Workshop Manual BSterndrive 2(0) DP-E, SP-E DP-E, SP-E Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Upper Gear Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Intermediate Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SP-E Lower Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 DP Lower Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Sterndrive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Transom Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Trim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 INTRODUCTION This Workshop Manual contains technical specifications, descriptions, and instructions for the repair of the Volvo Penta Check that the warning or information labels on products or product types described in the Table of Con- the product are always clearly visible. Replace tents. Check that you have the correct Workshop Manual for labels which have been damaged or painted the product you are servicing. over. Before starting work on the engine be sure to read, Engines equipped with turbocharger: Never start follow and underst and the “S understand afety Precautions,” “Gen- “Safety the engine without installing the air cleaner fil- eral Information,” and “Repair Instructions” sections of ter. The rotating compressor in the turbo can this W orkshop Manual. Workshop cause serious personal injury. Foreign objects In this book and on the product you will find the following entering the intake ducts can also cause me- special warning symbols: chanical damage. Never use ether spray or similar starting fluid Special instructions to aid assembly. when starting the engine. They may cause an explosion in the inlet manifold. There is a real Indicates an potentially hazardous situation which, if not avoided, may result in minor or moderate danger of personal injury. injury. It may also be used to alert against unsafe practices. Avoid opening the filler cap for engine coolant Indicates a potentially hazardous situation systems (freshwater cooled engines) when the which, if not avoided, could result in death or serious injury. engine is still hot. Steam or hot coolant can spray out. Open the filler cap slowly and release the pressure on the system. Take great care if a Indicates an immediately hazardous cock, plug, or engine coolant line must be re- situation which, if not avoided, will result in death or moved from a hot engine. Steam or hot coolant serious injury. This is a signal word is used in only the most extreme situations. can spray out in any direction. Below is a summary of the risks involved and safety precau- Hot oil can cause burns. Avoid getting hot oil on tions you should always observe or carry out when operating the skin. Ensure that the lubrication system is or servicing the engine. not under pressure before carrying out any work. Never start or operate the engine with the oil Immobilize the engine by turning off the power cap removed; otherwise, oil could be ejected. supply to the engine at the main switches and lock it (them) in the OFF position or by discon- Stop the engine and close the sea cock before necting the battery negative (-) lead. carrying out operations on the engine cooling system. As a general rule, all service operations must be carried out with the engine stopped. However, Only start the engine in a well-ventilated area. If some operations, such as certain engine adjust- operating the engine in an enclosed area, en- ments, will require the engine to be running. sure that there is exhaust ventilation leading out Approaching an engine that is operating is a of the engine compartment or workshop area to safety risk. Loose clothing or long hair may be remove exhaust gasses and crankcase ventila- caught in rotating parts and cause serious injury. tion emissions. If working in the proximity of an engine when it is operating, careless movements, or a dropped tool can result in personal injury or damaged Always use protective glasses or goggles when carrying out work where there is a risk of splin- equipment. Take care to avoid contact with hot surfaces; e.g., exhaust pipes, turbocharger, air ters, grinding sparks, acid splashes, or where intake pipe, start element, etc.; and hot liquid other chemicals are used. The eyes are ex- lines and hoses on an engine which is running tremely sensitive: an injury could result in blind- or which has just been stopped. Reinstall all ness! protective parts removed during service opera- tions before starting the engine. 2 Avoid getting oil on the skin! Repeated exposure Never expose a battery to open flame or sparks. to oil or exposure over a long period can result Never smoke in the proximity of batteries. The in the skin becoming dry. Irritation, dryness, and batteries give off hydrogen gas during charging eczema and other skin problems may occur. which, when mixed with air, can form an explo- From a health perspective, used oil is more dan- sive gas - oxyhydrogen. This gas is easily ignited gerous than fresh oil. Use protective gloves and and highly volatile. Incorrect connection of the avoid oil soaked clothes and shop rags. Wash battery can cause an explosion with resulting regularly, especially before eating. There are damage. Do not shift the connections when special skin creams which counteract drying out attempting to start the engine (spark risk) and do of the skin and make it easier to clean off dirt not lean over any of the batteries. after work is completed. Always ensure that the Plus (positive) and Minus Many chemicals used on the product (for ex- (negative) battery leads are correctly installed ample, engine and transmission oils, glycol, on the corresponding terminal posts on the bat- gasoline and diesel oil), or chemicals used in the teries. Incorrect installation can result in serious workshop (for example, de-greasing agents and damage to the electrical equipment. Refer to solvents) are dangerous to health. Read the wiring diagrams. instructions on the product packaging carefully! Always follow the safety precautions for the Always use protective goggles when charging product (for example, use protective mask, the batteries. Battery electrolyte contains sulfu- glasses, gloves etc.). Make sure that other per- ric acid, which is highly corrosive. If the battery sonnel are not exposed to hazardous chemicals electrolyte comes into contact with unprotected (for example, in the air). Ensure good ventilation skin, wash immediately with plenty of water and in the work place. Follow the instructions pro- soap. If battery acid comes in contact with the vided when disposing of used or leftover chemi- eyes, immediately flush with plenty of water cals. and obtain medical assistance at once. Exercise extreme care when leak detecting on Turn off the engine and turn off power at the the fuel system and testing the fuel injector jets. main switch, or disconnect the battery negative Use eye protection. The jet from a fuel injector (-) lead, before carrying out work on the electri- nozzle is under extremely high pressure and has cal system. a great penetrative energy, so the fuel can pen- Clutch adjustments must be carried out with the etrate deep into the body tissue and cause seri- engine stopped. ous personal injury. There is a real danger of blood poisoning. Use the lifting eyes fitted on the engine/reverse gear when lifting the drive unit. Always check All fuels and many chemical substances are that the lifting equipment used is in good condi- flammable. Do not allow open flame or sparks in tion and has the load capacity to lift the engine the vicinity. Fuel, certain thinner products, and (engine weight including reverse gear and any hydrogen from batteries can be extremely flam- extra equipment installed) mable and explosive when mixed with air. Smok- ing is prohibited in the vicinity! Ensure the work Use an adjustable lifting beam or lifting beam area is well ventilated and take the necessary specifically for the engine to raise the engine to safety precautions before starting welding or ensure safe handling and to avoid damaging grinding operations. Always ensure that there engine parts installed on the top of the engine. are fire extinguishers on hand when work is be- All chains and cables should run parallel to each ing performed. other and as perpendicular as possible in rela- tion to the top of the engine. Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely. Rags soaked If extra equipment is installed on the engine, in oil can spontaneously ignite under certain which alters its center of gravity, a special lifting circumstances. Used fuel and oil filters are envi- device is required to obtain the correct balance ronmentally dangerous waste and must be dis- for safe handling. posed at an approved site for disposal together with used lubricating oil, contaminated fuel, Never carry out work on an engine suspended paint remnants, solvents, de-greasing agents, on a hoist without other supporting equipment and waste from washing parts. attached. 3 About this Workshop Manual Never work alone when removing heavy engine components, even when using lifting devices This Workshop Manual contains technical specifications, such as locking tackle lifts. When a lifting de- descriptions and instructions for the repair of the SP-E, and DP-E Sterndrive. As a result, the illustrations and pictures in vice is in use, two people are usually required to the manual that show certain parts on the sterndrive do not, in do the work: one to take care of the lifting de- some cases, apply to the variations of the specific models of vice and the other to ensure that components the SP-E, and DP-E Sterndrive. However, the repair and are lifted clear and are not damaged during the service operations described are essentially the same. Where lifting operations. If working onboard a boat, the difference is considerable the operations are described check before starting work to make sure there is separately. The SP-E, and DP-E model designation and serial enough room to carry out removal work without number can be found on the product plate located on the risking personal injury or damage to the engine upper gear housing. Always include the model designation or parts. and the serial number in all correspondence. The components in the electrical system, in the The Workshop Manual is produced primarily for the use of ignition system (gasoline engines), and in the Volvo Penta workshops and service technicians. For this fuel system on Volvo Penta products are de- reason the manual assumes a basic knowledge of marine propulsion systems and that the user can carry out the work signed and manufactured to minimize the risk of described to a general standard of engineering competence. fire and explosion. The engine must not be run in areas where there are explosive materials. Volvo Penta products are under a continual process of development and we therefore reserve all rights concerning Always use the fuel and lubricating oil recom- changes and modifications. All the information in this manual is mended by Volvo Penta. Refer to the appropri- based on product specifications available at the time of ate Owner’s Manual. Use of fuel and lubricating printing. Any changes or modifications introduced into oil that are of a lower quality can damage the production or updated or revised service methods introduced engine or sterndrive. On a diesel engine, poor after the date of publication will be provided in the form of quality fuel can cause the actuating rod to seize Service Bulletins. and the engine to over-rev with resulting risk of Replacement Parts damage to the engine and personal injury. On Replacement parts for the sterndrive are subject to various gasoline engines, poor quality fuel can lead to national safety requirements, for example the United States detonation on server engine damage and short- Coast Guard Safety Regulations. Volvo Penta original spare ened engine life. Poor fuel and lubricating oil parts meet these specifications. Any type of damage which is quality can also lead to higher maintenance the result of using replacement parts that are not original costs. Volvo Penta spare parts for the product being serviced, will not be covered under any warranty or guarantee provided by Volvo Penta. 4 The working methods described in the Workshop Manual degreasing agents for all cleaning of components unless apply to work carried out in a workshop. otherwise stated in the Workshop Manual. When working on- board a boat, make a special point of preventing oil waste Carefully observe the safety alert symbols shown for dangers, water from washing components entering the bilge; instead, warnings, and cautions as shown below. They warn you of remove all such waste for safe disposal at an approved site. possible dangers or important information contained in this manual. Tightening Torques These instructions are not in any way comprehensive, since it The correct tightening torques for critical joints which must be is impossible to predict every circumstance under which tightened using a torque wrench are listed under “Technical service work or repairs may be carried out. Volvo Penta can Specifications - Tightening Torques” and stated in the method only indicate the risks considered likely to occur as a result of descriptions in the Workshop Manual. All tightening torques incorrect working methods in well equipped workshops using apply to cleaned threads, bolt heads, and mating surfaces. approved methods and tools tested by Volvo Penta. Tightening torques stated are for lightly oiled treads. Where grease, locking, or sealing agents are required for screwed All operations described in the Workshop Manual for which joints, it is so stated in both the operation description and in there are Volvo Penta special tools available assume that “Tightening Torques.” Where no tightening torque is stated these tools are used by the service technician or person for a joint use, refer to Volvo Penta’s General Information carrying out the repair. Volvo Penta special tools have been manual (P/N 7731073-8) for information on tightening specifically developed to ensure as safe and rational working torques. The tightening torques stated are a guide and the methods as possible. It is, therefore the responsibility of the joint does not have to be tightened using a torque wrench. person or persons using tools other than Volvo Penta special tools or approved Volvo Penta working methods (as de- Lock Nuts scribed in a Workshop Manual or Service Bulletin), to acquaint Do not reuse lock nuts that have been removed during themselves of the risk of personal injury or actual mechanical disassembly operations, since they have reduced service life damage or malfunction that can result from failing to use the when reused. Use new nuts during assembly or reinstallation. prescribed tools or working method. For a lock nut with a plastic insert (such as Nylock® nut) that In some cases, special safety precautions and user instruc- has the same head height as a standard hexagonal nut tions may be required to use the tools and chemicals men- without plastic insert, reduce the tightening torque by 25% tioned in the Workshop Manual. Always follow these precau- for bolt size 8mm or larger. Where Nylock® nuts are higher, or tions as there are no specific instructions given in the Work- of the same height as standard hexagonal nut, the tightening shop Manual. torques given in Volvo Penta’s General Information manual apply. By following these basic recommendations and using com- mon sense, it is possible to avoid most of the risks involved in Strength Classes the work. A clean work place and a clean engine will eliminate Bolts and nuts are divided into different classes of strength; many risks of personal injury and engine malfunction. the class is indicated by the number on the bolt head. A high Above all, when working on the fuel system, engine lubrication number indicates stronger material; for example, a bolt marked system, air intake system, turbocharger unit, or bearing seals 10-9 indicates a higher strength than one marked 8-8. It is it is extremely important to observe the highest standards of important, then, that bolts removed during the disassembly of cleanliness and avoid dirt or foreign objects entering the parts a bolted joint must be reinstalled in their original position when or systems, since this can result in reduced service life or you reassemble the joint. If a bolt must be replaced, check in malfunctions. the replacement parts catalog to make sure the correct bolt is used. Bear in mind that most of the chemicals used around boats are harmful to the environment if used incorrectly. Volvo Penta recommends the use of biodegradable 5 Sealant Room Temperature Vulcanizing (RTV) agents. These agents are used for gaskets, sealing gaskets joints, or coating A number of sealants and locking liquids are used on the gaskets. RTV is visible when a part has been disassembled; engines. The agents have varying properties and are used for old RTV must be removed before re-sealing the joint. different types of jointing strengths, operating temperature ranges, resistance to oil and other chemicals, and for different The following agents are mentioned in the Service Manual: materials and gap sizes in the engines. • Locktite® 5741 To ensure service work is correctly carried out, it is important • Volvo Penta P/N 840879-1 that the correct sealant and locking fluid type is used on the • Volvo Penta P/N 1161099-5 joint where the agents are required. • Volvo Penta P/N 1141570-0 Sealant Wherever appropriate, your Volvo Penta Workshop Manual • Permatex® No. 31 will indicate the proper sealants and locking liquids. • Permatex® No. 771 During service operations use the same agent or an alternative In all cases, old sealants may be removed by using methylated from a different manufacturer. spirits. Make sure that mating surfaces are dry and free from oil, Anaerobic agents. These agents cure in an absence of air. grease, paint, and anti-corrosion agents before you apply They are used when two solid parts, (for example, cast sealant or locking fluid. Always follow the manufacturer's components) are installed face-to-face without a gasket. They instructions for use regarding temperature range, curing time are also commonly used to secure plugs, threads in stud and any other instructions for the product. bolts, cocks, oil pressure switches, and so on. The cured material is glasslike and is therefore colored to make it visible. Two different basic types of agents are used on the engine: Cured anaerobic agents are extremely resistant to solvents room temperature vulcanizing agents and anaerobic agents. and the old agent cannot be removed. When reinstalling, the part is carefully de-greased, then new sealant is applied. The following anaerobic agents are mentioned in the Work- shop Manual: Loctite® 572 (white)1 Volvo Penta P/N 1161053-2 Thread Lock (Blue) 1 Loctite® is the registered trademark of Loctite corporation, Perma- tex® is the registered trademark of the Permatex Corporation. 6 REMOVAL Disconnect power to prevent accidental starting. FN R R Remove the shift linkage cover. O VOLV A PENT Move control to reverse. Remove the cotter pin and washer from the shift cable end. Remove the end pivot pin from the cable. Loosen propeller cone lock bolt. Remove the aft propeller cone. Move control to forward gear. Loosen screw holding the shift cable clamp and release shift cable. Remove the aft line cutter, forward propeller nut, and forward propeller. Return the shift control to neutral. 7 1 3 2 Remove the two screws (1) holding the steering pin to the upper gear head. Using two M6 screws 30mm or longer, install into the threaded holes of the steering pin. As the screws are turned in, the steering pin will be forced out of the steering pin socket and steering helmet bushing. Remove the clamp on the raw water hose. Remove the raw water hose. Remove special tool 885143-8 and carefully lower the drive. Remove the hook-up fork pin lock bolt. Using Pin removal tool P/N 885148-7, pull the pin half way out of the transom shield. Using special tool P/N 884573-7, remove the clamp around the u-joint bellows. Do not remove the pins completely, the sterndrive will fall off the boat. Remove the cotter pin on the trim cylinder pin. Remove the trim cylinder pin. Raise the drive manually and insert special tool 885143-8. Install special tool 885146-1 and remove the sterndrive from Only use special tool 885143-8 to secure the transom shield. outdrive. Serious injury may result if sterndrive is not properly blocked. See Installation found elsewhere in this manual. Using special tool 884573-7, disconnect the exhaust bellows. 8 UPPER GEAR HEAD Removal Disassembly 1 GR970385 Place a 4 quart drain pan under the sterndrive. Remove the drain plug and drain oil from drive. Reinstall the drain plug after the oil has drained. GR970034 1. Install the upper gear housing on special tool P/N 883830. GR990976 Remove cotter pin and washer from gear shift linkage, and remove the linkage. GR970035 2. Remove the 4 screws holding the shift mechanism and remove the mechanism. Be sure to remove the shift shoe with the shift mechanism. GR990975 Remove two retaining nuts from upper gear head studs. GR990974 Remove two allen head retaining bolts. Remove the gear GR970083 head. 3. Loosen and remove the 4 allen head bolts holding the double bearing box. 9 GR970038 7. Remove the LE LEFTFT HAN HAND THR D TH R EAD nut on the vertical GR970036 shaft. Use special tool P/N 884830 and the spline shaft as a 4. Pull out the double bearing box by pulling and turning counter-hold while removing the nut. simultaneously. Use strap wrench P/N 9999179-6 to rotate the double bearing box. Do not damage or lose the shims. GR970039 8. Lift out the upper bearing assembly along with the sliding GR970086 sleeve and the spring. 5. Remove the 4 screws holding the gear housing cover. 1 2 GR970040 9. Lift out the upper gear housing from the special tool. Disassemble the bearing assembly and shaft by lifting the shaft enough to remove the split locking ring (1), then the thrust washer (2). Do not scratch the sliding sleeve or the gear cups while removing them. GR970037 6. Remove the cover. The front right hand screw is a hollow screw with an O-ring. Do not damage or lose the shims for the cover. 10 GR970045 13. Use special tool P/N 3850608 to remove the locking ring, remove the shoulder washer. GR970041 10. Remove the needle bearings from the upper and lower The seal ring can be removed at a later time. gear cup assemblies. Do not mix upper and lower needle bearings. GR970042 11. Press out the upper and lower gear wheels from the bearings. Mount the bearing and gear assembly in holding GR970046 fixture P/N 884938, use special tools P/N 884259 with 14. Press out the input gear. Use special tool P/N 884938 and handle 9991801. 884266. Remove the crush sleeve and discard. GR970044 GR970047 12. Brace the universal joint in a vice. Use soft jaws to protect 15. Turn over the double bearing box and press out the seal the universal joint. Use special tool 885043 to remove the ring along with the roller bearing. Use special tool P/N TX50 torx head screw and the tapered washer; discard the 884263. screw. Remove the double bearing box from the universal joint. 11 Recondition Universal Joint 1 GR970048 GR980766 The bearing will be damaged if removed, only 1. Remove the locking rings (1) holding the needle bearing in remove if a new bearing will be installed. the yoke. 16. Use a “knife puller” to remove the roller bearing from the gear (if necessary). Also use special tool P/N 884266. To avoid having the locking rings “jump out” and getting lost, hold a rag over the universal joint when removing the locking rings. GR980767 2. Hold the universal joint in your hand and strike with a hammer until the bearing emerge from the yoke. Do not strike the splines or sealing surfaces. GR970049 The universal joint will be damaged and must be replaced. 17. When replacing the outer bearing races, the bearing races must be pressed out. Use special tool P/N 9991801 handle with 884938 and 884933 holding fixture. If neces- sary, recondition the universal joint. GR980768 3. Try to ease out the bearing using a pair of pliers or Channel Lock® pliers. If this is unsuccessful the bearing can be driven out by using a hammer and a drift punch. Once the bearings are removed, remove the spider from the yoke. 12 24 27 29 25 31 32 26 30 28 GR980769 4. Inspect the spider (29) and needle bearings for play in the yokes (25, 27, and 24) and possible wear marks in the bearing races (30). If faulty, the spider (29) and needle bearing caps (30) must be replaced as a complete unit. DO NOT install new bearings and caps onto a used spider or vice-versa. If the bearing caps (30) are found to have play in the yokes (25, 27, and 24), the yokes must also be replaced. 5. Install new seal washers (31) on the spider. Feed the spider in the yoke. 1 GR980771 6. Use a small amount of water resistant EP bearing grease to retain the needle bearings in the cap. Push the spider through the yoke in one directions to allow the needle bearing to align with the spider. Push the needle bearing cap into the yoke with the spider inside the needle bearing cap to keep the needle bearings in place. Press the needle bearing cap into the yoke far enough to allow the lock ring to be installed. Install the remaining needle bearing caps in the same manner. Be extremely careful when pressing the needle bearing caps into place. The needle bearings may come loose and fall to the bottom of the bearing cap. DO NOT force the needle bearing caps onto the spider. If the locking grooves for the needle bearings caps do not readily align, a bearing may have come loose and fallen to the bottom of the cap. 13 Assembly When assembling the upper gear housing it is very important that the drive gears and shift gears are installed in the correct positions relative to each other. This applies not only to the backlash between the teeth, but also to the gear teeth contact. Correct gear teeth contact spreads the load over a larger area of the gear tooth. This prevents gear break down and abnormal wear and, at the same time, provides quiet operation. GR970052 3. Install the input gear in the double bearing box and press on the smaller roller bearing, leaving approximately 1mm clearance. Use special tool P/N 884263 and 884259 to protect the gear wheel. GR970053 1. Install the outer bearing race. Use special tool P/N 884932 and handle 9991801. Make sure that the double bearing box is positioned horizontally. Turn the special tool over to use the small diameter when installing the other bearing race. GR970053 4. Press the seal ring until seated against the shoulder. Use special tool 884938 with handle 9991801 and 884932. Use special tool P/N 3850608 to install the lock ring. GR970051 2. Install the larger roller bearing on the input gear by pressing it on. Use special tool P/N 884263. Inst all a new crush Install sleeve. Protect the gear teeth while pressing on the bearing. 14 Forward and Reverse Gears GR970054 5. Coat the shoulder washer O-ring with petroleum jelly, then install it on the spline shaft of the universal joint. The O-ring must face the universal joint. GR970057 1. Lubricate the bearings with synthetic gear lube API GL-5. Press the bearing onto their respective gears. Use special tool P/N 884168. Protect the gear cups during pressing operations. GR970055 6. Install the clamp ring and the double bearing box on the universal joint. Install the tapered washer and new torx head screw screw. Coat the screw thread with Volvo Penta P/N A 1161053 thread locking compound. Always use a new screw during final assembly. Tighten the screw with special tool P/N 885043. NOTE! If the screw is tightened too much and preload becomes too high, the double bearing box must be disassembled and a new crush sleeve must be installed. GR970058 2. Always start by adjusting the forward gear (A). If the previously dismantled gears are to be used, it is important not to mix forward and reverse gears with each other when assembling. GR970056 7. Check the bearing preload between tightening intervals with spring scale Volvo Penta P/N 9985494. Preload new bearings to at least 500 grams minimum and 1000 grams maximum. Preload used bearings to 500 grams minimum and 800 grams maximum. 15 Shimming Method 1 GR970061 3. Only the decimal values of the “B” and “C” dimensions are stamped into the upper gear housing. The nominal value for both “B” and “C” is 61.00mm. Add this value to the value stamped into the gear to calculate shims for the forward and reverse gears. A The shim calculations can be seen in the example below: Measurement A 62.05mm (Fixed Dimension) + 0.05mm (Gear Etching) 62.10mm “C” Stamping – 61.78mm 0.32mm (0.013 in.) The shim thickness for the forward gear is 0.32mm (0.013 in.) The shim thickness for the reverse gear is calculated the same way, only using the “B” stamping. GR970059 1. Measurement “A” is a fixed distance at 62.05mm for When calculating the shim thickness for the forward calculating shims. and reverse gears, remember: The upper gear housing nominal dimension has two values values. If the stamped number is 50 or more, use the lower nominal value, 61.00mm. If the stamped number is 49 or less, use the higher nominal value, 62.00mm. Example: Stamping 50 or more “C” stamping: 78 = 00.78mm +5 Use Nominal Dimension = 61.00mm 61.78mm Example: Stamping 49 or less +.05mm “C” stamping: 43 = 00.43mm GR970060 Use Nominal Dimension = 62.00mm 2. Add or subtract the value marked on the gear. 62.43mm All markings are in hundreds of millimeters (e.g., +5 = 0.05mm.) 16 Method 2 1. Insert a 0.2mm shim under both forward and reverse gears as a starting point. The shim value is a number derived from experience. Then follow the procedure in points 2 through 10 below. Backlash and Contact Pattern GR970066 5. Install the pre-assembled double bearing box with 0.4mm shim. Make sure not to squeeze the shims in the O-ring groove. Tighten the 4 Allen head screws. GR970063 2. Install the forward gear with the calculated shims into the gear housing. Insert the needle bearings and the vertical shaft. Install the reverse gear into the gear housing, using the needle bearings as a guide. Split Lock Ring GR970084 Locking Washer 6. Use sufficient number of shims to create 0.1mm clearance between the top cover and the upper gear housing. Install the cover and tighten the cover screws. GR970064 3. Insert the washer and the split lock ring and tighten the 0 “Left Hand nut” at the opposite end of the vertical shaft. Use 90 10 80 20 70 30 60 40 special tool 3850598. 50 GR970069 7. Install a dial indicator to measure backlash. The correct backlash should be 0.15 – 0.25mm. If the backlash is too tight, shims must be added between the double bearing box and the gear housing. If the backlash is too loose, shims must be removed from the double bearing box. A shim thickness of 0.10mm is a safe adjustment step. GR970065 4. Brace the special tool P/N 885152 plate and ring in a vise and install the gear housing in the tool. 17 and positioned halfway on the gear tooth. It should be slightly toward the gear cup but not running off the end of the gear tooth. B GR970070 8. Install the double bearing box when the correct backlash has been obtained. To gain a clearer picture of the contact pattern, coat the gear 11. If the dye pattern shows contact, as shown in picture “B,” teeth with a thin coating of marking dye. Then install the the shim thickness for the double bearing box must be double bearing box again. reduced. The input gear moves toward the forward and reverse gears. The forward and reverse gears must be shimmed the same amount to maintain the correct backlash. C GR970071 9. Rotate the gears in the normal direction of rotation while 12. If the dye pattern shows contact as shown in picture “C,” wedging a wooden brace against the gear cups. The marking the shim thickness underneath the double bearing box dye will be pressed away from the point of contact on the gear tooth face, which will show a picture of the contact pattern. A GR970072 10. Dismantle the gear set and compare the contact patterns to that of picture “A.” This picture shows the desired contact pattern for the drive side of the forward and reverse gears. The drive side is the convex side of the gear. The dye pattern should be oval in shape 18 Assembling the Upper Gear GR970077 GR970075 Install the needle bearings and the spacer ring between the Install the lower gear unit along with the calculated number of bearings in the lower gear and insert the shaft in the gear. shims. The needle bearings are matched in pairs and must not be mixed up. GR970076 Install the washer (1), the locking ring (2), the spring (3) and the engagement sleeve (4) onto the shaft (5). The end of the engagement sleeve marked “TOP” must be facing upwards on the shaft. On earlier models there is a drilled recess, which must be turned upwards. The engagement sleeve must rest lightly on the spring. Feel by hand to make certain. GR970078 Install the washer and the split locking ring. Then place the gear housing in the splines sleeve P/N 884830. Carefully inspect the condition of the brass washer and replace if necessary. 19 GR970081 Measure the clearance between the nut and the bearing. The axial clearance should be 0.1-0.5mm. If it is not possible to obtain the correct clearance with any of the nuts, most probably the bearing is defective. GR970079 Place the upper gear wheel with the calculated shims in the gear housing. Install the needle bearings along with the spacer ring between the bearings. 1 GR970082 Install the shims and the new O-ring on the double bearing box. GR970080 In order to obtain the correct axial clearance, there are three left hand threaded nuts with shoulders of different thicknesses (1). Select a nut and tighten it with a tightening torque of 120 N•m (88.3 ft. lb.). Lubricate the threads with gear lube to prevent the nut from galling. GR970083 Coat the surfaces between the double bearing box and the gear housing with Volvo Penta White Sealing Compound for Drives P/N 1141570-0 or its equivalent. Install the double bearing box with the universal joint in the gear housing. Coat the screws with Loctite locking fluid or its equivalent and tighten them with a torque of 35 N•m (25.8 ft. lb.). 20 Shimming Upper Gear to Intermediate Housing A GR970084 Install a sufficient number of shims underneath the cover to obtain a clearance of max 0.1mm between the cover and the gear housing. Locate the cover and push it lightly into position and measure the clearance all around with a feeler gauge. GR970374 Measure the distance from the bottom of the upper gear housing to the top of the outer bearing race (A). Record the measurements in the table below. The shift mechanism must be in neutral (if installed) to achieve and accurate measurement. 1 B GR970085 Coat the cover with Volvo Penta White Sealing Compound for Drives P/N 1141570-0 and install the sealing ring (1) so that the sealing for the front, right hand screw ends up in the recess of the cover, provided for it. GR970373 Measure the distance from the top of the intermediate housing and the upper gear head lower bearing outer race seat. (B). Record the measurement in the table below. B mm - A mm Clearence mm + 0.06 mm Shims Required mm UPPER SHIM TABLE GR970086 Subtract the upper gear head bearing thickness (A) from the Insert the calculated shims and tighten the cover. intermediate housing measurement to find the bearing clearance. Add enough shims to take up the clearance plus The front, right hand screw is a hollow screw, to be 0.06mm shim to preload the upper gear head bearing. installed with an O-ring underneath the head of the screw. Tighten the screws with a torque of 15 N•m (11.4 ft. lb.) in diagonal sequence. 21 Volvo Apply a light coating of V Pent olvo P enta ent White a White Sealing Com- pound for Drives P/N 1141570 to the mating surfaces of the intermediate housing and the upper gear head. Install the upper gear head on the intermediate housing with the calculated shims in place. GR990975 Install the two nuts onto the upper gear head studs. Do not tighten the nuts. GR990974 Install the two allen head bolts into the upper gear head. Alternately tighten the allen head bolts and nuts in a crossing pattern. GR990976 Install the shift linkage rod, washer and cotter pin. Always use a new cotter pin. Never reuse a cotter pin that has been removed. 22 SHIFT MECHANISM The upper gear head does not have to be removed from the intermediate housing, nor the sterndrive from the transom shield, to replace the shift mechanism. GR970093 4. Pull the pin out. GR970035 1. Remove the shifter assembly from the upper gear head. GR970094 5. Remove the eccentric piston from the shift housing. GR970091 2. Remove the shift shoe, spring, and O-ring. GR970095 6. Tap the eccentric piston lightly on a wooden surface to remove the spring pin. Inspect the eccentric piston for scoring, distortion, or damage that may cause it to leak or bind in the housing. GR97009 3. Knock out the spring pin as far as necessary to free the locating pin. GR970096 7. Using a screwdriver, pry out the eccentric piston seal. Clean all surfaces and check for damage that may cause leaks. Replace parts as necessary. 23 GR970097 8. Oil all parts prior to assembly. Install a new eccentric piston seal with the steel edge facing inward, as shown. Use special tool 884793. 12. Install special tool 3856802 under the two starboard side retaining screws, as shown. GR970098 9. Install the eccentric piston in the housing (do not damage the seal). Push in the locating pin; align the hole with the housing. Lock it in place with a new spring pin. GR970100 This will position the shift locating pin on a “high” spot of the ramp. Do not attempt to mount the special tool on any GR970091 raised portion or raised lettering on the shift housing. 10. Install a new O-ring, then insert the spring and shift shoe. 13. With the special tool installed, add one shim to the Coat the contact surface with Volvo Penta white sealing shimming screw and install finger tight while rotating the compound P/N 1141570-0. propeller shaft by hand. If propeller shaft binds, repeat this step, adding one shim at a time, until no resistance is felt through 360° of rotation. Do not attempt to rotate the propeller shaft with any leverage devices (e.g., propellers or pliers). This will damage the sliding sleeve and/or the shift shoe. 14. After the proper amount of shims have been established: For DP-D add one more shim to the shimming screw. For DP-D1 and DP-E add three more shims to the shimming screw. GR970099 15. Coat the shimming screw threads with Teflon pipe sealing 11. Remove the shim screw and install the assembly in the compound and install. Tighten the shimming screw to 14 - 16 upper gear head. Make sure the long edge of the shift shoe is N•m (10 - 12 ft. lb.). toward the right side of the housing as viewed from the top. 16. Remove the special tool and install the shift linkage. 24 INTERMEDIATE HOUSING GR970354 Remove the 2 screws holding the hose connection. Remove the hose connection and the gasket. GR970356 Press out the lower steering spindle bushing. Use special tool P/N 884259-3 and 9991801-3. GR970355 Remove the hook up fork by driving out the steering spindle. Use special tool P/N 884311-2 and 9991801-3. GR970357 Press out the upper steering spindle bushing using special tool 884259-3 and 9991801-3. 25 3 1 2 GR980499 Should the shift fork require replacement, remove the cotter pin (1). Remove the shaft (2) and remove the shift yoke (3). To install reverse procedure. GR970360 Grease the lower hook up fork bushing with Volvo Penta P/N Always use a new cotter pin when reinstalling. 828250-1 water resistant grease. Using special tool 884259-3 and 9991801-2, press in the bushing. 1 GR970359 Remove the bearing race of the axial bearing. Use special tool P/N 884140-5 and 884143-9. Also replace the O-rings (1). GR970362 One on each side of the oil tube. Press the bushing into the hook up fork. Use special tool P/N 884259-3 with handle 9991801-2. 26 2 1 1 GR970363 GR970365 Place the wear washer (1) on the intermediate housing and Insert the plastic wear washer (1) between the intermediate push the steering spindle (2) in far enough to hold the wear housing and the hook up fork. Push the steering spindle in washer. until the collar bottoms. 2 1 GR970364 GR970354 Push the steering spindle (1) through the intermediate Install the O-ring and the hose connection on the yoke. Use a housing exhaust port (2) stopping short of the upper hook up small amount of Volvo Penta P/N 828250-1 water resistant fork bushing. grease to hold the O-ring in place while installing the hose connection. 27 3 1 2 GR980499 Install the shift yoke (3). Align the shift yoke with the shaft hole in the intermediate housing. Push the shaft (2) through and lock it with a new cotter pin (1). 28 SP LOWER UNIT Reconditioning the Lower Gear The Propeller Shaft Disassembly 1 1 203129 4. Remove the 6 nuts holding the washer (1) and knock the 203126 1. Remove the oil strainer (1). propeller shaft out of the bearing housing. Use a copper mallet or its equivalent in order not to damage the threads. 1 2 883830 203127 2. Use special tool P/N 883830 and install the lower gear 203130 upside down in this tool. 5. Fold down the locking washer (1) remove the round nut (2). 884168 203128 3. Remove the 2 screws holding the propeller bearing 203131 housing. Remove the propeller shaft and the propeller bearing 6. Press off the gear wheel and the bearing from the propeller housing. Use special tool P/N 884161. Remove the special shaft simultaneously. Use special tool P/N 884168. tool once the propeller bearing housing is free and pull out the bearing housing by hand. 29 2 3 3 1 1 2 3 203135 2. Fold down the tab of the locking washer (1) and remove 0203132 the round nut (2). Remove the locking washer and the spacer 7. Remove the locking ring (1) and the oil deflector (2) from ring (3). the gear wheel. In order not to damage the oil deflector during the dismantling, apply the bending tool close to the 2 carrier pins (3). (This is valid for sterndrives of earlier manufacture). On sterndrives of later manufacture the carrier pins have been replaced by a load pin. 884267 884830 203136 3 Use special tool P/N’s 884267 and 884830 to remove the pinion. 1 203133 8. Knock out the 2 sealing rings (1) off the propeller bearing housing. 1 2 3 1 203137 4. Lift out the pinion (1) and the needle bearing washer (2). The needle bearing is a full needle type of bearing 203134 with loose needles (3). Remove all 27 needles. The vertical shaft 1. Fold down the tab on the locking washer (1) and remove the nut holding the pinion to the vertical drive shaft. 30 884316 1 203141 203138 8. Should the needle bearing of the propeller shaft be da- 5. Carefully lift off the lower gear housing from the vertical maged, use special tool P/N 884316 to remove it. Insert the drive shaft. puller into the needle bearing in a way that the barbs of the puller end up at the backside of the needles. Then tighten the Take care of the shims (1). puller forcing the barbs apart and pull out the bearing. 884143 203142 9. Remove the bearing race on the propeller shaft by cracking it. Clean all parts and check them for wear. Replace parts if necessary. 203139 6. Press (knock) off the outer ring of the needle bearing. Use The gear wheels are sold in matched pairs in order special tool P/N’s 884381 and 884143. Insert the tool from to obtain the correct contact pattern. underneath and the shaft from above. 203140 7. Press off the ball and roller bearings from the vertical shaft (against the frame of the press). There are spacer pads between the bearings. 31 Assembly 884266 Oil all moving parts and the screws prior to assembly. 1 1 203146 The vertical shaft 203143 1. Fill up with grease between the two sealing rings (1) and 1. Press on the ball bearing on the vertical shaft. Use special press them home in the propeller bearing housing. Use special tool P/N 884266. tool P/N’s 884283 and 9991801. Turn the ball bearing in a way that the balls become Turn the sealing rings correctly. They are to seal visible (1). against the oil in the gear housing as well as against water. 884266 884283 9991801 1 203147 2. Install the spacer pad (1) on the ball bearing and press on 203144 2. Install the needle bearings for the propeller shaft. The side the roller bearing. Use special tool P/N 884266. of the needle bearing carrying the description must be turned facing aft. Use special tool P/N’s 884283 and 9991801. 3 1 2 1 203148 203145 3. Install the spacer ring (1), the locking washer (2) and the 3. Grease abundantly the outer race (1) with grease and round nut (3) on the vertical shaft. Tighten the nut. insert the 27 needles, well cleaned, into the ring letting the grease hold them. Insert special tool P/N 884385 in the Don’t lock the nut with the washer just yet. bearing and insert the bearing from underneath into the gear housing. Then install the special tool P/N 884241 from above and pull the bearing into its seat in the gear housing. 32 884143 884140 1 203152 7. Remove the conical roller bearing race in the intermediate 2 3 housing (if the old bearing can still be used). Use special tools 203149 P/N’s 884140 and 884143. 4. Insert the pinion (1) along with the washer (2) for the needle bearing (3) into the gear housing. 88 43 48 1 203153 8. Insert the bearing race on the roller bearing on the lower 203150 gear housing and install the spanner tool P/N 884348. Insert 5. Install the vertical shaft with a 0.35 mm (0.14") thick shims if necessary shims between the bearing race and the tool to package (1) consisting of a paper shim 0.25 mm (0.01") prevent the vertical shaft from moving axially. Tighten the between two metal shims 0.05 mm (0.002") each. spanner tool with two screws and nuts. 1 2 3 203154 203151 6. Install the washer and the nut. Tighten the nut with a torque The Propeller Shaft of 160Nm (16 kpm--118 lbs ft). Use special tool P/N 884830 1. Install the oil deflector (1) and the locking ring (2) on the on the splined end as a counter hold. gear wheel (3). Don’t lock just yet. Make sure that the two holes on the oil deflector coincide with the carrier pins (on sterndrive of earlier manufac- ture). On sterndrives of later manufacture a load pin acts as carrier of the oil deflector. 33 1 3 2 1 203158 203155 2. Press on the bearing race (1) on the propeller shaft (in 5. Install the locking washer (1) and the round nut (2). Tighten case it has been dismantled). the nut and lock it with the locking washer (3). Shimming 884263 B 884265 C 203156 3. Press on the gear wheel on the propeller shaft. Use special tools P/N’s 884265 and 884263. 884168 884265 F 2 1 G 203157 4. Install the locking washer (1) and press on the ball bearing (2). Use special tools P/N’s 884265 and 884168. NOTE! 203159 Install the bearing in a way that the recess in the bearing races (for the insertion of the balls) is turned facing the propeller. Method 1 1. The lower gear housing is stamped with a ‘F’-measurement (center vertical shaft- contact surface of the propeller bearing box), the propeller bearing box is stamped with a ‘G’-measurement (shoulder of the propeller bearing - contact surface of the propeller bearing box). Add these together. 34 F 496 10 3 G= 203160 2. The gear length is fixed at 5.85 mm (0.230"). Add or subtract the plus or minus marking of the gear wheel. Sub- tract from this sum the sum of the ‘F’ and ‘G’ measurements. 203162 The sum thus obtained denotes the thickness of the shim. 4. Install the propeller shaft along with bearings in the gear housing. Be careful so that the bearing does not end up On some gear housings for instance the figures 03 obliquely in the bearing housing or that the sealing rings are can be stamped or some other figure. In these cases add the damaged. Make sure that the six holes in the washer coincide number 5.00 to that of the ‘F’-measurement and the figure with the screws. Insert the nuts before the bearing is pushed 1.00 to that of the ‘G’-measurement. Then the ’F’ measure- home completely in the bearing box. Tighten the six nuts. ment ends up being for instance 5.03 or some other measure- ment above 5 mm and the ’G’-measurement for instance 1.03 or some other measurement above 1.0 mm. If the sum obtained does not coincide with available shims select the closest five - or ten - number. How to calculate the shim thickness can be seen in the following example: 1 Measurement ‘F’ stamped 4.97 (0.195”) Measurement ‘G’ stamped +0.98 (0.039”) 5.95 (0.234”) Gear wheel fixed measurement 5.85 (0.230”) Gear wheel marking etched* +0.04 (0.002”) 5.89 (0.231”) 203163 5. Install the propeller shaft with its bearing box in the gear 5.95 (0.234”) housing. Tighten the screws with a torque of 40 Nm (4.0 —5.89 (0.231”) kpm-29.5 Ibs ft). Calculated sum always positive! +0.06 (0.002”) The two O-rings (1) on the bearing housing should As per this example a 0.06 mm (0.002") shim is inserted not be installed. between the propeller bearing box and the propeller thrust bearing. Carry on according to points 4-12 below! * Only the figure 4 is etched on the gear wheel. Method 2 1 203164 6. Check the gear backlash and measure it directly against the 203161 3. Insert the 0.2 mm (0.008") shim (1) in the propeller bearing vertical splines shaft. The clearance should be 0.06-0.10 mm housing. This is a value of experience. (0.002-0.004") resulting in a gear backlash of 0.15-0.25 mm (0.0000.020"). 35 1 203167 9. Install special tool P/N 884830 onto the splines end and turn the gear in the set direction of rotation, clockwise for left handed propeller. At the same time brake the movement on the propeller shaft, as forcefully as possible. 2 203165 7. If the backlash is found not to be correct, adjust as follows: If the method 1 has been used: If the backlash is too small, increase the shim thickness underneath the ball bearing (1 ) and if the backlash is too big, decrease the shim thick- ness. A If method 2 has been used: If the backlash is too small decrease the shim thickness in the propeller bearing housing 203168 and if the backlash is too big, increase the shim thickness. 10. Check that the contact pattern on the teeth surfaces of the drive side coincide with that of the picture A, which is correct. The contact pattern should be positioned in the middle of the tooth but displaced towards the small end. B 203166 8. Remove the screws and pull out the propeller. Coat the gear teeth of the gear wheel and the pinion gear with marking 203169 dye. Then install the propeller shaft with the bearing box in the 11. Should the contact pattern correspond to that of picture gear housing. Tighten the screws with a torque of 40Nm (4.0 B, reduce the shim thickness for the vertical shaft and the kpm--29.5 lbs ft). propeller shaft. 36 Final Assembly 884830 C 203170 12. Should the contact pattern correspond to that of picture C, increase the shim thickness for the vertical shaft and the propeller shaft. 203171 13. Dismantle pinion and gear and clean parts from marking If the pinion is moved the gear wheel must be moved dye and then assemble with the calculated shims. Then install correspondingly in order not to alter the gear backlash. the spacer ring, the locking ring and the nut on the vertical shaft. Tighten the nut and lock with the locking washer. Use special tool P/N 884830 as a counter hold. 1 203172 14. Tighten the pinion nut with a torque of 160 Nm (16.0 kpm-118 Ibs ft). Then lock the nut with the locking washer (1). Use special tool P/N 884830 applied at the splines shaft end as a counter hold. 1 203173 15. Install the O-rings (1) in the propeller bearing housing. Coat the contact surfaces and the screws with Permatex. Install the propeller bearing housing in the gear housing and tighten the 2 Allen-head screws. NOTE! Turn the vertical shaft somewhat to allow the gears to engage. Tightening torque 40 Nm (4.0 kpm-29.5 kpm). 37 NOTES ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 38 DP LOWER UNIT Disassembly Clean the sterndrive externally. 1 GR970385 1. Drain the oil by removing the screw (1), if not already drained in previous steps. GR980765 4. Remove the spline sleeve (1) and the O-rings (2 and 3). Place a 4-quart drain pan under the sterndrive. Tilt Remove the spacer sleeve along with the O-ring (4) and the sterndrive all the way down to allow all the oil to drain. the oil strainer (5). GR970345 GR970394 Remove the two screws holding the anode to the lower unit. 2. Remove the shift mechanism cover and remove the 5 bolts holding the lower unit on the intermediate housing. (Two bolts are inside the shift mechanism cover.) GR970346 Remove the two propeller shaft housing bolts. 3. Install the suspension fixture 885192-5 in stand 99922520-8 and brace the lower unit in the stand. 347 Install special tool 884789 on the outer propeller shaft. Using special tool 884161 with a slide hammer, remove the outer propeller shaft and bearing housing. 39 1 381 6. Remove the 2 O-rings (1) from the propeller shaft housing. Discard the O-rings. Remove the nut from the pinion gear. Use a 23mm wrench. Do not discard the nut. Put it aside for use in the shimming procedure later. 348 8. Install special tool 885192-4 on the inner propeller shaft. 11. Lift the gear housing off the special tool and place it back in the work stand. Remove the nylock® nut with a hook GR970379 spanner wrench 885127-1 9. Install special tool 884802 over the inner propeller shaft. Add the washer and nut. The slot in the end of the tool should face the pinion gear. Tighten the nut until the shaft is extracted from the forward gear. Use a 30mm wrench. Install special tool 884267-6 on the vertical shaft. Attach special tool 884830-1, and turn counter clockwise until the shaft can be lifted out of the lower unit gear housing. Remove the tool from the shaft. Remove the shims from under the 449a vertical shaft bearing. Be sure not to damage the shims! 10. Brace special tool 884830 in a vise and place the lower Save them for use later in the assembly process. unit upside down in the tool. 40 GR970370 12. Remove the pinion gear and the front gear from the lower unit housing. The forward gear should be free to remove from the housing with the forward bearing attached to the gear. GR980462 15. Press off the roller bearing from the propeller shaft, using special tool 884797-2. Outer Propeller Shaft GR970371 13. Remove the forward gear bearing outer race from the lower unit, using special tool 884794-9 and slide hammer 884161. Remove the shims from the housing. Be careful not to damage the shims! Save them for use later. 1 GR980377 16. Insert the shaft in special tool 884831-9. Install puller halves between the shaft and the special tool. Install special tool 884789-9 on the shaft to protect the shaft during pressing operations. Press off the bearing race. GR970372 14. Use special tool 884791-1 with drift 884143-9. Drive the Do not use a knife puller or other, similar tool needle bearing from the lower unit gear housing. to remove this bearing race. Such tools may scratch the sealing surfaces of the shaft and result in water leaking into Inner Propeller Shaft the sterndrive. 41 Propeller Shaft Bearing Box 1 GR970351 20. Remove the O-rings from the propeller shaft bearing GR970350 housing and discard. Using special tool 884797-2 to press 17. Install special tool 884789-9 to protect the propeller out the seals and needle bearings. shaft. Install a knife puller on the outer propeller shaft roller bearing. Using a press, remove the roller bearing. Center the tool carefully. Locate a pair of wooden blocks underneath the bearing box to protect the Make sure the sealing surfaces of the bearing box. Always use new seals and O-rings during final shaft are not damaged during the process! assembly. GR970376 18. Install special tool 884832-7 under the intermediate bearing outer race. Insert handle 884143-9 to expand the bearing tool. Press out the intermediate bearing outer race from the rear propeller shaft gear. GR970352 21. Remove the outer bearing race using special tools 884796-4 and handle 9991801-3. Center the tool carefully. Locate a pair of wooden blocks underneath the bearing box to protect the bearing box while pressing out the bearing race. GR980463 19. Remove the inner needle bearing and seals using special tools 884803 and 884143. Install special tool 884789-9 to protect the propeller shaft threads. NOTE! If you only want to replace the seals, it is still easier to remove the seals along with the bearings. 42 Forward Gear GR970369 23. Use a knife puller to press off the front roller bearing from the gear. GR980466 27. Remove the ball bearings (use a knife puller). The Vertical Shaft 25. Use a knife puller to remove the bearings one by one or together. GR980467 28. Check the bearing race. Replace as necessary, using a Use spline socket 3850598-8 to protect the knife puller. Clean and check all parts for wear. spline when pressing off the bearings There is a shim ring (944970-3) located between the roller bearing and the ball bearing. This one, however, is smaller. GR980465 26. Remove the spacer washer located between the bear- ings. 43 Assembly 20.85 mm Shimming the Front Bearing 0,821 in. 3. The nominal height of the bearing is 20.85mm. The front and rear roller bearings are different and must not be mixed. G=85 F=91 G=85 H=37 GR980 1. Find the G-marking on the parting plane of the lower gear housing. 2. Only the decimals of the G-marking are stamped into the gear housing. In this case, the G-stamping is 85. The nominal value of the G-measurement is 60.00mm. Add 60.00 and 4. The nominal measurement of the forward gear is 39.50mm. 0.85, which yields 60.85. The tolerance (±) is engraved on the gear. All engraved numbers are decimal millimeters. In this instance, -10 equals - When calculating the shim thickness for the lower 0.10mm. The real measurement of the gear is 39.50 – 0.10 = unit gears, remember: 39.40mm. The lower unit gear housing nominal dimension has two 5. Add the height of the forward roller bearing to the real values values. measurement of the forward gear: If the stamped number is 50 or more, use the lower nominal ADD: value: 60.00mm. Roller Bearing = 20.85mm If the stamped number is 49 or less, use the higher nominal Forward Gear = + 39.40mm value: 61.00mm. Total forward gear length 60.25mm EXAMPLE: This sum should be subtracted from the G-stamping resulting in a shim thickness for the front bearing: Stamping is 50 or more G-measurement 60.85mm G stamping: 85 = 00.85mm Total forward gear length – 60.25mm Use Nominal Dimension= +60.00mm Shim Thickness = 00.60mm G-measurement 60.85mm Stamping 49 or less G stamping: 02 = 00.02mm Use Nominal Dimension= +61.00mm 61.02mm 44 1 6. Lubricate the bearing position before assembly. Place the 8. Use special tool P/N 884263 to press the gear and calculated shim thickness in the gear housing and install the bearing assembly onto the propeller shaft. Use special tool outer bearing race (marked 30209) with special tool P/N 884799 to protect the bearing. 884795. Do not press on by using the bearing race! The plastic disk (1) should be pressed as far in as possible on the tool. 7. Press on the front roller bearing onto the forward gear. Use special tool P/N 884801. Use special tool 884797 to protect gear teeth. 45 Shimming the Vertical Shaft 884241 884792 2259 2262 9. Grease the bearing location. Carefully align the needle 12. Place the thin spacer pad (1) on the ball bearing and bearing when installing it in the gear housing. Use special tool press on the roller bearing. Use special tool 884266. 884792 in combination with 884241. Turn the bearing to allow the tool 884792 to press against the text on the bearing. Tighten the screw until the bearing bottoms. 2263 13. Install the thick spacer ring and tighten the plastic insert 2260 locknut. Use a hook spanner wrench. 10. Press a new inner bearing race onto the vertical shaft. Use special tool P/N 884793-1. H=37 F=91 G=85 H=37 2264 14. Find the H-stamping on the parting plane of the lower gear housing. The H-stamping in this instance is 37. Remem- ber, the stamping is in hundreds of millimeters. The nominal 2261 H-measurement is 277. Add the H-stamping to the nominal 11. Press a new ball bearing onto the vertical shaft. Use dimension of 277. The sum will be 277.37mm. special tool 884266. ADD: Install the bearing so that the thick part of the inner H-Nominal 277.00mm race faces up. H-Stamping +00.37mm H-Measurement 277.37mm 46 2265 15. Find the marking on the pinion gear. In this instance the pinion etching is -5. Remember, the etching is in hundreds of millimeters. This etching is -0.05 mm. The nominal measure- ment of the pinion gear is 60.00mm. Subtract the pinion gear etching from the nominal measurement for a difference of 59.95mm. 16. The nominal measurement of the vertical shaft is 2292 217.75mm. This measurement is added to the calculated 19. Center the pinion gear and nut carefully; then, with the pinion measurement of 59.95mm. This combined distance other hand, install the vertical shaft. equals 277.70mm, as illustrated below: ADD: The groove of the nut must face the pinion gear. Vertical Shaft Nominal 217.75mm 20. Install the nut on the vertical shaft. Pinion Calculated +59.95mm Vertical Shaft Calculated 277.70mm A new nut must be used for final assembly. Subtract the H-stamping dimension from the Vertical Shaft Calculated (277.70) to arrive at the shim thickness: SUBTRACT: Vertical Shaft Calculated 277.70mm H-Measurement – 277.37mm Calculated Shims 0.33mm 2298 21. Hold the pinion nut with a 23mm socket. Use special tool 884830-6, or 3850598-8 as an alternative, and a torque 2266 wrench. Torque the vertical shaft to 110 N•m (81.5 ft. lb.). 17. Place the propeller shaft with gear installed in the gear housing. Be careful not to allow the counter-hold wrench to damage the lower gear housing. Use a piece of soft wood to brace the wrench and protect the housing while applying torque to the pinion nut. 2267 18. Place the calculated shim thickness (1) in the gear housing. In this case, it is 0.33mm. With one hand, hold the pinion gear and the original pinion gear nut in the gear together in the housing. 47 The Bearing Box +10 +10 25. The nominal measurement of the aft gear is 39.50mm. F=91 Find the variation marking on the gear. In this case it is +10. F=91 Remember, hundreds of millimeters only! G=85 H=37 ADD: Gear nominal 39.50mm 22. The nominal dimension of the F-measurement is 80.00mm Gear marking +0.10mm ± 0.10 mm. Figures between 90 and 99 are stamped into the Gear measurement 39.60mm lower gear housing indicating the amount of variation from nominal that the housing is machined. When the F-stamping is 20.75 mm between 90-99, add 79.00mm to the figure. If the F-stamping is 00-10, add 80.00mm to the figure. In this case, the F- 0.817 in. stamping is 91. Add 0.91 to the nominal figure of 79.00. The sum for the F-measurement is 79.91. C25 26. The nominal bearing height is 20.75mm. The forward and aft gear bearings have different nominal dimensions by .10 mm. DO NOT mix them up. For the aft bearing, make sure that the inner bearing race is marked BK-358X and the outer bearing race is marked K354X. Installing the bearings in the wrong location will cause incorrect lower unit gear contact patterns, incorrect bearing preload, and shorten gear life. 23. Find the stamping “C” on the bearing box. In this case, C=25. Again, the stamping is in decimal millimeters. The 27. Add the gear measurement to the bearing nominal nominal dimension for the bearing box is 19.00 mm. Add the dimension. C-stamping to the nominal dimension to get the C-measure- ADD: ment. Gear measurement 39.60mm ADD: Nominal bearing height +20.75mm C-nominal 19.00mm Total aft gear dimension 60.35mm C-stamping +0.25mm C-measurement 19.25mm 28. Now subtract the Total aft gear dimension from the bearing box location. 24. Now subtract the C-measurement from the F-measure- SUBTRACT: ment. C-measurement 60.66mm SUBTRACT: Gear dimension -60.35mm F-measurement 79.91mm Bearing box shims 0.31mm C-measurement - 19.25mm Aft gear bearing location 60.66mm The Outer Propeller Shaft 48 Shimming the Intermediate Bearing Start by adding the F-measurement and G-measurement. ADD: G-measurement 60.85mm F-measurement +79.91mm 140.76mm Now subtract the C-measurement of the propeller bearing box. SUBTRACT: F&G combined 140.76mm C-measurement -19.25mm 121.51mm Now add the front and rear gear shims. ADD: 2269 Grease the bearing location with propeller shaft grease and Forward gear shims 0.60mm insert the calculated bearing box shims from the previous step Aft gear shims +0.31mm (0.31mm). Install the bearing race using special tool 884795- 0.91mm 6. Add nominal value +120.00mm 120.91mm The shim thickness is obtained by subtracting: SUBTRACT: 121.51mm -120.91mm Intermediate bearing shim 0.60mm 2272 Press the bearing race into the aft gear. Use special tool 884797-2. 384a Turn the bearing box over. Use special tool 884797-2, install the needle bearing in the bearing box. Make sure the bearing marking is facing the tool. 49 28. Apply marking dye on the convex side of the aft gear. Place the calculated shims for the intermediate bearing and the intermediate bearing on the inner propeller shaft. Install special tool 885197-4 onto the threads until the tool bot- toms. Press the needle bearing into the propeller shaft with the text 366 on the bearing turned facing the tool. Use special tool Install special tool 884798-0 on the propeller shaft with the 884806-1. Press the tool until it bottoms. washer and nut. Using a 30mm wrench, tighten the nut until the intermediate bearing bottoms. Use special tool 884830-1 DO NOT install the seal rings, wait until the gear or 3850598-8 and a wrench as a counter hold on the vertical tooth clearance and contact pattern are checked. shaft. After the intermediate bearing is pressed on completely, remove the special tools from the propeller shaft. 367 Coat the convex side of the aft gear with marking dye. Insert the gear assembly onto the inner propeller shaft. Press the roller bearing onto the propeller shaft. Use special tool 884801-2. - 346 Grease the bearing box and install on the lower unit. Tighten the allen bolts to 40 N•m (29 lb.ft.). Press the inner needle bearing race onto the propeller shaft. Use special tool 884801-2. 50 Checking Backlash Place the outer bearing race on the vertical shaft roller bearing and hold it steady in position. Use a depth gauge to measure the height of the bearing assembly “A.” Note this dimension. Propeller Nut yyyy ;;;; yyyyy ;;;;; ;;;;; yyyyy Lock the vertical shaft to prevent it from being turned. Install ;;;; yyyy ;;;;; yyyyy A DP propeller nuts and or cone on the propeller shafts. Rig a ;;;; yyyy ;;;;; yyyyy dial indicator gauge against the wings of the rear nut as far ;;;; yyyy ;;;;; yyyyy out on the wing as possible. Check the flank clearance of the front gear by turning the propeller shaft (both ways) by hand to check the backlash. The clearance at the wing should be B 0.08 – 0.17mm (0.003-0.007”), which results in a clearance Using a depth gauge, measure special tool 88438-4 at of 0.15 – 0.30mm (0.006-0.013”) at the gear. position “B.” Subtract measurement "A" from measurement “B.” This will give you the clearance dimension. If negative clearance is obtained, install the tool without shims. If a positive clearance is obtained, add shims according to the following procedure. To determine the correct bearing preload, 0.02mm should be added to the clearance dimen- 0.315“ 8mm sion. EXAMPLE: SUBTRACT: Measurement ‘A’ 10.02mm Measurement ‘B’ -9.77mm Propeller Cone 0.25mm If the rear propeller is locked with a propeller cone, measuring Bearing Preload +0.02mm the gear backlash must be done the same way as when Shim 0.27mm measuring using the propeller nut. The only difference is that A 0.27mm shim should be placed on the outer bearing. the measuring must be done 8mm (0.315”) in from any of the tips of the cone’s wings, and towards the propeller shaft center. The measuring is done at the same radius from the propeller shaft center as when measuring is done on the propeller nut. 386 Insert the bearing race on the vertical shaft roller bearing. Install shims between the bearing race and the special tool to prevent the bearing from moving axially. Install special tool 884348-4. Tighten the special tool with two screws and nuts finger tight to prevent axial movement but not enough to preload the vertical shaft. 51 in. lb.) and maximum preload value should be 2.3 N•m (20.3 in. lb.). If the preload is too high, the shim thickness on top of the bearing race should be reduced. If the preload is too low, the shim thickness on top of the bearing race should be increased. Contact Pattern Move the dial indicator gauge to the outer nut. Measure the backlash of the rear gear the same way as the front gear. The clearance should be 0.15 – 0.27mm (0.006 –0.010 in.), which is 0.20–0.35mm (0.008 – 0.014 in.) at the gear. 2 1 1 2282 Turn the vertical shaft both ways. Use the spline sleeve 884830 while applying braking action. 3 2285 If it is necessary to increase the backlash without changing the A contact pattern, add and remove shims from the front and rear gears (1) and the vertical shaft (2). Add the correspond- ing shim thickness underneath the bearing (3) to maintain preload. Reverse the steps if the backlash needs to be reduced. Checking Preload 970072a Remove the special tool and propeller shaft bearing box. Check the contact pattern on the gear wheel. Also check the front gear wheel inside the gear housing. The contact pattern should be located toward the big end with a slight displace- ment toward the root of the tooth (A). B 2282 After calculating the shims required according to points “A” and “B”, place the calculated shim on top of the bearing race and install special tool 884830 on the vertical shaft. Use GR970073 torque gauge 9999177 and turn the shaft one revolution per second. The minimum preload value should be 1.2 N•m (10.6 52 If the contact pattern is toward the root of the tooth and at the big end, the shims should be increased under the front and rear roller bearing (1). To maintain correct bearing preload, reduce the shims under the intermediate bearing (3) by a corresponding amount. To maintain the correct backlash, increase the shims under the vertical shaft ball bearing (2). C After the correct preload, backlash, and contact pattern have been obtained, remove the preload tool and tighten the vertical shaft nut. Remove the bearing box and outer propeller shaft. GR970074 If the contact pattern is too far toward the top of the tooth and toward the small end, reduce the shim thickness for under the front and rear roller bearing (1). To maintain proper bearing preload, increase the shim thickness correspondingly under the intermediate bearing (3). To maintain the correct backlash, decrease the shim thickness under the vertical shaft ball bearing (2). 2 1 1 Remove and discard the old pinion gear nut. Grease the threads of the vertical shaft. Install a new nut with the groove against the pinion gear. Tighten to 110 N•m (81 ft. lb). 3 2285 Final Assembly Grease the new seal rings and install in the propeller shaft. Turn the steel edge (1) facing forward. Use special tool 884975-4. Turn the broad shoulder against the seal ring. Press until it bottoms. 53 Turn the tool over and press in the “single lip” seal ring. Turn the spring facing aft. Press until it bottoms. 51. Install seal protector 884807 in the bearing box to protect the seal during installation. 1 52. Install new O-rings on the bearing box. Coat the entire sealing surface and O-rings with White Sealing Compound for Drives, Volvo Penta P/N 1141570-0. Install the bearing box in 48. Grease the seal rings and install in the bearing box with the gear housing. the springs facing away from each other. Use special tool 884801-2. Press until it bottoms. 49. Insert the protective ring 884976 into the outer propeller Tighten the bolts to 40 N•m (30 lb. ft.). shaft seals so that the seal lips are protected during installa- tion. 1 50. Carefully insert the outer propeller shaft in the gear housing. Remove the seal protector. Remove the seal protector (1) when the bearing box has been installed and tightened. Clean off any excess sealing com- pound. 54 Install the zinc ring on the lower gear housing. Check to make sure that the contact surfaces are clean and there is a good electrical contact. An ohmmeter may be used to ensure there is little or no resistance between the zinc ring and the lower unit housing. For more detailed information about Electrochemical Corrosion, what causes it and how to GR980491 prevent it, consult publication 7733534-7, Marine Electrical Press the outer race of the vertical shaft bearing with the Systems available from Volvo Penta. calculated shims into the intermediate housing. Use special tool 884168-6. Shimming the Lower Unit to the Intermediate Housing 1 4 A 5 2 3 Place the bearing race on the bearing and hold in position. GR980765 Using a depth gauge, measure the bearing height above the yyyyy ;;;;; Insert the oil strainer (5) into the lower gear housing. Check lower unit parting plane “A.” that the oil pipe (4) is provided with an O-ring . Use new O- yyyy ;;;; ;;;;; yyyyy rings (3) and (4). Install the spline sleeve (1) on the vertical shaft with the groove in the up position. Coat the contact ;;;; yyyy ;;;;; yyyyy surfaces with a thin coating of Volvo Penta White sealing ;;;; yyyy ;;;;; yyyyy compound for sterndrives 1141570-0. ;;;; yyyy ;;;;; yyyyy B Using the depth gauge, measure the intermediate housing “B.” Subtract measurement “A” from measurement “B.” This will give the clearance dimension. Add 0.02 mm to the clearance dimension to establish bearing preload. Example: Measurement “A” 10.02mm Measurement “B” – 9.77mm 203174 Clearance 0.25mm Use new screws and washers. Coat the screw threads with Bearing Preload + 0.02mm Loctite® Primer N and V olvo P Volvo ent Pent entaa thread locking com- Shim Thickness 0.27mm pound 1161053-2. First tighten the 4 larger screws holding the lower unit to the intermediate housing diagonally and in sequence with a torque wrench to 38 N•m (28 ft. lb.). Use special tool 885008-3. Tighten the 3 smaller screws to 15 N•m (11 ft. lb.). 55 Pressure and Vacuum Testing Before filling the drive with gear oil, it must be pressure and vacuum tested to verify proper sealing during assembly. Remove the oil drain plug from the lower unit housing. Install pressure tester 3810152-3 in the drain plug hole. Pressurize the sterndrive to 7 psi. Rotate the universal joint clockwise while shifting into forward and reverse. The drive must hold pressure before making the vacuum test. It must not loose more than 1 psi in 3 minutes. If a pressure drop is indicated, apply a soapy water solution to all sealing surfaces until the leak is found. Repair the leak and re-test the unit. Attach a vacuum tester 3858578-2 to the sterndrive. Pull 14-16 inches of mercury (Hg”) vacuum. Rotate the universal joint clockwise while shifting into forward and reverse. The drive must hold vacuum. It must not lose more than 1 inch in 3 minutes. If a vacuum drop is indicated, apply a heavy oil to the sealing surfaces to find the source. Repair the leak and re-test the unit. 56 STERNDRIVE INSTALLATION Install the exhaust bellows on the transom shield. Turn the hose clamp so that the screw points downward and is accessible. Install frame of special tool 885146-1 on the suspension pins. Be sure the drain hole in the bellows is mounted toward the transom and facing down. Remove the rear cover from the sterndrive. Place the large hose clamp on the front of the upper gear head. Install yoke 885144-6 on the upper gear head. Hang the yoke with the sterndrive attached on the frame. The sterndrive is heavy. It weighs approxi- Install the hose clamp on the universal joint bellows. Install the mately 54 Kg (120 lb.). Attempting to lift it by hand may cause universal joint bellows onto the flywheel housing with “UP” injury. where it protrudes from the transom shield. Locate the screw and the 4 o’ clock position. SE GREA E AS RE G Remove the locking screw and remove the suspension pin. Grease the suspension pins with Volvo Penta low tempera- ture grease 1161417-9 and install in the transom shield flush with the interior face to the transom shield. Grease the locking bolt with Volvo Penta low temperature grease 1161417-9. Thread the shift cable through the shift cable hose on the Put the locking bolts aside for installation later. inside of the transom until it protrudes from the transom shield. Slide the sterndrive up to the transom shield close enough to install the shift cable. Once the shift cable is installed, clamp the cable housing in place. 57 2 Align the sterndrive suspension yoke with the pins in the transom shield. Using a plastic mallet, drive the pins into the 1 transom shield until approximately 4mm of the pin is left on the outside of the transom shield. Remove the special tool. DO NOT use a metal hammer to drive the Install the plastic bushings (1) in the suspension yoke (2). pins. This will damage the suspension pin and make pin removal impossible. Slide the sterndrive forward. While turning the u-joint assem- bly align the U-joint with the primary shaft. The U-joint has a counterbore to aid in alignment of the splines. While looking into the locking screw hole of the transom shield, drive the pin in until the grove in the pin aligns with the locking screw hole. Grease the threads of the locking screw with Volvo Penta low temperature grease 1141644-3. Install the locking screw and washer. Torque the screws to 24 N•m (17 lb. ft.). Lift the trim cylinders simultaneously and push the sterndrive forward. 58 Hang the hose clamp on the exhaust bellows. Turn the Push the rubber U-joint bellows onto the upper gear head. sterndrive to port. Hold the port side of the bellows against Check to make sure the ring on the inside of the bellows is the port side of the exhaust opening. While holding the completely in the groove of the upper gear head. bellows in place move the sterndrive to the starboard posi- tion. At this point, the bellows will be much easier to attach the starboard side of the bellows to make the connection complete. After the hose attachment is complete, tighten the hose clamp in the indicated position. Lift the sterndrive and install special tool 885143-8 between the transom shield and the suspension yoke. Hang the hose clamp on the water intake hose and connect the hose to the hose attachment on the suspension yoke. Turn the hose clamp so that the screw is vertical on the starboard side. Only use special tool 885143-8 to secure outdrive. Serious injury may result if sterndrive is not properly blocked. The hose clamp must be positioned Check to make sure that all bellows and hoses have been vertically and on the starboard side of the attachment. Any installed correctly and the clamps are positioned properly and other position will damage either the U-joint bellows or the tight. Tilt the sterndrive and turn it fully in both directions. exhaust bellows. Check that the screws on the clamps do not touch the sterndrive, transom shield, or the other bellows. Loosen the clamps and adjust if necessary to keep the screws from cutting other bellows around them. Use special tool 885060- 4 and 884573-7. The illustration demonstrates the correct orientation of the clamps. 59 Lift sterndrive enough to remove special holding tool. While holding the trim cylinders up slightly, carefully lower the sterndrive onto the trim cylinders until the holes align between 1 the trim cylinder ram and the suspension yoke. 3 2 Lower the steering helmet and align the helmet bushing with the recessed hole of the upper gear head. Grease the attachment (2) with Volvo Penta low temperature grease 1161417-9. Install the attachment in the helmet bushing with the recessed holes vertical (one hole over the other). While moving the sterndrive slightly from side to side, push home the attachment until it bottoms in the upper gear head recessed hole. Install the two allen head bolts (1) and tighten to 35 N•m (25 ft. lb.). Be sure the attachment is aligned in the 970119 upper gear recess before tightening the allen head bolts. Apply generous amounts of Volvo Penta low temperature grease 1161417-9 to the trim pins and install. N A 1 2 A Before connecting the shift cable be sure that if the remote control moves forward, the shift cable extends from the cable housing, (i.e. cable pushes for forward gear, pulls for reverse gear). Set the sterndrive shift lever to horizontal making sure Install the cotter pins (1) and carefully bend the ends back- that it is in the neutral detent position. Set the remote control wards. shift lever to neutral. Push the shift cable in as far as possible. Using a fiber tip marker or suitable substitute, mark the position of the cable at the cable housing (A). Pull the control cable as far out as possible. Note the distance between the cable housing and the marked position on the cable. Push the cable into the housing half the distance to the mark (A2). Install the swivel onto the shift cable to the point it will attach to the shift lever without moving the lever for attachment. Install the washer and cotter pin. Bend the tabs backwards onto the swivel. 60 Filling the Unit Twin Engine Installation A 1 Install the oil drain plug with a new o-ring. A- 15 - 25mm (9/16 - 1 in.) In a twin installation the “Toe-out angle between the sterndrives must be adjusted until an operation free from 1 ventilation has been obtained. Increase the angle between the sterndrives on a boat with a deeper V-hull. Adjust the stern- drive according to the following illustration. If the measure- ment at the center of the steering pivot is “A”, the measure- ment between the outside edges at the exhaust outlet must be “A” minus 15-25mm (9/16 - 1 in.). Push the sterndrives apart by hand when taking the. Tilt the sterndrive to the full up position. Remove the fill plug (1) and fill with approx. 2.2 litres of DuraPlus™ GL-5 synthetic gear oil. Install the fill plug with a new gasket. Tighten the fill plug to 35 N•m (26 ft. lb.). Lower the sterndrive and check the oil level with the dipstick. If necessary, top off the sterndrive with oil through the dip stick hole. Install the shift mechanism cover. 61 NOTES ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 62 TRANSOM SHIELD Changing Trim Cylinders Removal B C D A Install a grease nipple 940194-4 where the ground terminal bushing or plastic plug was removed. Remove the 2 hoses (A) from the starboard cylinder. If only the port cylinder is to be replaced, remove the pipe connec- tions on that cylinder (B). Be sure to catch any oil which will leak when the hydraulic lines are disconnected. Remove the lock bolt from the trim cylinder attachment pin. Port Cylinder: If the port cylinder is to be removed, remove the ground strap terminal (C) and insert from the transom shield. Starboard Cylinder: Remove the plastic plug (D) adjacent to the trim cylinder attachment pin. Use a grease gun to pump the pin out of the hole. 63 If the pin will not come out by using a grease gun, special tool 884978-8 (2) should be used as follows: Remove the grease fitting. The transom shield must have cutouts called for on the transom template to allow sufficient clearance for Fill the tool (2) with grease. the pins to be removed. If the cutouts are not made, the Screw the tool into the transom shield and carefully tighten. transom shield must be removed from the boat to enable trim cylinder pin removal. Unscrew the locking trim cylinder pin locking bolt approx. 10mm (¼ in.). Hit the tool piston with a hammer so that the trim cylinder pin is forced against the locking bolt. Unscrew the locking bolt completely. Force the pin the rest of the way out of the hole. The locking bolt may be used in the trim cylinder pin to pull the pin completely out of the hole. 64 Always use a new O-ring on the dowel pin during reassembly. Check the pin hole and pin for scratches or other damage. Remove the trim cylinder from the shield. Install the ground strap insert, attach the ground strap to the insert. Be sure there is good electrical contact (low resistance) between the trim cylinders and the transom shield. High resistance between the transom shield and the trim cylinders will result in corroded trim cylinders. For more information on electrochemical corrosion, consult publication 7733534-7 “Marine Electrical Systems” available from Volvo Penta parts. Starboard Cylinder: Install the plastic plug. Install the sterndrive according to “Sterndrive Installation” found elsewhere in this book. Remove the grease fitting that was used to remove the Raise and lower the sterndrive several times to bleed any air attachment pin. trapped in the hydraulic system. Installation Remove any shipping plugs installed in the new trim cylinder. Install the new trim cylinder and pipes and hoses. Make sure all the pipes and hose fittings are attached finger tight before torquing any of the fittings. Final tightening of any of the fittings before all fittings are started could cause cross-threaded fittings and damage the cylinder. Install the trim cylinder attachment pin. Remove the attachment bolt from the end of the pin and lock With the sterndrive lowered as far as possible, check the oil the pin in position with the bolt. level in the hydraulic trim pump. Refill with Volvo Penta power steering and power trim fluid 3851039-2 to the MAX indica- Port Cylinder: tor on the reservoir. Remove the block off plugs from the old cylinder and install in the same holes of the new cylinder. For cold weather operation or prolonged commer- cial operation, use only Volvo Penta power steering and power trim fluid 3851039-2. If the system is filled with engine oil, the system must be drained completely before using power steering and power trim fluid. Keep the pump and oil clean to prevent dirt from entering the hydraulic system. 65 Changing Steering Helmet Steering Fork Steering Helmet 980615 Gently pry the steering fork down from the transom shield. To ensure the integrity of the steering system the steering helmet is not serviceable as a separate part from the steering fork as in years past. If there is a problem with the steering helmet or the steering fork, they must be replaced as a unit. Removal Remove the sterndrive according to procedure elsewhere in this book. A 11315 Install a new bushing (8) into the new steering fork. GR980759 Disconnect the power steering (A) if equipped. Disconnect and remove the trim sending unit. GR980763 Align the square on the steering fork with the square in the tiller arm and install into the transom shield. 980616 Loosen the tiller arm set screw using a 5/32 allen wrench. 66 GR980762 Make sure the square on the steering fork and the tiller arm are aligned. 11351 Install a new seal (9) and O-ring (7) on the gear wheel. Install the trim sending unit, gear wheel and gear rack. See “Trim System” elsewhere in this manual. GR980764 Using a rubber mallet tap the steering helmet into position 980616 Lock the setscrew with a 5/32 in. allen wrench. 67 NOTES .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... 68 TRIM SYSTEM Changing the Sending Unit 15 Kg (33 lb) Lower the sterndrive to its bottom position. Ensure the sterndrive is at its lowest position, place a 15 Kg Lower the sterndrive to the full down position. Turn the helm load on the rear of the sterndrive. full starboard. Using a 13mm wrench, remove the trim sender holding bracket and the trim sender. Unplug the sender from the wiring harness. -4 -4 should be shown in the instrument window for a 12° transom angle. Move the sending unit in either direction until Plug the new sending unit into the wiring harness. Align the the correct number is displayed on the trim gauge. Other white notch on the drive coupling with the white notch on the transom angle settings are as follows: sending unit housing. Transom angle Insturment indication 10° —2 11° —3 12° —4 13° —5 14° —6 15° —7 Install the sending unit housing into the steering shaft on the transom shield. Rotate the sending unit slightly to align the drive coupling with the gear wheel. Do not force the sending unit into the hole. This may damage the sending unit and/or the gear wheel. Install the trim sender bracket and hold down screw. Finger Tighten the trim sender bracket hold down screw. Be sure the tight only, do not tighten until all adjustments have been made. sending unit does not move when the bracket is tightened. 69 Changing the Trim System Gear Rack 398 Remove the damaged gear rack by removing the screw. Install the new gear rack with the marked tooth of the gear wheel in the first slot of the gear rack. 1 397 Bend the gear rack up slightly to clear the nut and pull it our Align the gear rack with the hole in the steering helmet. Push from the steering helmet. the nut (1) through the helmet and into the gear rack. 396 Turn the gear wheel until the tooth with a white recessed marking appears. Install the screw and carefully tighten. It is recommended that a new screw be used whenever the gear rack is removed. Do not overtighten the screw. Use extreme caution to prevent stripping the threads from the screw. 70 Changing the Trim System Gear Wheel 15 Kg Remove the sterndrive according to the section installation (33 lb) and removal. Lower the sterndrive to its bottom position. Ensure the sterndrive is at its lowest position, place a 15 Kg load on the rear of the sterndrive. -4 Pull the steering helmet aft far enough to clear the gear wheel. -4 should be shown in the instrument window for a 12° Turn the gear wheel so that the digital trim instrument indi- transom angle. If not, loosen the trim sender hold down clamp cates -4. and move the sending unit in either direction until the correct number is displayed on the trim gauge. Other transom angle settings are as follows: Transom angle Insturment indication 10° —2 11° —3 12° —4 13° —5 14° —6 15° —7 Pull the gear wheel straight down. There will be some resist- ance because of the retaining pawl in the bushing. Note the position of the drive end of the shaft when removing it. This will ease installation of the new shaft in the same position. After all adjustments are made, tighten the trim sender bracket hold down screw. Be sure the sending unit does not move when the bracket is tightened. 71 1 Push the steering helmet into position with the marked tooth of the GR980498 gear wheel engaging the first notch of the gear rack. Push the steering helmet as far forward as possible. Install the sterndrive Always use a new O-ring whenever the gear wheel is according to the installation section earlier in this chapter. Check the removed. trim adjustment according to adjusting the trim instrument section. Grease the new gear wheel shaft and O- ring liberally with Volvo Penta Propeller shaft grease 828250-1. Install the new gear wheel with the marked tooth pointing starboard just enough aft to be visible from under the steering fork. If the shaft will not fit easily into place, rotate the gear wheel slightly in either direction to engage the -4 gear wheel shaft and the trim sender coupling. Be sure the gear is completely seated before trying to engage the gear rack on the steering helmet. -4 should be shown in the instrument window for a 12° transom angle. If not, loosen the trim sender hold down clamp and move the sending unit in either direction until the correct number is displayed on the trim gauge. Other transom angle settings are as follows: Transom angle Insturment indication 10° —2 11° —3 12° —4 13° —5 Position the gear wheel as shown. 14° —6 15° —7 After all adjustments are made, tighten the trim sender bracket hold down screw. Be sure the sending unit does not move when the bracket is tightened. 72 Trim sender GN/W 1 Y GN 2 BL 2 (30) VO (85) W/SB (86) SB (87) SB GN/W SB/W (87 a) R/W GN W BL/W 1 BL BL/R (30) R (85) (86) (87) (87 a) R/W SB/W GN/W GN BL SB W/SB 5 GN/W 7 BL/R 1 W/SB 9 R/W 8 VO 8 SB 6 BL 2 GN 1 GN 3 BL 2 W4 BL/R Y7 SB BL/R SB W1 GR 2 BN 3 Y4 GN 5 BL/R 1 GN 2 BL 3 W4 W1 GR 2 SB 5 BN 3 BN 8 Y4 W6 GN 5 R/W 4 BL/R 2 BL 3 VO 2 BL 1 BN 4 BL 5 BL 1 W4 W/SB 2 VO 7 BL/R 5 Y SB 3 GR 2 GN/W 1 W/GN 4 BL 6 W/SB 1 R8 Y2 SB 7 VO 5 W3 BN 1 W/BN 1 (30) P2 Relay (85) (86) (30) (87) (85) (86) Digital trim instrument (87 a) 73 NOTES ................................................................................................................................................... ................................................................................................................................................... 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................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 74 WELDING Welding on certain parts of the sterndrive and the transom exhaust channel except around the bearing positions. The shield is allowed. Extreme caution must be used to prevent lower fin provided no more that 2/3 of it is missing measured damage to the precision machined surfaces or precision parts vertically. The water intake channel at the front of the housing, used in the sterndrive (i.e. near bearing locations). Always use however, it is important to maintain the channel profile. The Volvo Penta welding electrode 839643-4 when making any correct profile is important to prevent restricted water flow to welding repairs to the sterndrive or transom shield. the engine. The exhaust outlet, trim tab and propeller cone may be welded. It is important to protect the rubber exhaust Parts that cannot be welded flap during welding. The steering fork, steering helmet, clamp ring, tiller arm, 6. Pressurize the housing after repair. See Pressure and suspension yoke and exhaust elbows, trim cylinders, trim Vacuum Testing earlier in this book. cylinder attachment, power steering cylinder attachment, power steering cylinder, and the area around the suspension Repair instructions pins. On or around precision machined surfaces or precision Dismantle and clean the damaged part of the sterndrive. Grind parts. the area to be welded according to industry standard for Parts which can be welded welding aluminium. The welding should not be done at less than 20°C (68°F). If a part has been broken off and hasn’t 1. The neck of the flywheel housing for the attachment of the been lost, it should be used. Even if the surfaces are to be rubber bellows. Grind the neck smooth after welding to get welded, there should be a V groove approximately 45° on an even surface. both sides of the joint. Make the repair using Argon welding 2. The transom shield except on and around the suspension and Volvo Penta electrode 839643-4. Always pressure and ears, steering journals, around the suspension pins and the vacuum test the sterndrive as an assembly before returning to attachment of the trim cylinders. service. The shaded portions of the sterndrive and flywheel housing indicate where welding is permitted except where 3. The shift mechanism cover. noted above. 4. The exhaust channel in the intermediate housing except at the steering spindle and around the upper and lower bearing positions of the vertical shaft. 5. The lower unit housing on the cavitation plate and the 75 NOTES ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 76 PAINTING Recommendations must have good electrical contact to function properly. All antifouling paints preventing marine growth are poison- Never paint the zinc or magnesium anodes! ous and may harm our marine environment. The legislation Painting the anodes will prevent them from working properly. concerning antifouling paints has also been changed in many countries and others have announced coming changes in Blister in the paint may also be caused by unsuitable antifoul- their legislation. ing paint, galvanic currents, unpainted stem fittings etc. Be sure the anodes are not above the waterline when the In general, the new legislation is or will be considerably more sterndrive is tilted. They must be submerged in order to restrictive as far as the allowed leakage of the active ingredi- function properly. ents in the paints to the water is concerned. Several countries have put into practice (or will put into practice) a more Always read, understand and follow the restrictive legislation for pleasure boats than for commercial paint manufactures instructions for the safe and proper use of boats and vessels. The reason is that leisure boat harbors the paint product to be used. often are situated in shallow waters, which are spawning grounds for fish. Contrary to commercial boats, leisure boats Painting with Antifouling Paints spend most of their time tied up in the harbor, which adds to Do not use an airborne paint processes (i.e. the impact on the environment in these waters. aerosol, airless, or HVLP) to apply antifouling paint. The same Since the protection of the environment is in the best interest toxic material that makes antifouling paint work will make you of all, it is important to minimize the use of antifouling paints. sick. Always read, understand and follow the paint manufactures As far as smaller boats are concerned (trailer boats) which instructions for safe and proper use. can be taken out of the water, we recommend teflon type only, combined with cleaning a few times during the season. Only use antifouling paint specifically de- signed for use on aluminium sterndrive components. Never This procedure can prove somewhat impractical as far as use copper-based antifouling paints. Serious damage will larger boats are concerned and therefore antifouling paints result. might have to be used. However, always take care to find out the valid legislation in the area where you intend to use When making the purchase make sure that you receive the the boat prior to starting the treatment of the boat! Please correct product meeting the legislation prevailing in the area note that it might be completely forbidden to use antifouling where you are going to use the boat. The product must paints on leisure boats for instance in fresh water. The contain the correct properties for the boat hull type. Alu- legislation can also provide rules as to the boat weight or minium hulls often require an initial treatment with an etching overall length. Always follow local laws and regulations. primer. Use a pure copper based antifouling paint, containing copper tiocyanate, not copper oxide. Leave a 1“ strip Preparing the Sterndrive unpainted around the transom shield/sterndrive. Prior to painting the sterndrive with antifouling paint, check and Tin-based (TBT-paints) are no longer allowed. Make sure to repair possible paint damage to the finish coat. If the paint has prepare the hull in accordance with the directions of the paint been removed to bare metal, grind the area with 220 or finer manufacturer. aluminium oxide sandpaper. Wash the area clean with mineral spirits or its equivalent. Any porus area must be filled with The complete sterndrive including the trim cylinders, cooling putty. After applying putty the surface must be sanded water intake and transom shield should be painted in order to smooth and washed. maximum protection. Do not allow the antifouling paint on the transom shield (which is tin based) to come into contact with Paint the area with Volvo Penta primer 1141561-9 (2 the antifouling bottom paint on the boat (which is usually copper component ½ litre can) if bare aluminium is visible. The primer based). This will cause severe galvanic corrosion of the does not have to be sanded before applying the finish coat. sterndrive and/ or thru hull fittings. Always allow a Paint the repair area with two coats of finish paint Volvo 25.4mm (1 in.) border between the transom shield and Penta 1141575-9 (spay can) or 1141578-3 (2 component the bottom paint on the transom. Also, any metallic thru ½ litre can). Wet sand with 220 grit sandpaper between hull fittings that are bonded to the engine must have a finish coatings. border around each fitting. Do not sand to bare metal. If bare metal is For the paint to be effective you should allow the paint to dry exposed during finish sanding, the area must be repaired overnight between coats . The boat should remain out of the with primer and the process repeated. water at least 12 hours after the last coat of paint is applied. If paint repair is needed due to paint blistering, the cause must The quantity of the paint determines the longevity of the be found and remedied before paint repairs are made. protection it gives. One can (¼ litre) is a suitable quantity of Repairing the paint without finding the cause will only post- paint for the sterndrive and the transom shield. pone damaged pant. Consult Volvo Penta publication 7733534-7 Marine Electrical Systems, Part 1 under chapter 1:14 Electrochemical Corrosion for more information. Check the zinc anodes. There must be at least 50% of the anodes remaining to provide adequate protection of the sterndrive and transom shield. If there is less than 50% of the anodes remaining, they must be replaced. The anodes 77 NOTES ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... ................................................................................................................................................... 78 TECHNICAL DATA General Data DP-E Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aquamatic DUOPROP Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self adjusting Silent Shaft type of cone clutch, servo as- sisted disengagement. Maximum tilt angle, approx . . . . . . . . . . . . . . . . . . . . . . . . . 60" Power Trim & tilting device . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Steering angle, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Overall gear ratio Model DP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.95:1, 2.30:1, 1.78:1 Weight Model DP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Kilos (127.9 lb) Gear backlash Lower gear, measured on the wings of the inner propeller shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08-0.17 = 0.15-0.30 mm (0.003-0.007 in.) backlash in the gear Lower gear, measured on the wings of the outer propeller shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11-0.34 = 0.20-0.35 mm (0.008-0.014 in.) backlash in the gear Upper gear, ratio 1.95:1 and 1.78:1, measured directly on the gear . . . . . . . . . . . . . . . . . . . . . 0.15-0.25 mm (0.006-0.010") Upper gear, ratio 2.30:1, measured directly on the gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08-0.18 mm (0.003-0.070") Lubricating system Pump, type . . . . . . . . . . . . . . . . . . . . . Circulation pump for distribution of oil to all lubricating points Lubrication System Oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API-GL5* Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 90 or 80W90 Oil quantity, approx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 liters (2.4 UK Ots. 2.8 IS Qts.) Oil quantity, 1 in. extension, approx . . . . . . . . . . . . . . . . . 2.7 liters (2.4 UK Ots. 2.8 US Qts.) Oil quantity, 4" extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 liters (2.6 UK Ots. 3.0 US Qts.) Oil quantity between min. & max. marks . . . . . . . . . . . . . . 0.15 liters (0.13 UK Qts. 0.16 US Ots.) Power Trim, oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexron II Tightening torques NM Kpm Lb. ft. Upper nut on vertical shaft (upper gear) . . . . . . . . . . . . . . 125 12.5 92 Tightening universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . 75 7.5 55 Assembly double bearing box - gear housing . . . . . . . . . . 35 3.5 26 Assembly of top cover to upper gear housing . . . . . . . . . 15 1.5 11 Lower nut on vertical shaft . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.0 81 Bearing box with propeller shaft in gear housing . . . . . . . 40 4.0 30 Interm. housing - lower gear housing . . . . . . . . . . . . . . . . . 15 1.5 11 Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.0 7.5 Oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.5 25 Interm. housing - upper gear housing . . . . . . . . . . . . . . . . 20 2.0 15 Steering helmet 'attachment bolt’ . . . . . . . . . . . . . . . . . . . 35 3.5 25 Prestressing Input gear in double bearing box . . . . . . . . . . . . . . . . . . . . 5-10 N (0.5-1.0 kp/1.102-2.205 lb.) Input gear in double bearing box, run-in gears . . . . . . . . . 2.5-5 N (0.25-0.5 kp/0.55-1.102 lb.) Lowergear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2-2.3 N (0.12-0.23 kp/0.265-0.507 lb.) *Synthetic oil grade 75W90 corresponding to API GL5 requirements is recommended for commercial use. 79 General Data SP-E Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aquamatic SP-E Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self adjusting Silent Shaft type of cone clutch, servo as- sisted disengagement. Maximum Propeller Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16” Maximum tilt angle, approx . . . . . . . . . . . . . . . . . . . . . . . . . 60" Power Trim & tilting device . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Steering angle, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Overall gear ratio Model SP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.61:1 Weight SP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Kilos (127.9 lb) Gear backlash Upper gear, ratio 1.61:1, measured directly on the gear . . . . . . . . . . . 0.15-0.25 mm (0.006-0.010") Lower gear, measured on the intermediate shaft spline joint . . . . . . . 0.06-0.10 = 0.15-0.25 mm gear backlash in the gear (0.002-0.004 in) Lubrication System Pump, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circulation pump for distribution of oil to all lubricating points Oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API-GL5* Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 90 or 80W90 Oil quantity, approx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 liters (2.25 UK Ots. 2.75 US Qts.) Oil quantity, 1 in. extension, approx . . . . . . . . . . . . . . . . . 2.6 liters (2.25 UK Ots. 2.75 US Qts.) Oil quantity, 4" extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 liters (2.5 UK Ots. 3.0 US Qts.) Oil quantity between min. & max. marks . . . . . . . . . . . . . . 0.15 liters (0.13 UK Qts. 0.16 US Ots.) Power Trim, oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexron II Tightening torques NM Kpm Lb. ft. Upper nut on vertical shaft (upper gear) . . . . . . . . . . . . . . 125 12.5 92 Tightening universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . 75 7.5 55 Assembly double bearing box - gear housing . . . . . . . . . . 35 3.5 26 Assembly of top cover to upper gear housing . . . . . . . . . 15 1.5 11 Lower nut on vertical shaft . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.0 81 Bearing box with propeller shaft in gear housing . . . . . . . 40 4.0 30 Interm. housing - lower gear housing . . . . . . . . . . . . . . . . . 15 1.5 11 Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.0 7.5 Oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.5 25 Interm. housing - upper gear housing . . . . . . . . . . . . . . . . 20 2.0 15 Steering helmet 'attachment bolt’ . . . . . . . . . . . . . . . . . . . 35 3.5 25 Prestressing Input gear in double bearing box . . . . . . . . . . . . . . . . . . . . 5-10 N (0.5-1.0 kp/1.102-2.205 lb.) Input gear in double bearing box, run-in gears . . . . . . . . . 2.5-5 N (0.25-0.5 kp/0.55-1.102 lb.) *Synthetic oil grade 75W90 corresponding to API GL5 requirements is recommended for commercial use. 80 TOOLS 885322-8 Upper Gear Housing Tool Kit 885324-4 Lower Gear Housing Tool Kit Standard Handle, Slide Hammer, Sp Bearing Remover, 9991801-3 884316-1 Used On Upper & Intermediate Lower 3850608-5 Snap Ring Plyers, Upper 3850598-8 Spline Socket, Upper & Lower Bearing Press Drift, 3855876-3 New Style Fwd Prop Nut Tool, Lower 884168-6 Upper, Intermediate, Lower Standard Handle, Pointed, Lower & 884143-9 Press Tool, Bearing Installer, Upper & Intermediate 884263-5 Lower 884161-1 Tool, Slide Hammer, Lower 884265-0 Press Tool, Upper & Lower 884241-1 Bearing Installer, Lower 884266-8 Press Tool, Tube, Upper 884267-6 Shaft Remover, Lower 884312-0 Seal Installer, Upper 884283-3 Drift, Seal & Bearing Installer, Lower 884386-4 Press Tool, Sleeve, Upper 884348-4 Holding Fixture, Lower 884483-9 Tension Tool, Upper 884381-5 Bearing Drift, Remover, Lower 884793-1 Seal Install Tool, Upper 884385-6 Bearing Installer, Lower 884932-5 Mandrel, Seal Installer, Upper 884789-9 Puller, DP Prop Shaft, Lower 884933-3 Mandrel, Bearing Install Tool, Upper 884791-5 Drift, Bearing Remover, Lower 884938-2 Sleeve, Bearing Press, Upper 884792-3 Bearing Install Tool, Lower 90 Deg Allen Wrench, Puller, Fwd Bearing Race Remover, 885008-3 884794-9 Upper, Intermediate & Lower Lower 885009-1 Wrench, Upper & Intermediate 884795-6 Bearing Install Tool, Lower 885043-0 Torx 50 Bit, _ Inch Drive, Upper 884796-4 Drift, Bearing Remover, Lower 885152-9 Mounting Plate, Upper 884797-2 Press Tool, Bearing & Seal, Lower 885153-7 Spacer Ring, Mounting Plate, Upper Install Tool, Prop Shaft Bearing 884798-0 9985494-5 Spring Gauge/Scale, Upper Installer, Lower 884799-8 Press Fixture, Lower 885323-6 Intermediate Housing Tool Kit Press Tool, Bearing & Seal Installer, 884801-2 Expander, Axial Bearing Remover, Lower 884140-5 Intermediate 884802-0 Shaft Puller, DP, Lower 3810105-1 Pin Installer, Intermediate Drift, Tube Gear Brg & Seal Remover, 884803-8 Drift, Bearing Installer/Remover, Lower Unit 884259-3 Intermediate Drift, Tube Gear Bearing Installer, 884806-1 Drift, Bearing Installer/Remover Lower 884311-2 Intermediate Large Protective Sleeve/Ring, Black, 884807-9 Flex Driver, Bellows Clamps, Lower 884573-7 Intermediate Press Fixture, Bearing Race Remover, 884831-9 884874-9 Tool, Remover, Intermediate Lower 884978-8 Trim Cyl Removal Tool, Intermediate Drift Set, Tube Gear Race Remover, 884832-7 884982-0 Tool, Bearing Remover, Intermediate Lower Drive Support Kit, Attachment, DP Prop Shaft Runout, 885143-8 884940-8 Intermediate (885142-0) Lower 885148-7 Pin Remover, Intermediate Small Protective Sleeve/Ring, White, 884976-2 Lower 885325-1 SP-DP Power Steering Cylinder Tool Kit, (884975 & 884976), Seal 884977-0 885207-1 Hook Spanner Installer, Lower 3810152-3 Drive Pressure Tester 885127-1 Old Style Fwd Prop Nut Tool, Lower 3858578-2 Drive Vacuum Tester 885149-5 Drilling Sleeve, DP, Lower Alignment Wedge, Engine To Transom 885197-4 Tool, DP, Threaded Screw, Lower 884502-6 Shield 885208-9 Hook Spanner Drive Tools Not Included On New Tool Boards 885209-7 Sleeve 884521-6 280 Drive Hanging Tool Drive Repair Welding Rod (Aluminum 839643-4 Tool Boards Electrode) 885326-9 Upper Gear Housing 854668-1 Prop Wrench For16mm Bolt Cone 885327-7 Intermediate Gear Housing 873058-2 Prop Wrench For 20mm Bolt Cone 885328-5 Lower Gear Housing Drive Support, Part Of Kit 885143-8, 885142-0 885329-3 SP-DP Power Steering Cylinder Tools Intermediate 885146-1 290 Drive Hanging Tool 81 82 Shimming the front bearing Shimming the bearing box G – nominally (60.00 or 61.00) F – nominally (79.00 or 80.00) G – stamped + F – stamped + G= (61.00 ± 0.15) F= (80.00 ± 0.15) Front gear wheel, nominally = 39.50 C bearing box, nominally = 19.00 Front gear wheel, stamped = ± C bearing box, stamped = ± Front gear wheel = C= Front bearing, height = + 20.85 F= G= C= – – X = Shim thickness = Rear gear wheel, nominally = 39.50 Shimming the vertical shaft Rear gear wheel, stamped = ± H – nominally 277.00 H – stamped + Rear bearing, height + 20.75 H= Pinion, nominally = 60.00 Pinion, stamped = ± – Pinion = Vertical shaft = + 217.75 Z = Shim thickness H= – Shimming the intermediate bearing Shim thickness = G= X= F= Z= Constant = + 120.00 C= – – Shim thickness = H 217.75 P 217.75mm = 8.57" 39.50 mm = 1.56" 20.85 mm = 0.821" 20.75 mm = 0.817" 39.50 20.85 39.50 C 20.75 G F Reference to Service Bulletins Group No. Date Concerns .................................................................................................................................................................................................................... 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Report form Do you have any complaints or other comments about this manual? Please make a copy of this page, write your comments down and post it to us. The address is at the bottom of the page. We would prefer you to write in English or Swedish. From: ............................................................................ ...................................................................................... ...................................................................................... ...................................................................................... Refers to publication: ............................................................................................................................................. Publication no.: ..................................................................... Issued: .................................................................... 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Date: ........................................................... Name: ......................................................... AB Volvo Penta Technical Information SE-405 08 Göteborg Sweden 7797525-8 English 10-2000