Re installimg outdrive

S

Scott215

Well-Known Member
Jun 4, 2022
2,241
Boat Info
2006 215 weekender 5.0 mpi
Engines
5.0 mpi alpha 1 gen 2
Replaced my gimble bearing and it is 100% aligned and cannot get the drive to go back in. Tried for 2 hours last nite and the alignment as i said is perfect. Any suggestions. Would like to get back on the water someday. Thanks
 
Is your drive not going on at all, or going on partially then stopping? Aligning the drive to the gimbal assy is everything.

My drives have been Bravo's for last 3 boats and had one Alpha. Method has been the same. I remove my drive every winter and store in garage. Putting it back on is normally without incident, IF the drive is aligned perfectly. Sometimes, it helps to grab the input shaft with your hand and guide it in and slightly turn the input so the splines align with the hub on the engine.
 
Most likely you can’t get your hand in there to turn the input shaft but while you are installing and get to the spot where it no longer moves forward, rotate the prop and that should line up the splines. Remember it will click in one direction so go the other way.

I am assuming you have it in forward?
 
How far is it going on? Is it possible you have the wrong O rings on the drive shaft creating too much interference?
 
I can barely get it on the six studs and we had it in almost all the way but took it out to check something to double check something and we had trouble after that so I'm thinking it's just an alignment issue I'm going to take a panel off the back of the boat and see if I can reach in and align it with the drive coupler but it's a professional mechanic doing it he works at a very high-end Marina he just said he's never had this much trouble with putting it out drive back on after replacing the bearing and it is the right bearing
 
So we worked on it last night which is when we had these problems and I when I went out this morning to look at it the only thing I can see that may or may not make a difference is that the steering or the bell housing is not straight saying the steering wheel is not centered with equal distance all around the alignment tool that's the only thing I can see
 
Usually have to turn the input shaft to line up the splines to get it to slide in the last inch or so.
 
I watched a few videos and I'm going to take Emery cloth to the shaft where the shaft rides in the bearing because it has some crud on it hopefully it's just that little bit that's preventing it from going in and oil on the o-rings no grease
 
Thornton69 said:
How far is it going on? Is it possible you have the wrong O rings on the drive shaft creating too much interference?
Click to expand...
THIS is a common occurrence. The kits have a large O-ring that looks like it's the right one. It's actually a very small O-ring that goes ON the shaft. EDITED: Those ARE OEM O-Rings as provided in the kit!!! Replace those two with a smaller set and it will slip right in assuming everything else lines up.
 
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So only install the last two towards the u joint only
 
All oem parts Mike I don't get it . The machanic that works at a well respected Marina is my neighbor
 
May have to tilt the motor a little bit, I'm puzzled it cam out kinda easy
 
So I'll just cut to the chase here I have a certified Mercury Master tech helping me he is my next door neighbor and we cannot get this to go in we have the alignment tool the new gimbal bearing isn't all the way just do not understand what the problem could be you can slide the alignment tool in and out nice and easy and then when you go to put the drive on it's stopping right before the threads on the studs I just don't understand it can somebody please help me
 
You have one of two issues working against you or even both. One, you do not have the splines on the drive shaft lined up. You should have the drive in 'forward' gear, put a prop on the drive, slide the shaft in, as you meet resistance, grab the prop and turn it until you feel the resistance of the transmission which means you are turning the correct direction. Continue turning the prop in small increments while applying forward pressure on the outdrive, until it slides in. And the drive MUST be in forward gear or your shift shaft on the drive will not line up with the shift shaft in the transom assembly. The drive can easily come out of forward gear so applying the pressure on the prop also holds it in gear and aligns the shift shafts. This could also stop it as well. O-ring size should make no difference. Most alignment tools go in easily because they have no splines. Don't raise the outdrive and do not turn it right or left. You want the entry to be as straight as possible. I'm surprised you neighbor does not know this. If he does, you did not mention you've tried this method. I've installed countless Alpha drives and this is the only method for installation.
 
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Just to add a bit to @NorCal Boater's great suggestion: the outdrive must be in Forward but, since the forward gear dogs are tapered, it'll move back to neutral unless you apply and maintain pressure to the prop in the "Reverse" direction. When doing them by myself, I'd rest my left foot on a prop blade, thus turning it backwards. Assuming you're just having a spline alignment issue, this should take care of your trouble.
 
Now he thinks the gimbal bearing is not in all the way. How close to the inner seal should it be , he was one the fone with another tech and the guy said it should almost be touching the inner seal
 
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