STERNDRIVE UNIT. Table of Contents. Section 3B - Bravo One Gear Housing

Transcription

1 SERVICE MANUAL NUMBER 11 Tle of Contents STERNDRIVE UNIT Setion 3B - Brvo One Ger Housing BRAVO ONE GEAR HOUSING Speifitions B-2 Torque Speifitions B-2 Prelods B-2 Lurints/Selers/Adhesives B-2 Speil Tools B-3 Ger Rtio - Teeth per Ger (Ger Housing) B-3 Brvo One Ger Housing Exploded View. 3B-4 Drive Shft Components B-4 Propeller Shft Components B-6 Pre-Disssemly Inspetion B-8 Drive Shft Housing nd Ger Housing Seprtion B-8 Ger Housing Disssemly B-10 Component Serviing B-15 Drive Shft nd Pinion Bering Inspetion nd Clening B-15 Drive Shft Disssemly B-15 Pinion Bering Removl B-16 Pinion Bering Instlltion B-17 Drive Shft Ressemly B-18 Bering Crrier Inspetion B-19 Bering Crrier Serviing B-19 Propeller Shft Inspetion B-21 Propeller Shft Bering Removl.... 3B-21 Propeller Shft Bering Instlltion... 3B-22 Driven Ger Bering Removl nd Inspetion B-22 Driven Ger Bering Removl B-22 Driven Ger Bering Instlltion B-23 Driven Ger Bering Cup Removl nd Inspetion B-23 Driven Ger Bering Cup Instlltion. 3B-24 Speedometer Wter Tue Pikup Inspetion nd Clening B-24 Speedometer Wter Tue Sel Replement B-25 Ger Housing Ressemly nd Shimming 3B-26 Driven Ger Shimming for Models with Shims B-32 Driven Ger Shimming for Models with Lod Ring B-37 3 B MARCH 1998 Pge 3B-1

2 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Speifitions Torque Speifitions Prelods DESCRIPTION TORQUE l. in. l. ft. N m Pinion Nut Bering Crrier Retiner Torque to Proper Prelod Drive Shft Housing to Ger Housing Nuts nd Bolt Anodi Plte Srew Oil Fill/Drin Plug TORQUE DESCRIPTION l. in. N m Driveshft Berings Propeller Shft Berings - Cheked t Propeller Shft (New Berings) 8-12* * Propeller Shft Berings - Cheked t Propeller Shft (Used Berings)** 5-8* * *DOES NOT inlude 3 to 5 l. in. ( N m) of prelod on drive shft erings. **A ering is used if spun one under lod. Lurints/Selers/Adhesives DESCRIPTION PART NUMBER Quiksilver High-Performne Ger Lue A2 Quiksilver 2-4-C Mrine Lurint with Teflon A12 Quiksilver Speil Lurint A1 Quiksilver Needle Bering Assemly Lurint A1 Perfet Sel M Adhesive Lotite Quiksilver Engine Coupler Spline Grese A4 Pge 3B MARCH 1998

3 SERVICE MANUAL NUMBER 11 Speil Tools BRAVO ONE GEAR HOUSING DESCRIPTION PART NUMBER Dil Inditor Set A1 Bklsh Inditor Rod Dil Inditor Adptor Kit Slide Hmmer Puller A1 Torque Wrenh (l. in.) Drive Shft Pinion Ger Shimming Tool Bering Crrier Retiner Nut Wrenh Bering Crrier nd Br Puller A1 Clmp Plte Drive Shft Adptor Tool Universl Puller Plte Bering Sel Driver Threded Rod Bering Driver Bering Crrier Sels nd Bering Cup Driver Bering Cup Driver Bering Cup Driver Driver Rod Bering Removl Tool Bering Adptor Instlltion Tool A2 Ger Rtio - Teeth per Ger (Ger Housing) RATIO PINION DRIVEN 1.65: : : MARCH 1998 Pge 3B-3

4 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Brvo One Ger Housing Exploded View Drive Shft Components C A B A D Pge 3B MARCH 1998

5 SERVICE MANUAL NUMBER Retiner 2 - Coupler 3 - O-Ring 4 - Sper 5 - Shim(s) 6 - T Wsher 7 - Bering Cup 8 - Bering Cup 9 - Shim(s) 10- Drive Shft 11- Tpered Bering (Lrger Di.) 12- Tpered Bering (Smller Di.) 13- Sel Wter Pssge 14- Sel Speedometer Pitot Tue 15- Lok Nut 16- Flt Wsher 17- Ger Housing 18- Srew 19- Anodi Plte 20- O-ring 21- Fill/Drin Srew 22- Srew BRAVO ONE GEAR HOUSING Lurints, Selers, nd Adhesives A - Quiksilver High Performne Ger Lue A4 B - 3M Adhesive C - Quiksilver 2-4-C Mrine Lurint with Teflon A12 D - Perfet Sel Torque Speifitions 23 l. ft. (32 N m) 35 l. ft. (47 N m) l. in. ( N m) MARCH 1998 Pge 3B-5

6 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Propeller Shft Components B E C (ID) A B B (OD) C B D C F (OD) Pge 3B MARCH 1998

7 SERVICE MANUAL NUMBER Ger Housing 2 - Shims 3 - Bering Cup 4 - Tpered Bering 5 - Driven Ger 6 - Needle Bering 7 - Pinion Ger 8 - Wsher 9 - Loknut 10- Propeller Shft 11- Wsher 12- Tpered Bering 13- Bering Cup 14- Lod Ring 15- Wsher 16- O-ring 17- Sels 18- Bering Crrier 19- Wsher 20- Drin Srew 21- Propeller Anode 22- Lokwsher 23- Srew 24- T Wsher 25- Bering Crrier Retiner 26- Continuity Wsher 27- Thrust Hu 28- Spline Wsher 29- T Wsher 30- Loknut BRAVO ONE GEAR HOUSING Lurints, Selers, nd Adhesives A - Quiksilver 2-4-C Mrine Lurint with Teflon A12 B - Quiksilver High Performne Ger Lue (Use on All Bering Surfes) A4 C - Lotite D - Quiksilver Speil Lurint A1 E - Quiksilver Engine Coupler-Spline Grese A4 F - Perfet Sel Rolling Prelod Speifitions Tighten Until You Ahieve Proper Ger Cse Prelod Torque Speifitions 100 l. ft. (135 N m) l. in. ( N m) Speil Note d There re two models of ering rriers, identil in size nd instlltion, exept tht one is modified to inlude drin plug, whih is essile when propeller is removed. Ger Rtio - Teeth per Ger (Ger Housing) RATIO PINION DRIVEN 1.65: : : MARCH 1998 Pge 3B-7

8 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Pre-Disssemly Inspetion 1. Chek propeller shft for side to side movement, s follows:. Position dil inditor on propeller shft.. Push propeller shft to one side nd zero the dil inditor.. Move propeller shft to opposite side while oserving dil inditor. Without rotting propeller shft, reposition dil inditor nd hek up nd down defletion. A shft defletion of more thn.003 in. (0.08mm) indites one of the following: Worn propeller shft erings. Improper propeller shft prelod Chek for ent propeller shft, s follows:. Rotte propeller shft while oserving dil inditor. If defletion is more thn.005 in. (.127mm), ent propeller shft is indited. Drive Shft Housing nd Ger Housing Seprtion 1. Ger Lue Monitor models, only: remove, empty, nd len ger lue monitor. Lurite nek O-ring sel with ger lue efore repling monitor p. 2. Drin drive unit t lotion or, s pplile. - Fill/Drin Srew - Remove - Fill/Drin Srew - Remove Pge 3B MARCH 1998

9 SERVICE MANUAL NUMBER Remove vent plug. BRAVO ONE GEAR HOUSING Vent Plug 4. Remove trim t or nodi plte. - Plsti Plug - Removed - 1/2 in. Bolt - Remove 5. Remove ger housing from drive shft housing Nuts nd Wshers - Remove - 1 Bolt (Loted in Trim T Cvity) - Remove 6. Finish drining ger se y turning upside down over ontiner MARCH 1998 Pge 3B-9

10 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Ger Housing Disssemly 1. Remove propeller. - T Wsher - Bend Ts - Nut - Remove - Spline Wsher - Remove d - Continuity Wsher - Remove e - Thrust Hu - Remove f - Propeller e f d CAUTION Clmp plte ( ) must e instlled on ger housing when ger housing is seprted from drive shft housing. 2. Instll lmp plte on ger housing. Tighten seurely Clmp Plte - Nut - Wsher Pge 3B MARCH 1998

11 SERVICE MANUAL NUMBER Bend ts of t wsher wy from ering rrier retiner. BRAVO ONE GEAR HOUSING -T - Srew Driver Remove ering rrier retiner nut, using ering rrier retiner wrenh ( ) Bering Crrier Retiner Wrenh 5. Remove ering rrier with ering rrier puller, (P/N ). - Bering Crrier Puller ( ) MARCH 1998 Pge 3B-11

12 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER Remove propeller shft. - Propeller Shft 7. Remove wsher, shims nd O-ring Wsher - Shims - O-ring 8. By hnd, temporrily reinstll ering rrier retiner in ger housing to protet housing threds. Remove pinion ger, nut, nd wsher d Drive Shft Adptor Tool ( ) - Breker Br nd Soket - Pinion Ger d - Bering Crrier Retiner Pge 3B MARCH 1998

13 SERVICE MANUAL NUMBER 11 BRAVO ONE GEAR HOUSING 9. Remove lmp plte (instlled in Step 2), then remove O-ring, sper, shim(s) nd t wsher. d e - Clmp Plte - O-ring - Sper d - Shim(s) e - T Wsher 10. Remove drive shft nd pinion ger Drive Shft - Pull Up - Pinion Ger 11. Remove driven ger nd ering Driven Ger - Bering Cup MARCH 1998 Pge 3B-13

14 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER Remove drive shft ering up nd shims. - Drive Shft Bering Cup - Shims Unless you pln to remove the pinion ering, remove needle erings from drive shft needle ering re. (See Pinion Bering Removl on pge 3B-16.) - Needle Berings - Drive Shft Needle Bering Re 14. Remove wter pssge O-ring Wter Pssge O-ring Pge 3B MARCH 1998

15 SERVICE MANUAL NUMBER 11 Component Serviing BRAVO ONE GEAR HOUSING Drive Shft nd Pinion Bering Inspetion nd Clening Drive Shft Disssemly 1. The ondition of the drive shft tpered ering ups is n indition of the ondition of the tpered roller erings on the drive shft. Reple ering nd ering up if up is pitted, grooved, sored, worn uneven, disolored from overheting, or hs emedded metl prtiles. 2. The ondition of the ering surfe on drive shft t needle ering lotion is n indition of the ondition of needle erings. Reple needles nd sleeve if pitted, grooved, sored, worn uneven, disolored from overheting, or hs emedded metl prtiles. 3. Inspet splines for worn or twisted ondition. Replement of drive shft is neessry if either ondition exists. 4. Clen ll prts tht re to e reused with solvent. Dry prts ompletely using ompressed ir, eing reful not to spin erings. NOTE: Bering ssemly must e repled if removed from drive shft. Tpered roller erings re dmged when removing. 1. Press tpered roller ering from shft using universl puller plte ( ) to support ering. Remove seond tpered roller ering in sme mnner. - Drive Shft - Bering - Universl Puller Plte MARCH 1998 Pge 3B-15

16 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Pinion Bering Removl IMPORTANT: All needle erings MUST BE in ple inside ering sing while driving pinion ering from ger se or ering sing will end or rek nd eome diffiult to remove. 1. Remove pinion ering. d d Bering Driver ( ) - Used s Pilot - Driver Rod ( ) - Bering Remover ( ) - Ensure Ts Align with Slots in Ger Housing d - Het Bering Are of Housing to pproximtely 200 F (99 C) to Assist in Bering Removl. DO NOT use Open Flme Pge 3B MARCH 1998

17 SERVICE MANUAL NUMBER 11 Pinion Bering Instlltion BRAVO ONE GEAR HOUSING 1. Instll needles in sing. Use Needle Bering Assemly Lurint to help keep needles in ple. Position ering ssemly over ering instlltion tool with numer on ering sing fing up. Cot sing O.D. with Ger Lue. - Needle Berings - Csing Instll pinion ering using tools s shown. Instll the ering with the seril numer on the re fing up. d Bering Driver ( ) - Used s Pilot - Threded Rod ( ) - Wsher nd Nut - Turn Clokwise d - Bering Driver ( ) MARCH 1998 Pge 3B-17

18 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Drive Shft Ressemly 1. Press smll tpered roller ering onto drive shft. Ensure smller O.D. fes pinion end of shft Universl Puller Plte - Drive Shft - Smll Tpered Roller Bering 2. Press lrge tpered roller ering onto drive shft. Ensure lrger O.D. fes pinion end of shft. - Suitle Mndrel - Support on Inner Bering Re - Drive Shft - Lrge Tpered Roller Bering Pge 3B MARCH 1998

19 SERVICE MANUAL NUMBER 11 Bering Crrier Inspetion Bering Crrier Serviing DISASSEMBLY BRAVO ONE GEAR HOUSING 1. The ondition of the propeller shft tpered roller ering up is n indition of the ondition of tpered roller ering on propeller shft. Reple ering nd up if up is pitted, grooved, sored, worn, uneven, disolored from overheting or hs emedded metl prtiles. 2. Chek ering rrier for signs of orrosion, espeilly on ger housing to ering rrier mting surfes. If orrosion is evident, reple ering rrier. NOTE: Oil sels nd ering up my e removed nd repled individully. It is not neessry to remove ering up to reple oil sels or remove oil sels to reple ering up. 1. Remove ering up. - Slide Hmmer Puller - Bering Cup Remove oil sels from ering rrier. - Oil Sels (2) - Punh MARCH 1998 Pge 3B-19

20 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 REASSEMBLY 1. Cot O.D. of oil sel with either Lotite Type A or Instll outer oil sel with lip fing outwrd. - Oil Sel - Lip Outwrd - Cup nd Sel Driver ( ) Cot O.D. of oil sel with Lotite or Type A. Instll inner oil sel with lip fing inwrd Oil Sel - Lip Inwrd - Cup nd Sel Driver ( ) Instll ering up with ering surfe inwrd. - Bering Cup - Cup nd Sel Driver ( ) Fill re etween sels with 2-4-C Mrine Lurint with Teflon Are Between Sels Pge 3B MARCH 1998

21 SERVICE MANUAL NUMBER 11 Propeller Shft Inspetion 1. Chek propeller shft for ent ondition. Use either method following: LATHE AND DIAL INDICATOR METHOD: BRAVO ONE GEAR HOUSING. Position propeller shft enters in lthe.. Mount dil inditor t front edge of propeller shft.. Rotte shft nd oserve dil inditor. Movement of more thn.005 in. (.127mm) is reson for replement. V-BLOCKS AND DIAL INDICATOR METHOD: d. Position propeller shft ering surfes on V-loks. e. Mount dil inditor t front edge of propeller shft. f. Rotte shft nd oserve dil inditor. Movement of more thn.005 in. (.127mm) is reson for replement. 2. Inspet for ent or twisted splines. 3. Inspet surfe of shft where ering rrier oil sel lips ontt shft. Oil sels will hve to e repled if ny grooves re found. Propeller Shft Bering Removl 1. Press ering from propeller shft. Remove wsher. d - Propeller Shft - Universl Puller Plte ( ) - Tpered Roller Bering d - Wsher MARCH 1998 Pge 3B-21

22 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Propeller Shft Bering Instlltion 1. Instll wsher on shft. Apply Ger Lue to I.D. of new ering. Instll ering to shft using universl puller plte nd suitle mndrel (old ering re) whih supports ering on inner re. Press into ple. d e Propeller Shft - Wsher - Tpered Roller Bering d - Suitle Mndrel e - Universl Puller Plte ( ) Driven Ger Bering Removl nd Inspetion 1. Remove ering from driven ger. Inspet oth the driven ger nd the pinion ger for pitting, hipped or roken teeth nd exessive or uneven wer. Reple oth gers if ny of these onditions exist. 2. Reple tpered roller ering nd up if up is pitted, grooved, soured, worn uneven, disolored from overheting, or hs metl prtiles emedded in the up. Driven Ger Bering Removl 1. Remove ering from driven ger. d - Suitle Mndrel - Universl Puller Plte - Bering d - Driven Ger Pge 3B MARCH 1998

23 SERVICE MANUAL NUMBER 11 Driven Ger Bering Instlltion BRAVO ONE GEAR HOUSING 1. Apply light ot of Ger Lue to I.D. of new ering. Ple suitle mndrel (old ering re) ginst new ering re. Ple nother mndrel on fe of ger nd press ger nd ering together. d Hrd Wood or Metl Blok - Driven Ger - Tpered Roller Bering d - Mndrel - Contting Inner Re Driven Ger Bering Cup Removl nd Inspetion 1. Remove ering up nd shims. Reple tpered roller ering nd up if up is pitted, grooved, sored, worn uneven, disolored from overheting, or hs metl prtiles emedded in the up. - Slide Hmmer Puller ( A1) - Bering Cup - Shims MARCH 1998 Pge 3B-23

24 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Driven Ger Bering Cup Instlltion 1. Instll driven ger ering up with originl thikness shims(s). Ensure up is not nted. Cot up O.D. with Ger Lue. d Shim(s) - Bering Cup - Driver (P/N ) d - Old Propeller Shft or Driver Rod Speedometer Wter Tue Pikup Inspetion nd Clening 1. Inspet opening (pitot tue), on leding edge of ger housing, for ostrution. Clen opening with short piee of wire, if neessry. If ostrution n not e removed with wire, refully reopen tue using 5/64 in. (2mm) dimeter drill it. Do not drill eyond depth of 2-7/16 in. (62mm). - Pitot Tue Inspet wter tue sel for niks, uts, or distortion. Reple if neessry. - Wter Tue Sel Pge 3B MARCH 1998

25 SERVICE MANUAL NUMBER 11 Speedometer Wter Tue Sel Replement 1. Pry ruer sel out with suitle tool. BRAVO ONE GEAR HOUSING Ruer Sel 2. Lightly ot O.D. of sel with 3-M dhesive ( ) nd instll in speedometer wter tue ore. Ensure top edge of sel is flush with ger housing surfe. - Sel MARCH 1998 Pge 3B-25

26 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Ger Housing Ressemly nd Shimming 1. Lurite ll gers nd erings with ger lue efore instlling. Components must e lurited to otin urte ering prelod redings. 2. Instll wter pssge O-ring nd oil pssge qud ring. Hold in ple using 3-M dhesive (P/N ). - O-ring - Oil Pssge Qud Ring Instll needle erings into lower needle ering sing. Use Needle Bering Assemly Lurint to hold needle erings in ple Needle Berings - Needle Bering Csing Pge 3B MARCH 1998

27 SERVICE MANUAL NUMBER Instll driven ger ssemly. BRAVO ONE GEAR HOUSING - Driven Ger Assemly Instll originl shim(s) nd drive shft lower ering up, using up driver (P/N ). Use originl shims, or if lost or mispled, strt with.050 in. (1.27mm) thikness. - Shim(s) - Lower Bering Cup - Cup Driver MARCH 1998 Pge 3B-27

28 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER Instll drive shft nd pinion ger. - Drive Shft - Pinion Ger Determine shim thikness required for drive shft ering prelod.. Mesure distne etween top of ger housing nd t wsher. - 0-to-1 in. Depth Mirometer Mesure thikness of sper from top mhined surfe to ottom mhined surfe Outside Mirometer - Sper. Clulte shim thikness s shown. Mesurement step Mesurement step in. = Shim Thikness Required. Pge 3B MARCH 1998

29 SERVICE MANUAL NUMBER Instll upper ering up, t wsher, originl shims, sper, nd O-ring. BRAVO ONE GEAR HOUSING d e Upper Bering Cup - T Wsher - Originl Shims d - Sper e - O-ring 9. Instll lmp plte (P/N ) on ger housing with 4 nuts nd wshers. Torque to 35 l. ft. (47 N m). - Clmp Plte Instll wsher, nd pply either Lotite to threds of new nut. - Wsher - Nut MARCH 1998 Pge 3B-29

30 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER Temporrily instll ering rrier retining nut to void dmge to threds. Torque pinion nut to 100 l. ft. (135 N m). d - Drive Shft Adptor Tool ( ) - Breker Br nd Soket - Torque Wrenh nd Soket d - Bering Crrier Retiner By hnd, remove ering rrier retiner previously pled in unit for protetion of threds. 13. Using dil-type l. in. torque wrenh, hek the rolling prelod [3-5 l. in. ( N m)]. - Dil-type l. in. Torque Wrenh - Drive Shft Adptor If too tight or loose, djust s required. Pge 3B MARCH 1998

31 SERVICE MANUAL NUMBER 11 BRAVO ONE GEAR HOUSING 15. Chek pinion height.. Insert shimming tool into ger housing.. Mesure lerne etween tool nd ger with feeler guge. Clerne must e.025 in. (.635mm). Tke mesurement t 3 lotions on ger (120 degrees prt). - Shimming Tool (P/N ) - Feeler Guge If lerne is less thn speified: Add pproprite thikness of shim(s) under lower tpered roller ering up. Any thikness dded here must e sutrted from shim thikness t upper ering. If lerne is more thn speified: Remove pproprite thikness of shim(s) from under lower tpered roller ering up. e - Shims, Lower - Bering Cup, Lower - Shims, Upper d - Sper e - O-ring d d. Rehek lerne fter hnging shim(s) in step, ove. 16. Using dil-type (l. in.) torque wrenh, hek the rolling prelod [3-5 l. in. ( N m)]. - Dil-type l. in. Torque Wrenh - Drive Shft Adptor MARCH 1998 Pge 3B-31

32 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 Driven Ger Shimming for Models with Shims NOTE: Brvo One drives with seril numers OD nd higher use lod ring insted of shims. See Driven Ger Shimming for Models Using Lod Ring, on pge 3B Instll wsher, originl shims, O-ring, propeller shft, ering rrier, ted wsher nd retining nut. Torque to 150 l. ft. (203 N m). d e f g Wsher - Originl Shims - O-ring d - Propeller Shft e - Bering Crrier f - Ted Wsher g - Retining Nut 2. Chek propeller shft ering prelod Torque Wrenh - Rotte - Dil Inditor - New Berings 8-12 l. in. ( N m) Used Berings 5-8 l. in. ( N m) - Adptor - Propeller Shft Nut Cn Be Used Pge 3B MARCH 1998

33 SERVICE MANUAL NUMBER 11 BRAVO ONE GEAR HOUSING 3. If dil indition is other thn speified: If dil indition is lower thn speified: Remove shim(s) from in front of ering rrier. If dil indition is higher thn speified: Add shim(s) in front of ering rrier. - Wsher - Shims - O-ring - T Wsher - Retining Nut 4. Instll the following speil tools: Dil Inditor Adptor (P/N ), Bklsh Inditor Rod (P/N ), nd Dil Inditor (P/N A1), s shown. Ensure dil rod is ligned with II on inditor rod Dil Inditor Adpter - Bklsh Inditor Rod - Dil Inditor Chek ger klsh y lightly rotting drive shft k nd forth. Do not llow propeller shft to turn. Oserve dil inditor nd reord the reding. 6. Chek the klsh in four different positions y rotting the drive shft 90 fter tking eh reding. Averge the redings. The redings should verge in. ( mm). Mke sure ll the redings re within the in. ( mm) rnge MARCH 1998 Pge 3B-33

34 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER If klsh is not orret, disssemle nd proeed s follows:. If klsh is more thn speified: Add shim(s) under driven ger ering up.. If klsh is less thn speified: Remove shim(s) under driven ger ering up. - Driven Ger Bering Cup IMPORTANT: Bering rrier nd threds on ering rrier retining nut must e lurited to prevent orrosion nd rking in ger housing. Cot O.D. on rrier mting surfes () with Perfet Sel. 8. Lurite ering rrier. Fill spe etween sels with 2-4-C Mrine Lurint with Teflon nd ot mting surfes with Perfet Sel. - Spe Between Sels - Mting Surfes Pge 3B MARCH 1998

35 SERVICE MANUAL NUMBER Instll wsher, shims, O-ring nd propeller shft. BRAVO ONE GEAR HOUSING d - Wsher - Originl Shims - O-ring d - Propeller Shft IMPORTANT: The ering rrier is kept from spinning in ger se y the t wsher. Be sure tht the inner t is positioned in the V noth in ering rrier nd outer t fits into hole in ger se ore Inner T - Position in V-noth of Crrier - Outer T - V -Noth 10. Instll ering rrier nd t wsher in ger housing. Position inner t in V-noth. d Bering Crrier - T Wsher - Inner T d - Outer T MARCH 1998 Pge 3B-35

36 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER Lurite threds on ering rrier retiner with Speil Lurint 101; then instll retining nut nd torque to 150 l. ft. (203 N m). - Bering Crrier Retiner Nut - L. ft. Torque Wrenh 12. Rehek klsh from preeding steps t this time. Remove dil inditor if orret. DO NOT remove lmp plte. IMPORTANT: A ering is onsidered used if spun under lod one. 13. Chek propeller shft ering prelod. New erings should e 8-12 l. in. ( N m). used erings should e 5-8 l. in. ( N m) Torque Wrenh - Rotte - Adptor - Propeller Shft Nut Cn Be Used If dil indition is other thn speified: If dil indition is lower thn speified: Remove shim(s) from in front of ering rrier. If dil indition is higher thn speified: Add shim(s) in front of ering rrier. - Wsher - Shims - O-ring - T Wsher - Retining Nut Pge 3B MARCH 1998

37 SERVICE MANUAL NUMBER 11 BRAVO ONE GEAR HOUSING Driven Ger Shimming for Models With Lod Ring 1. Instll the lod ring, thrust ring, nd o-ring into the ger housing. d - Lod Ring (0.105) - Thrust Ring (.105 Thikness) - O-ring d - Propeller Shft 2. Instll the lter style ering rrier (41641A8) nd t wsher in the ger housing. d Bering Crrier - T Wsher - Inner T - Position in V-noth d - Outer T 3. Lurite threds on ering rrier retining nut with Speil Lurint 101. Instll nd tighten ering rrier retiner until resistne to propeller shft rottion n e felt MARCH 1998 Pge 3B-37

38 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER Instll nd tighten ering rrier retining nut until no more end-ply n e felt. DO NOT TORQUE. IMPORTANT: Alwys use new lod ring when ressemling nd for finl ssemly. - O-ring - Thrust Ring - Lod Ring IMPORTANT: Bering rrier nd threds on retiner must e lurited to prevent orrosion nd rking in ger housing. Use Speil Lurint 101 on retiner; ot O.D. on rrier rounds with Perfet Sel. 5. Lurite ering rrier sels. Fill spe etween sels with 2-4-C Mrine Lurint with Teflon nd ot rrier mting surfes with Perfet Sel Spe Between Sels - Mting Surfes 6. Instll ering rrier nd loting key in ger housing Bering Crrier - Loting Key Pge 3B MARCH 1998

39 SERVICE MANUAL NUMBER Instll t wsher with V-noth positioned s shown in reess in rrier. BRAVO ONE GEAR HOUSING - T Wsher - V Noth in Reess in Crrier - Bering Crrier - Bering Crrier Retiner Lurite threds on ering rrier retining nut with Speil Lurint 101. Instll, nd tighten ering rrier retiner until resistne to propeller shft rottion n e felt (to prelod erings). 9. Tighten the retiner to the proper overll prelod. To determine overll ger se prelod dd ering prelod to drive shft prelod s outlined in the exmple elow. IMPORTANT: The overll prelod inludes oth the drive shft prelod nd the ger se prelod. Prelods New Berings 8-12 l. in. ( N m) ** Used Berings* 5-8 l. in. (.6-.9 N m) ** Drive Shft 3-5 l. in. ( N m) * Bering is onsidered used if spun under lod even one ( under lod mening: with power pplied ). **Plus drive shft prelod [3-5 l. in. (.3-.6 N m)] Exmple: Drive Shft Prelod 3 l. in. (.3 N m) + New Bering Prelod 8 l. in. (.9 N m) 11 l. in. (1.2 N m) 10. Tighten the retiner to the proper prelod using the following proedure.. Tighten the retiner in smll inrements. - Bering Crrier Retiner Wrenh ( ) MARCH 1998 Pge 3B-39

40 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11. After tightening, hek overll ger housing ering prelod t propeller shft. Rotte shft in diretion of norml rottion in smooth, stedy motion. - L. in. Torque Wrenh Propeller Nut (under soket) - Shft Rottion Diretion ALL MODELS 11. Bend one t into retining nut s shown fter propeller shft prelod hs een set orretly. Bend remining ts down into ger housing. - T Wsher - Retining Nut Instll ger housing to drive shft housing. Torque ll fsteners to 35 l. ft. (47 N m). - 6 Nuts nd Wshers (3 Eh Side) - 1 Bolt (Loted in Trim T Cvity) Pge 3B MARCH 1998

41 SERVICE MANUAL NUMBER 11 BRAVO ONE GEAR HOUSING NOTE: Lter model Brvo One drive units re equipped with n nodi plte insted of trim t. Replement proedure is the sme. - Trim T - Anodi Plte 13. Instll trim t or nodi plte. Torque olt to 23 l. ft. (32 N m) Bolt 14. Instll plsti plug Plsti Plug 15. Reinstll drive unit. Refer to Setion 2A. 16. Fill drive unit with ger lue. Refer to Setion1B MARCH 1998 Pge 3B-41

42 BRAVO ONE GEAR HOUSING SERVICE MANUAL NUMBER 11 THIS PAGE IS INTENTIONALLY BLANK Pge 3B MARCH 1998