hE
18
21
19
20
13
11
10
32
343
9
38
37
337
5
4
1
216
15
14
8
23
17
24
22
6
27
36
12
38
ALPHA ONE GEN. II STERN DRIVE 2 - 1590-806534960
1 - Gear Housing2 - Pin3 - Stud4 - Oil Fill/Drain Screw5 - O-ring6 - Seal7 - Dowel Pin8 - Roller Bearing9 - Speedometer Fitting10- Drive Shaft11- Shim12- Bearing and Cup13- Nut14- Gear Drive15- Washer16- Nut17- Face Plate18- Carrier19- Oil Seal20- Oil Seal21- O-ring22- Water Pump23- Gasket24- Gasket25- Face Seal26- Screw27- Impeller28- Key29- Coupling30- O-rings31- Sleeve32- Shift Shaft33- Retaining Ring34- Sleeve35- Bushing Assembly36- Oil Seal37- O-rings38- Screw
Lubricants, Sealers, and Adhesives
A - Quicksilver 2-4-C Marine Lubricant with Teflon 92-825407A12. . .
B - 3M Brand Adhesive 92-25234-1. . . . . . .
C - Loctite 8831 92-823089-1. . . . . . . . . . . . .
D - Quicksilver High Performance Gear Lube 92-816026A4.
E - Quicksilver Needle Bearing Assembly Lubricant 92-825265A1. . . . .
Torque Specifications
a 60 lb. in. (6.8 N·m)
b 70 lb. ft. (95 N·m)
c 28 lb. ft. (38 N·m)
d 35 lb. ft. (47 N·m)
e 23 lb. ft. (31 N·m)
f 100 lb. ft. (136 N·m)
g 210 lb. ft. (285 N·m)
h 30-50 lb. in. (3.4-5.6 N·m)
2 - 16 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Propeller Shaft Components
73601
c
d
g
F(OD)
A(ID)
C
C
B
CE
D
2223
e
35
25 24
2627
282930
12
1415
1617
18
2
45
6
10
8
11
3
9
7
31
33
34
1
20
21
13
19
32
ALPHA ONE GEN. II STERN DRIVE 2 - 1790-806534960
1 - Gear Housing2 - Shift Crank3 - Shift Spool Assembly4 - Shim, Bearing Outer Race5 - Bearing and Cup6 - Forward Gear7 - Roller Bearing8 - Sliding Clutch9 - Cross Pin10- Spring11- Propeller Shaft12- Reverse Gear13- Thrust Washer14- Thrust Hub15- Ball Bearing16- O-ring17- Roller Bearing18- Bearing Carrier Assembly19- Anode20- Screw21- Star Washer22- Oil Seal (Inside)23- Oil Seal (Outside)24- Tab Washer25- Retainer26- Thrust Hub27- Continuity Washer28- Spline Washer29- Tab Washer30- Locknut - Propeller31- Anodic Trim Tab (Anodic Plate - Some Models)32- Screw33- Star Washer34- Screw35- Nut
Lubricants, Sealers, and Adhesives
A - Quicksilver 2-4-C MarineLubricant with Teflon 92-825407A12. . . .
B - Loctite 8831 92-823089-1. . . . . . . . . . . . .
C - Quicksilver High Performance Gear Lube 92-16026A4. .
D - Quicksilver Perfect Seal 92-34277-1. . . .
E - Permatex Ultra Blue Silicone Sealant Obtain Locally. . . . . . . .
F - Quicksilver Special Lubricant 101 92-13872A1. . . . . . . . . . . .
Torque Specifications
a 60 lb. in. (6.8 N·m)
b 70 lb. ft. (95 N·m)
c 28 lb. ft. (38 N·m)
d 35 lb. ft. (47 N·m)
e 23 lb. ft. (31 N·m)
f 100 lb. ft. (136 N·m)
g 210 lb. ft. (285 N·m)
2 - 18 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Standard Rotation GearHousing AssemblySpecificationsPre-Disassembly Inspection
Action Reading
Move propeller shaftfrom one side to anoth-er
Less than .003 in. (0.08 mm)
Rotate propeller shaft .005 in. (.127 mm) orless
22086
Pinion Gear HeightCheck pinion height at four locations. Average pinion gear height: .025 in. (0.64 mm).
26410
Shift Spool End Play
23142
ea
fg
d
b c
h
a - Washers (2)b - Springc - Retainerd - Spoole - Shift Shaftf - Castle Nutg - Cotter Pinh - End Play Measurement: .002 in. (.05mm) to
.010 in. (.25mm)
ALPHA ONE GEN. II STERN DRIVE 2 - 1990-806534960
Forward Gear BacklashApply forward pressure to the propeller shaft withpuller jaws. Torque the puller bolt to 45 lb. in. (5 N·m ).
70719
a - Puller Jawsb - Puller Bolt
Take readings at four different locations, 90� apart,and average them for the backlash reading.Backlash reading: .017-.028 in. (0.43-0.71 mm)
70717
fed
a
a
cb
a - Nuts (4)b - Threaded Rodc - Dial Indicator Holding Toold - Dial indicatore - Indicator Pointer-Set at “I” on Backlash Indicator Rodf - Backlash Indicator Rod
Reverse Gear BacklashUse the pinion nut adaptor to apply backward pres-sure on the propeller shaft. Torque Propeller nut to 45 lb. in. (5 N·m).
23355
abc
a - Pinion Nut Adaptorb - Washerc - Propeller Nut
Backlash reading: .034-.054 in. (0.86-1.37 mm).
70717
fed
a
a
cb
a - Nuts (4)b - Threaded Rodc - Dial Indicator Holding Toold - Dial indicatore - Indicator Pointer-Set at “I” on Backlash Indicator Rodf - Backlash Indicator Rod
2 - 20 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Counter-Rotation GearHousing SpecificationsTorque SpecificationsNOTE: Securely tighten all fasteners not listed below.
DESCRIPTIONTORQUE
DESCRIPTIONlb. in. lb. ft. N⋅m
Water Pump Body Screws 60 6.8
Pinion Gear Nut 70 95
Gear Housing to DriveShaft Housing Screws
28 38
Gear Housing to DriveShaft Housing Nuts
35 47
Trim Tab Screw 23 31
Shift Shaft Bushing Screws 60 6.8
Drive Shaft Retainer 100 136
Bear Carrier Retainer 210 285
Oil Fill/Drain Screw 30-50
3.4-5.6
Propeller Nut 1 55 75
1: Amount specified is MINIMUM.
Shimming Specifications
DESCRIPTIONGEAR LOCATION
DESCRIPTIONinches millimeters
Pinion Gear Height .025 0.64
Forward GearBacklash
.017-.028 0.43-0.71
Reverse GearBacklash
.040-.050 1.02-1.27
Lubricants, Sealers, and Adhesives
DESCRIPTION PART NUMBER
Quicksilver 2-4-C Marine Lubricant with Teflon
92-825407A2
3m Brand Adhesive 92-25234-1
Quicksilver Bellows Adhesive 92-86166
Quicksilver Needle BearingAssembly Lubricant
92-825265A1
Quicksilver Perfect Seal 92-34227-1
Permatex Ultra Blue Silicone Sealant
Obtain Locally
Quicksilver Special Lubricant 101
92-13872A1
Loctite 8831 92-823089-1
Quicksilver High Performance Gear Lube
92-816026A1
ALPHA ONE GEN. II STERN DRIVE 2 - 2190-806534960
Special Tools
Description Tool Part No.
Backlash Indicator Rod 91-53459Bearing Adaptor Installation Tool 91-18605A1Bearing Carrier Retainer Wrench 91-61069Bearing Driver ♦ 91-807944Bearing Preload Tool 91-14311A2*Bearing Removal Tool 91-816245Belleville Washer 12-54048Dial Indicator 91-58222A1Dial Indicator Holding Tool 91-89897Drive Shaft Nut Wrench 91-56775Drive Shaft Bearing Retainer Wrench 91-43506Guide Plate 91-816243Needle Bearing Driver 91-15755Oil Seal Driver 91-31108Oil Seal Driver 91-817569Pinion Gear Shimming Tool 91-56048Pinion Nut adapter (Includes the following item) 91-61067A3
Drive Shaft Adapter 91-61077Puller Bolt 91-85716Puller Jaws 91-46086A1Puller Jaws 91-816242Slide Hammer Puller 91-34569A1Forward Gear Installation Tool 91-815850Torque Wrench (inch pound) 91-66274Universal Puller Plate 91-37241Water Pump Alignment Pins 91-821571A1Universal Bearing Removal and Installation Tool (Includes the following items) 91-31229A5
Driver Head 91-36569Driver Head Rod 91-37323Nut 11-24156Pilot Washer 91-36571Puller Plate 91-29310Puller/Driver Head 91-38628Puller Shaft 91-31229Washer 12-34961
*The 91-14311A2 Bearing Preload Tool is also usedon Mercury and Mariner V-6 gear housings.
♦ New Tool
NOTE: Water Pump Face Seal Tool is not availableseparately, 26-816575A2 is a kit part number whichincludes the tool and the face seal.
74242
18
21
19
20
11
28 32
34
3
9
38
337
4
1
2
16
15
14
8
7
23
17
24
30
2526
29
31
a
f
a
b
A
D
A
A
A(ID)
C
A
B
D
A
6
hE
5
37
36
10
13
1227
22
39
2 - 22 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Counter-Rotation Gear Housing Exploded Parts ViewDrive Shaft Components
ALPHA ONE GEN. II STERN DRIVE 2 - 2390-806534960
1 -Gear Housing2 -Pin3 -Stud4 -Screw5 -Oil Fill/Drain Screw
O-ring6 -Seal7 -Dowel Pin8 -Roller Bearing9 -Speedometer Fitting10-Drive Shaft11 -Shim12-Bearing and Cup13-Nut14-Gear Drive15-Washer16-Nut17-Face Plate18-Carrier19-Oil Seal20-Oil Seal21-O-ring22-Water Pump23-Gasket24-Gasket25-Face Seal26-Screw27-Impeller28-Key29-Coupling30-O-rings31-Sleeve32-Shift Shaft33-Retaining Ring34-Sleeve35-Bushing Assembly36-Oil Seal37-O-rings38-Screw39-Stuffer Plug
Lubricants, Sealers, and Adhesives
A - Quicksilver 2-4-C Marine Lubricant with Teflon 92-825407A12. . .
B - 3M Brand Adhesive 92–25234-1. . . . . . .
C - Loctite 8831 92-823089-1. . . . . . . . . . . . .
D - Quicksilver High Performance Gear Lube 92-816026A4.
E - Quicksilver Needle Bearing Assembly Lubricant 92-825265A1. . . . .
Torque Specifications
a 60 lb. in. (6.8 N·m)
b 70 lb. ft. (95 N·m)
c 28 lb. ft. (38 N·m)
d 35 lb. ft. (47 N·m)
e 23 lb. ft. (31 N·m)
f 100 lb. ft. (136 N·m)
g 210 lb. ft. (285 N·m)
h 30-50 lb. in. (3.4-5.6 N·m)
d
c
e
E
g
G(OD)
E
H
F
74723
39
14
1516
17
19
20
21
2223
24
25
26
27
28
272625
29
30
31
33
34
363738
35
8
9
1011
12
13
7
6
5
1
18
2
3
4
40
33
32
6
(ID)A
2 - 24 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Propeller Shaft Components
ALPHA ONE GEN. II STERN DRIVE 2 - 2590-806534960
1 - Gear Housing2 - Screw - Trim Plate or Tab3 - Nut4 - Screw5 - Lockwasher6 - Anodic Plate or Tab7 - Shift Crank8 - Shift Spool Assembly9 - Shims10- Bearing Adapter - Reverse Gear11- Roller Bearing12- Thrust Washer13- Thrust Bearing14- Roller Bearing15- Reverse Gear16- Retainer Spring - Cross Pin17- Clutch18- Cross Pin19- Propeller Shaft20- Forward Gear21- Shim Spacer22- Thrust Bearing23- Roller Bearing24- Bearing Adapter - Forward Gear25- Thrust Washer26- Thrust Bearing27- Thrust Race28- Keepers29- O-ring30- Needle Bearing31- Bearing Carrier32- Propeller Anode and Screws33- Seals34- Tab Washer35- Retaining Nut36- Thrust Hub37- Continuity Washer38- Spline Washer39- Tab Washer40- Locknut
Lubricants, Sealers, and Adhesives
A - Quicksilver 2-4-C Marine Lubricantwith Teflon 92-825407A12. . . . . . . . . . . .
B - 3M Brand Adhesive 92–25234-1. . . . . . .
C - Quicksilver Bellows Adhesive 92-86166. . . . . . . . . . . . . . . . . . .
D - Quicksilver Needle Bearing Assembly Lubricant 92-825265A1. . . . .
E - Quicksilver Perfect Seal 92-34227-1. . . .
F - Permatex Ultra Blue Silicone Sealant Obtain Locally. . . . . . . .
G - Quicksilver Special Lubricant 101 92-13872A1. . . . . . . . . . . .
H - Loctite 8831 92-823089-1. . . . . . . . . . . . .
I - Quicksilver High Performance Gear Lube 92-816026A4.
Torque Specifications
a 60 lb. in. (6.8 N·m)
b 70 lb. ft. (95 N·m)
c 28 lb. ft. (38 N·m)
d 35 lb. ft. (47 N·m)
e 23 lb. ft. (31 N·m)
f 100 lb. ft. (136 N·m)
g 210 lb. ft. (285 N·m)
2 - 26 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Counter-Rotation GearHousing AssemblySpecifications
Pre-Disassembly Inspection
Action Reading
Move propeller shaftfrom one side to another
Less than .003 in. (0.08 mm)
Rotate propeller shaft .005 in. (.127 mm) orless
22086
Forward and Reverse GearIdentificationIMPORTANT: The forward and reverse gears look al-most identical. There are two ways to distinguish be-tween the reverse and forward gears. The reverse gearhas a shorter hub and it has a groove cut into the backof the gear just inside the thrust bearing race.
50885
REVERSE FORWARD
ab
a - Shorter Hubb - Groove
Pinion Gear HeightTake readings in three locations, 120� apart. Readings: .025 in. (0.64 mm).
26410
.
Shift Spool End Play
74877
ea
fg
d
b c
h
a - Washers (2)b - Springc - Retainerd - Spoole - Shift Shaftf - Castle Nutg - Cotter Pinh - End Play Measurement: .002 in. (.05mm) to
.010 in. (.25mm)
ALPHA ONE GEN. II STERN DRIVE 2 - 2790-806534960
Forward Gear BacklashApply a slight preload on forward gear using tools asshown.
50880
a b
c
d
a - Torque Wrench (91-66274)b - Propeller Nut [Torque to 45 lb. in. (5 N·m)]c - Washer (91-54048)d - Pinion Nut Adaptor (91-61067A3)
Check Backlash in four places. Rotate the drive shaft90� after each check.
Backlash Reading: .017-.028 in (0.43-0.71mm).
70717
a
a
b c
d
e f
a - Nuts (4) (obtain locally)b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]c - Dial Indicator Holding Tool (91-89897)d - Dial Indicator (91-58222A1)e - Indicator Pointer-set indicator pointer at “I” on
backlash indicator rodf - Backlash Indicator Rod (91-53459)
Reverse Gear BacklashApply a slight preload on reverse gear using tools asshown.
70973
b
c
d
a
a - Torque Wrench (91-66274)b - Driver Bolt [Torque to 45 lb. in. (5N·m)]c - Bearing Adaptor Installation Tool
(91-18605A1)d - Reverse Gear
Check Backlash in four places. Rotate the drive shaft90� after each check.
Backlash Reading: .050-.060 in. (1.27-1.52 mm).
a - Nuts (4) (obtain locally)b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]c - Dial Indicator Holding Tool (91-89897)d - Dial Indicator (91-58222A1)e - Indicator Pointer-set indicator pointer at “I” on backlash indicator rodf - Backlash Indicator Rod (91-53459)
70717
a
b c
d
e f
a
2 - 28 ALPHA ONE GEN. II STERN DRIVE 90-806534960
THIS PAGE IS INTENTIONALLY BLANK
ALPHA ONE GEN. II STERN DRIVE 2 - 2990-806534960
Transom AssemblySpecifications
Torque SpecificationsNOTE: Securely tighten all fasteners not listed below.
DESCRIPTIONTORQUE
DESCRIPTIONlb. in. lb. ft. N⋅m
Shift Cable Core Wire Anchor Screws
20 2.3
Bellows Hose Clamps 35 4
Gimbal Ring to Bell Housing Hinge Pins
102 143
Gimbal Ring Screws 55 74
Steering Screw and Nut 60 81
Transom Assembly Attaching Screws, Nut
20-25
27-34
90�Fitting Nut 10-14
14-19
90�Fitting 70-90
8-10
Oil Fill/Drain Screw 23 30
Special Tools
DESCRIPTION PART NUMBER
Bearing Removal andInstallation Tool
91-31229A5
Bellows Expander Tool 91-45497A1
Slide Hammer Puller 91-34569A1
Shift Cable Removaland Installation Tool
91-12037
Driver 91-33492
Driver 91-33491
Driver 91-33489
Driver Head 91-32325
Driver Rod 91-37323
Drive Shaft Nut Wrench 91-56775
Alignment Tool Assembly
91-805475A1
Expander Tool 91-45497A1
Hinge Pin Tool 91-78310
Mandrel 91-30366
Nut 11-24156
Special Tools (continued)
DESCRIPTION PART NUMBER
Plate (2) 91-29310
Puller 91-63616
Puller Head 91-38919
Puller Shaft 91-31229
Washer 12-34961
Bushing InstallationTool
91-806928T
Sleeve Installation Tool 91-818169
Sleeve Removal Tool 91-818162
Lubricants, Sealers, and Adhesives
DESCRIPTION PART NUMBER
Quicksilver BellowsAdhesive
92-86166
Quicksilver 2-4-C Marine Lubricantwith Teflon
92-825407A12
Quicksilver U-Joint andGimbal Bearing Grease
92-828052A2
Perfect Seal 92-34227-1
Anti-Corrosion Grease 92-78376-12
Locquic Primer “T” 92-59327-1
Loctite 8831 92-823089-1
Quicksilver Special Lubricant 101
92-13872A1
6
16
a
A
A
73316
17
18
3
13
22
24
10
12
23
7
A
b
20
11
36
38
5
3537
33
34
2
14
15
14
14
3130
2928
32
26
25
4
9
18
a21
B
A
27
1
C
E
CB
F
B(O.D.)
c
2 - 30 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Alpha One Transom Assembly Exploded ViewBell Housing Components
ALPHA ONE GEN. II STERN DRIVE 2 - 3190-806534960
1 - Bell Housing Assembly2 - Gasket3 - Connector4 - Pipe Plug5 - Bushing6 - Bushing 7 - Gasket (Rubber)8 - O-ring9 - Washer (Synthane)10-Stud11- Washer12- Nut13- Universal Joint Bellows14- Ground Clip15- Clamp16- Sleeve17- Hose18- Clamp19- Exhaust Bellows20- Seals21- Clamp22- Lever Assembly23- Washer24- Screw25- Shift Shaft (Upper)26- Coupling Assembly27- Tubing28- Clip29- Clamp30- Fitting Assembly31- Connector32- Clamp33- Hose34- Clamp35- Connector36- O-ring37- Valve Assembly38- O-ring
Lubricants, Sealers, and Adhesives
A - Quicksilver Bellows Adhesive 92-86166. . . . . . . . . . . . . . . . . . . . . . . . . . . .
B - Loctite 8831 92-823089-1. . . . . . . . . . . . . . . .
C - Perfect Seal 92-34227-1. . . . . . . . . . . . . . . . .
D - Special Lubricant 101 92-13872A1. . . . . . . .
E - Quicksilver High Performance. . . Gear Lube 92-816026A4. . . . . . . . . . . . . . . . . . . . . .
F - 3M Brand Adhesive 92-25234-1. . . . . . . . . .
Torque Specifications
a Tighten SecurelyApproximately 35 lb. in. (4 N·m)
b 50 lb. ft. (68 N·m)
c 8 lb. ft. (11 N·m)
38
34
36
37
35
39
a
b
74861
18
20
A
47
19
48
B
d
C
D
1
21
27 26
33
32
14
16
15
17
13
6
12
11
31
7
29
9
41
41
40
42
43
44
5 3
440
8
2
14
45
46
30
10
49 c
2 - 32 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Gimbal Housing Components
ALPHA ONE GEN. II STERN DRIVE 2 - 3390-806534960
1 - Gimbal Housing2 - Stud3 - Lower Bushing4 - Oil Seal5 - Upper Bushing6 - Grease Fitting7 - Lubricap8 - Grease Seal9 - Bearing Assembly10- Tolerance Ring11- O-Ring12- Stud13- Seal14- Pipe Plug15- Water Tube16- Bushing17- Cover18- Screw19- Lower Swivel Pin20- Cotter Pin21- Washer22- Bolt23- Washer24- Washer25- Nut26- Bolt27- Clamp28- Clamp29- Washer30- Nut31- Gasket32- Connector33- Lockwasher34- Nut35- Anodic Plate36- Seal37- Gasket38- Screw39- Lockwasher40- Hose41- Clamp42- 90� Fitting43- Nut44- Washer45- O-ring46- Connector47- Continuity Wire48- Continuity Wire
Connection49- Hose Clamp
Lubricants, Sealers, and Adhesives
A - Quicksilver Bellows Adhesive 92-86166. . . . . . . . . . . . . . . . . . .
B - Quicksilver Perfect Seal 92-34227-1. . . .
C - Loctite 8831 92-823089-1. . . . . . . . . . . . .
D - Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2. .
Torque Specifications
a 70-90 lb. in. (8-10 N·m)
b 10-14 lb. ft. (14-19 N·m)
c 35-42 lb. in. (3.96-4.75 N·m)
d 25 lb. ft. (34 N·m)
2 - 34 ALPHA ONE GEN. II STERN DRIVE 90-806534960
Inner Transom Plate Components
c 4
9
2
3
1
74850
10a
11
b
5
6
7
8
74865
13
1219
20
1718
16
14
15
1 - Transom Plate Assembly2 - Pivot Bolts3 - Tab Washers4 - Screw Engine Mounting5 - Washer6 - Spacer7 - Washer - Fiber8 - Lockwasher - Double Wound9 - Locknut10- Washer11- Locknut12- Shift Cable Outer Casing13- End Guide14- Core Wire Anchor
15- Anchor Screws16- Core Wire17- Shift Slide18- Screw - Core Wire Cavity19- Gimbal Housing Eyelet20- Cable Wrapping
Torque Specifications
a 25 lb. ft. (34 N·m)
b 23 lb. ft. (30 N·m)
c 37 lb. ft. (50 N·m)
ALPHA ONE GEN. II STERN DRIVE 2 - 3590-806534960
Gimbal Ring and Steering Lever Components
24
25
13
19
23
22
5
109
8
2
34
20
621
18
7
16
1517
1
73318
c
a
b
26
A
14
11
12
8
9
10
d
1 - Gimbal Ring2 - Bushing3 - Grease Fitting4 - Lubricap5 - Hinge Pin6 - Trim Limit Switch7 - Washer8 - Screw9 - Lockwasher10- Retainer11- Trim Wire Clamp12- Screw13- Steering Lever14- Swivel Shaft15- Washer16- Washer17- Nut18- Screw19- Nut20- Screw21- Washer
22- Washer23- Locknut24- Clevis Pin25- Cotter Pin26- Trim Position Sender
Lubricants, Sealers, and Adhesives
A - Resiweld Sealer 92-65150-1. . . . . . . . . .
Torque Specifications
a 60 lb. ft. (81 N·m)
b 55 lb. ft. (74 N·m)
c 110 lb. ft. (148 N·m)
d 90-100 lb. in. (10-11 N·m)