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Z~ Safety Warning This Workshop Manuam will alert you to certain procedures that must be done very carefully, if you ignore this information, you could... ® Injure yourself or people around you ® Injure the boat operator, boat passengers, or people around the boat o Damage the Volvo Penta product or its systems Understand the following symbols before proceeding: Alerts you to the possibility of danger and Z~ Safety Warning identifies information that will help prevent injuries. Identifies information that will help prevent damage to machinery. Appears next to information that controls correct assembly and operation of the product. This Workshop Manual is written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools. This Workshop Manual tells you how to correctly maintain and service Volvo Penta products and systems. When correctly serviced, the Volvo Penta product will be reliable and safe to operate, When Volvo Penta special tools are called for, use them. Where mentioned, the tools are required to perform the service procedure. If you use service procedures or service tools that are not recommended in this manual, YOU ALONE must decided if your actions might injure people or damage the Voavo Penta product. Contents General Information .................................... Transom Shield SX Models .......................................... Upper Gear Unit SX Models .......................................... Lower Gear Unit SX Models .......................................... Drive Unit Removal/Installation SX Models .......................................... Trim/Tilt System - Hydraulics SX Models .......................................... Propeller Selection SX Models .......................................... Safety .................................................. (c31994Volvo Penta of the Americas, inc. AIII Rights Reserved. VD/TB/eng i This workshop manual is one of a set of seven that covers Volvo Pentastern drive models. All seven books can be ordered as a set from Volvo Penta Parts. Order P/N 7796741-2. nndividual workshop manuals covering these models are also available. Order the following part numbers from Volvo Penta Parts. ¯ WN 7796484-9 Drive Unit and Transom Shield -SX models Includes information on Transom Shield, Upper Gear Unit and Lower Gear Unit service; Drive Unit removal and installation; Propellers; and Trim/Tilt hydraulic operation. ¯ PiN 7796485-6 Engines Includes information on Engine service and troubleshooting; Engine removal and installation; Steering systems; Throttle and Shift Control systems; and Cooling systems. ¯ P/N 7796456-7 Electrical~ignitionSystems-all models includes service and troubleshooting information on Cranking systems; Charging systems; Trim/Tilt electrical systems; Ignition systems; and Engine and instrument wiring diagrams. ¯ PIN 7796457-5 Fuel Systems -all models includes service and troubleshooting information on all carbureted and EFI fuel systems and related components. ¯ P/N 7796458-3 Diagnostic Manual -Ford Fi Models Only Includes step by step troubleshooting procedures for all EFi related components and wiring. ¯ PIN 7796431-0 Diagnostic Manual -GMGi Models Only Contains troubleshooting procedures for all Gi models and relared components. e PIN 7731624-8 SP and DP WorkshopManual Includes information on Upper Gear Unit and Lower Gear Unit overhaul procedures, installation and removal. +This Volvo Penta Stern Drive Workshop Manual Covers The Following Volvo Penta SX Models Engine Model Number Transom Shield Drive Unit o GL 0 GS (M) (e) 3868033 3868034 3 GL 3 GS 3 GS (P) (P) (P) 3868046 3868089 3868007 0 FL 0 Fi 0 Fi (P) (P) (P) 3868055 3868127 3868127 7 GL 7 GL 7 Gi (P) (P) (P) 3868067 3868013 3868010 8 FL 8 Fi (P) {P) 3868056 3868128 4 GL 4 GL 2 GL (P) (P) (P) 3868O15 3868132 3868019 2 GL (P) 3868133 (M) = Mechanical Steering (P) = ~pt~ Duoprop and DPX Drive Unit repairs Manuals, 3868090 3868090 3868036 3868036 3868003 3868036 3868036 3868036 3868036 3868003 3868003 3868036 3868036 3868003 3868003 3868024 3868024 Power Steering are covered extensively 3868035 (1.85:1) 3868035 (1.85:1) 3868077 (1.66:1) 3868077 (1.66:1) 3868008 (2.30:1)* 3868077 (1.60:1) 3868077 (1.60:1) 3868068 (1.60:1) 3868068 (1.60:1) 3868002 (1.95:1)* 3868022 (1.78:1)+ 3868058 (1.51:1) 3868058 (1.51:1) 3868022 (1.78:1)+ 3868022 (1,78:1)* 3888020 (1+59:1) 3868021 (1.68:1) 3868023 (1.78:1) 3868020 (1.59:1) 3868021 (1.68:1) 3868023 (1.78:1) ¯ DPX DRIVE UNiT *DuopropDRIVEUNiT in the Duoprop/DPX Workshop NOTES Section 1 General Information Table of Contents Conversion Charts Drill Size ..................................... 1-11 Metric ....................................... 1-10 introduction ..................................... I-2 Lubrication Gimbal Bearing ................................. 1-9 inspection Chart ............................... 1-13 Power Trim/Tilt ................................. 1-6 U-joints ....................................... 1-9 Drive Unit -SX ................................. 1-5 Off=Season Storage Preparations SX Nlodels ..................................... 1-7 Preparation for Boating After Storage ................. 1-8 Symbols ....................................... 1-12 20-Hour Check ................................... 1-8 /k Safety Warning Before working on any part of a Volvo Penta® stern drive, read the section called Safety at the end of this manual. |ntroduction This workshop manual covers Volvo Penta SXstern drive models. It’s divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section covering the system or assembly requiring service. Each section title pagehas an additional listing that wiIR describe the section’s contents in more detail. Be sure to read the Safety Section at the end of this manual, and pay special attention to all safety warnings as they appear throughout the text. Since models are subject to change at any time, some photos may not depict actual product. Good Service Practice Service required for Volvo Penta stern drives is generally one of three kinds: Normal care and maintenance -which includes putting a new stern drive into operation, storing engines, lubrication, and care under special operating conditions such as salt water and cold weather. ® Operating malfunctions -due to improper engine or drive mounting, propeller condition or size, boat condition, or the malfunction of some part of the engine. This includes engine servicing procedures to keep the engine in prime operating condition. ¯ Complete disassembly and overhaul -such as major service or rebuilding a unit. It’s important to determine before disassembly just what the trouble is and how to correct it quickly, with minimum expense to the owner. When repairing an assembly, the most reliable way to ensure a good job is to do a complete overhaul on that assembly, rather than just to replace the bad part. Wear not readily apparent on other parts could cause malfunction soon after the repair job. Repair kits and seal kits contain all the parts needed to ensure a complete repair, to eliminate guesswork, and to save time. Repair time can also be minimized by the use of special tools. Volvo Penta Special Tools are designed to perform service procedures unique to the product that cannot be completed using tools from other sources. They also speed repair work to help achieve service fiat rate times, in some cases, the use of substitute tools can damage the part. Do not operate engine out of water even momentarily, if operated in test tank, use proper test wheel Failure to do so can damage water pump, overheat engine, or allow excessive engine RPM. 1-2 VD/TB/eng Preparationfor Service Proper preparation is extremely helpful for efficient service work. A clean work area,at: the start of each job will minimize tools and parts becoming misplaced. Clean an engine that is excessive[ly dirty before work starts. Cleaning will occasionally uncover troubre sources. Obtain tools, instruments and parts needed for the job before work is started. Interrupting a job to locate special tools or repair kits is a needless delay. Use proper lifting and handling equipment. Workingon stern drives without proper equipment can cause damage and personal injury. Always use clean fresh fuel when testing engines. Troubles can often be traced to the use of old or dirty fuel. Service Policy Whetherwithin or following the warranty period, Volvo Penta ha=s a constant interest in their products. It’s VolvoPenta’spolicy to provide dealers with service knowledge so they can give professional service demanded by today’s consumer.TheVolvo Penta Service Schools, frequent mailing of Service Bulletins, Letters and Promotions, Special Tools and this WorkshopManual represent Volvo Penta’s efforts to assist dealers in giving consumers the best and most prompt service possible, if a service question does not appear to be answered in this manual, you are invited to write to the Volvo Penta Service Departmentfor additional help. Always be sure to give complete information, including engine model number and serial number. Be sure that you are familiar with Volvo Penta’s Warranty. if you have any questions, write the Volvo Penta Service Department. If other than genuine Volvo Penta replacement components or parts are used, Volvo Penta may refuse subsequent warranty claims involving that engine. Whena brand-name product or specific tool is called for, another item may be used. However, the substitute must have equivalentcharacteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and personal injury to anyone. To avoid hazards, equivalent products which are used must meet all current U.S. Coast Guard Safety Regulations and ABYC standards. Replacernent Parts When replacement parts ere required, always use genuine Volvo Penta parts, or parts with equivalent characteristics, including type, strength, and rnaterial, Failure to do so may result in product malfunction endpossible injury to the operator and/or passengers, Parts CataJogs Parts Catalogs contain exploded views showing the correct assembmyof all parts, as well as a complete listing of the parts for replacement. These catalogs are helpful as a reference during disassembly and reassembJy, and are available from the Volvo Penta Parts Dept. Volvo Penta Special Service Tools Volvo Penta has specially designed tools to simplify some of the disassembly and assembly operations. These tools are illustrated in this Workshop Manual, in many cases in actual use. All Volvo Penta special tools can be ordered from the Volvo Penta Parts Dept. Individual purchasers of Workshop Manuams must order Special Tools through an authorized Volvo Penta dealer. Product References, Illustrations & Specifications Volvo Penta reserves the right to make changes at anytime, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. The right is reserved to make changes at anytime without notice. All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only. The continuing accuracy of this manual cannot be guaranteed. Safety Related 1-4 VD/TB/eng Drive Unit Lubrication -SXModels Adding Lubrmant to Drive Unit ~-~ Occasionally check oil level in drive unit. Screw dipstick (8~ fully into hole. Remove and read oil level in reference to mark on dipstick. If oil level is low, add oil through dipstick opening. Add only enough Jubricant to bring the oil level to the full mark. Drive Unit Oil Capacity Change Lubricant Every 100 Hours or Once Each Season Use DuraPlusTM synthetic GL5 gear oil All Volvo Penta SX Models 71 oz. (2100 cc) Draining and Riling Drive Unit Whena complete change of lubricant is required in the drive unit, proceed as follows" 1. Place drive unit in the run (full down) position. Place a 4 quart drain pan under lower gear unit skeg to catch oil. 2. Removeoil drain plug ® (port side of lower gear unit) and oil level dipstick (~) (top of drive unit). Removing dipstick vents drive to improve oil draining. Allow oil to drain completely. ~] ~] 3. Remove three screws securing the rear cover to access the oil level plug ©. Fill drive unit with DuraPlus" synthetic GLSgear oil through oil drain plug hole ~). Fill slowly to purge air. Vertical drive is properly filled when the oil level appears at the oil level plug hole. When filled to the proper level, install oil level dipstick and the oil level plug first to prevent excessive oil loss, then the oil drain plug. Tighten oil level drain plugs securely. ~o~ Filling drive unit too quickly may form air pockets that will cause an inaccurateoil level reading. Running the drive unit with improper oil level wil| result in immediate internal damage. 4. install rear cover and tighten screws securely. ~ 5. Check oil level with dipstick. Oil level must appear on the blade of the dipstick. Add oil if required, through the dipstick hole. 34086 34172 34O84 vo.~,,~ 1-5 6. Tighten fill plug to 60-84 in. Ibs. (6,8-9,5 N-m). Tighten oil level dipstick to 48-72 in. ibs. (5,4-8,1 N.m) If lubricant has been completely changed, oil level must be rechecked after unit has been run and trapped air purged. Improper oil level will result in serious internal drive unit damage. Add make-up oil through dipstick opening to bring oil up to proper level. PowerTrim/Tilt-Fluid Level [~ The trim/tilt assembly contains the electric motor, hydraulic pump, and reservoir. At the beginning of each boating season, check the fluid level in the reservoir as follows: The trim/tilt hydraulics are pressurized when the drive unit is in the down position. The drive unit must be tilted full up to relieve hydraulic pressure before removing level/fill plug Failure to tilt the drive unit to the full up position before removing leveUfill plug wou|d result in a hazardous spray of hydraulic oil. Caution should always be taken when removing |evellfill plug by placing a rag over the level/fill plug to prevent residual pressure from spraying oil 1. With the drive unit tilted full up, slowly and carefully remove the level/fill plug. 2. Check the fluid level. The fluid should be level with the bottom of the fill hole when the drive unit is at full tilt. 3. if necessary, add Volvo Penta power trim/tilt & steering fluid. Replace the level/ffil plug and tighten securely. When checking fluid level, inspect the trim/tilt unit for leaks and proper operation. Repair or replace defective components. //~ Safety Related 1-6 VD,q’B/eng Off-Season Storage Preparations -SX Models 1. Change Drive Unit Lubricant: Drain and refill with fresh DuraPius synthetic GL5 gear oil. Refer to Drive Unit Lubrication elsewhere in this section. 2. Lubricate Girnbal Bearing and Universal Joints: Refer to information elsewhere in this section, 3. inspect Drive Unit Water Pickup Screens for Obstructions. See Engine Workshop Manual for additional engine offseason storage procedures. Preparation for Boating After Storage See Engine Workshop Manual for specific information, VOLVO PENTA DEALER Service -20-Hour Check 20-Hour Check includes: 1. Changeengine oil and oil filter. 2. Drain and refill drive unit. Check the trim/tilt reservoir for proper fluid level. Z~ 3. Lubricate steering cable ram with Volvo Penta Grease, and check power steering pump reservoir for correct fluid level. 4. Changefuel filter/water separator. 5. Check tension on alJ drive belts. 6. Non-EFI Models Only: Check engine timing. 7. Non-EFI Models Only: Check and adjust carburetor for correct idle mixture and idle RPM. 8. Check all engine mount screws for tightness. 9. Lubricate gimbal bearing grease fitting on transom shield. Lubricate both U-joint grease fittings on drive unit. 10. Check engine alignment. 11. Check for any deficiencies, malfunctions, signs of abuse, etc. Correction of any problems at this time will prevent worsening of a minor problem and help ensure a trouble-free boating season. 12. Inspect exhaust system and tighten all hose clamps. 13. Make sure engine can achieve maximum rated RPM. For the U.S., Canada, and Mexico, the 20-Hour Check is paid for by the boat owner and performed by your Volvo Penta dealer at local rates. Jn other markets the Warranty Inspection is paid for according to the Warranty Policy for importers. Safety Related 1-8 VD/TB/eng Gimbal Bearing and Universal Joints Lubrication The gimbal bearing and universal joints MUSTbe lubricated each year. Lubricate the gimbal bearing and universal joints when preparing your boat for off-season storage. This requires the removal of the drive unit; therefore, Volvo Penta recommends that your Volvo Penta dealer perform this operation. [~ Failure to lubricate the gimbal bearing and universal joints each year will result in damage to the transom shield and drive unit. F’I~] The gimbal bearing is lubricated by a grease fitting located on the starboard side (~), Volvo Penta SX models, of the gimbal housing. Volvo Penta recommends of the gimbal that lubrication bearing be done with drive unit removed. This wiUl allow observation of old grease as it’s being replaced by the new. if there is evidence of water, the bearing should be inspected and replaced. Lubricate gimbal bearing with Wheel Bearing Grease. Apply grease until all old grease has been removed and new grease appears. r27 The drive unit must be removed to lubricate the universal joints. Lubricate U-joints with Wheel Bearing Grease. Apply grease to the two U-joint grease fittings © until all old grease is removed. When the drive unit is removed, wipe old grease and dirt off driveshaft splines, then thoroughly clean splines before applying new grease. The driveshaft splines @ must be lubricated with Molybdenum Grease, and light oil applied to the shaft O-rings (~). The bellows should be checked for damage and deterioration. Replace if necessary. Engine alignment must also be checked. Refer to Drive Unit Installation in Drive Unit Removal andinstallation section of this manual. vo~e~ 1-9 METRIC CONVERSION CHART inches X 25.4 = mimlimetres (ram)foot-pounds X 1.3558 = joules (j) feet X 0.3048 = metres (m} calories X 4.187 = joules (j) yards X 0.9144 = metres (m} Btu X 1055 = joules (j) miles X 1.6093 = kilometres (kin) watt-hours X 3500 = joules (j) inches X 2.54 = centimetres (cm) kilowatt - hrs X 3.600 = megajoules (M J) = inchesX 645.16 = inchesX 6.452 = feetX 0.0929 = yardsX 0.8361 acres X 0.4047 = milesX 2.590 3 inchesX 16387 s inchesX 16.387 3 inchesX 0.01639 quartsX 0.94635 gallonsX 3°7854 3 feetX 28.317 3 feetX 0.02832 fluid oz X 29.57 3 yardsX 0.7546 ounces (av) X 28.35 pounds (av) X 0.4536 tons (2000 Ib) X 907.18 tons (2000 Ib) X 0.90718 ounces-f (av) X 0.278 pounds-f (av) X 4.448 kiUograms - f X 9.807 2 feeUsecX 0.3048 2 inches/secX 0.0254 2} = mill[metres= (ram =) = centimetres= (cm =} = metres = (m =} = metres = (m= hectares (104 2) (ha} 2} = kilometres= (kin 3) = millimetress (ram s) = centimetres3 (cm = I[tres (I) = litres (I) = mitres (I) = litres (I) s) = metress (m= miHiEitres (mm) s) = metres3 (m = grams (g) = kilograms (kg} = kilograms (kg} = metric tons (t) = newtons (N} = newtons (N} = newtons (N) =) = metres/sec2 (m/S =) = metres/sec2 (m/Sm[les/gal X 0°42514 = k[Iometres/litre (kin/I) Note: 235.2/(mi/gal) = litres/100 km 235.2/(litres/100 kin) = mi/gal =) footcandmes X 10.76 = lumens/metre= (Im/m inches HG (60°F) X 3.377 = k[lopascals (kPa) pounds/sq in X 6.895 = kilopascals (kPa) inches H=O (60°F} X 0.2488 = ki[opascals (kPa) bars X 100 = kilopascals (kPa) pounds/sq ft X 47.88 = pascals (Pa} horsepower X 0.746 = kilowatts (kW) ft-Jbf/min X 0.0226 = watts (W) °Celsius = 0.556 X (°F -32) °Fahrenheit= (1.8 X °C) +32 pound-inches X 0.11299 = newton-metres (N.m} pound-feet X 1.3558 = newton-metres (N.m} miles/hour X 1.6093 = kilometres/hour (kin/h) feet/sec X 0.3048 = metres/sec (m/s) kilometres/hr X 0.27778 = metres/sec (m/s) miles/hour X 0.4470 = metres/see (m/s) 1- 10 VD~r~..Q DR2949 Drill Size Conversion Chart SHOWINGMILLIMETER SIZES, FRACTIONALAND DECIMAL iNCH SIZES AND NUMBER DRILL SIZES Milii-Dec. Frac-Nurn-Milli-Dec. Frac-Num-Milli-Dec. Frac-Num- Milli- Dec. Frac-Num-Milli-Dec. Frac- Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tionat ber Meter Equiv. tional .’1 .0039 1.75 .0689 .... 1570 22 6.8 .2677 0.72 .4219 27/64 .15 .0059 .... 0700 5O 4.0 .1575 6.9 .2716 1.0 .4330 .2 .0079 1.8 .0709 .... 1590 21 .... 2720 I ~1.11 .4375 %e .25 .0098 135 .0728 .... 1610 20 7.0 .2756 11.5 .4528 .3 .0118 .... 0730 49 4.1 .1614 .... 2770 J 1.51 .4531 2%4 .0135 80 1.9 .0748 4.2 .1654 7.1 .2795 1.91 .4687 1%zo138 .... 0760 48 .... 1660 19 .... 2811 K 2.0 .4724 .0415 79 1.95 .0767 4.25 .1673 7.14 .2812 %2 .. i12.30 .4843 3~4 .39 .0156 ’44 .. 1.98 .0781 5/64 ... 4.3 .1693 7.2 .2835 i12.5 .4921 .4 .0157 .... 0785 47 .... 1695 18 7.25 .2854 !12.7 .5000 ~ .0160 78 2.0 .0787 4.37 .t719 I%4 7.3 .2874 i13.0 .5118 ,45 ,0177 2.05 .0807 .... 1730 1"7" .... 2900 L 113.10 .5156 33/64 ,. ,0180 77 .... 0810 46 4.4 .1732 7.4 .2913 13.49 .5312 17/32 ,5 .0197 .... 0820 45 .... 1770 16 .... 2950 M 13.5 .5315 .0200 76 2.1 .0827 4.5 .1771 7.5 .2953 13.89 .5469 3%4 r # .0210 75 2.15 .0846 .... 1800 15 7.54 .2968 19/64 .. 14.0 .5512 .55 .0217 .... 0860 44 4.6 .1811 7.6 ,2992 14.29 .5624 ~ .0225 74 2.2 .0866 .... 1820 14 .... 3020 N 14.5 .5709 .t3 ¯0236 2.25 .0855 4,7 .1850 13 7.7 ,3031 14.68 .5781 3%4 ¯ ¯0240 73 .... 0890 43 4.75 .1870 7,75 .3051 15,0 .5906 .0250 72 2.3 .0905 4.76 .1875 ~6 7.8 .3071 15.08 .5937 W32 .65 .0256 2.35 .0925 4.8 .1890 1"2 7.9 ,3110 15.48 .6094 z%4 . .0260 71 .... 0935 42 .... 1910 11 7.94 .3125 ~6 .. 15.5 .6102 .0280 70 2.38 .0937 3/32 ... 4.9 .1929 8.0 .3150 15.88 .6250 % .,)’ .0276 2.4 .0945 .... 1935 10 .... 3160 O 16.0 .6299 ,. .0292 69 .... 0960 41 .... 1960 9 8.1 .3189 16.27 .6406 4144 .75 .0295 2.45 .0964 5.0 .1968 8.2 .3228 16.5 .6496 ¯ 0310 68 .... 098O 4O .... 1990 8 .... 3230 P 16.67 .6582 2~279 o312 .. 2.5 .0984 5.1 .2008 8.25 .3248 17.0 ¯6693 .8 .0315 .... 0995 39 .... 2010 7 8.3 .3268 17.06 .6719 43/54 .. .0320 67 .... 1015 38 5.t6 .2031 t3/64 8.33 .3281 2%4 .. 17.46 .6875 1¼6 .033066 2.6 .1024 .... 2040 6" 8.4 .3307 17.5 .6890.0335 .... 1040 37 5.2 .2047 .... 3320 Q 17.86 ¯7031 45/e4 .0350 65 2,7 .1063 .... 2055 5 8.5 .3346 18.0 .7087 ,~)" .0354 .... 1065 36 5.25 .2067 8.6 .3386 18.26 .7187 23/32 .. .0360 64 2.75 .1082 5.3 .2086 .... 3390 R 18¯5 .7283 .0370 63 2.78 .1094 %4 ... .... 2090 4 8.7 .3425 18.65 .7344 47/~4 .95 .0374 .... 1100 35 5.4 .2126 8.73 .3437 ~½2 ..o 19.0 .7480 .0380 62 2.8 .1102 .... 2130 3 8.75 .3445 19.05 .7500 3/4 .0390 61 .... 1110 34 5.5 .2165 8.8 3465 19.45 .7656 ~9/e4 1.9 .0394 .... 1130 33 5.56 .2187 7/32 .. .... 3480 S 19.5 .7677 ,. .0400 60 2.9 ,1141 15.6 .2205 8.9 .3504 19.84 .7812 =s/~ ,. ¯0410 59 .... 1160 32 .... 2210 2 9.0 .3543 20.0 .7874 1.35 ¯0413 3.0 .1181 5.7 .2244 .... 3580 T 20.24 .7969 ~%4 .... 0420 58 .... 1200 31 5¯75 .2263 9.1 .3583 20.5 .8071 .... 0430 57 3.1 .1220 .... 2280 1 9.13 .3594 2~/~4 ... 20.64 .8125 ~¾~ 1.1 .0433 3.18 .1250 ~ ... 5.8 .2283 9.2 .3622 21.0 .8268 1.15 .0452 3.2 .t260 5.9 .2323 9.25 .3641 21.04 .8218 s~/~4 .... 0465 56 3.25 .1279 .... 2340 A 9.3 .3661 21.43 .8437 z7/~2 1.19 .0469 344 ... .... 1285 30 5.95 .2344 W64 . . .... 3680 U 21.5 .8465 1.2 .0472 3.3 .1299 6.0 .2362 9.4 .3701 21.83 .8594 ~%4 1.25 .0492 3.4 .1338 .... 2380 B 9.5 .3740 22.0 .8661 1.3 .0512 .... 1360 29 6.1 .2401 9.53 .3750 % ... 22.23 .8750 7/a .... 0520 55 3.5 .1378 .... 2420 C .... 3770 V 22.5 .8858 1.35 .0513 .... 1405 28 6.2 .2441 9.6 .3780 22.62 .8906 57/64 .... 0550 54 3.57 .1406 9/64 ... 6.25 .2460 D 9.7 .3819 23,0 .9055 1.,4 .0551 3.6 .1417 6.3 .2480 9.75 .3838 23,02 ,9062 z%2 1.45 .0570 .... 1440 27 6.35 .2500 V4 E 9.8 .3858 23.42 .9219 ~9/~4 ~.5 .0591 3.7 .1457 6.4 .2520 .... 3860 W 23.5 .9252 .... 0595 53 .... 1470 26 6.5 .2559 9.9 ,3839 23.8t .9375 ~/~ 25/54 .9449 1.55 .0610 3.75 .1476 .... 2570 F 9.92 3906 ... 24.0 1.59 .0625 ¼6 ... .... 1495 25 6.6 .2598 10.0 .3937 24.21 .9531 sVs4 1,6 .0629 3.8 .1496 .... 2610 G .... 3970 X 24.5 .9846 .... 0635 52 .... 1520 24 6.7 .2638 .... 4O40 Y 24.61 .9687 ~/~2 1.65 .0649 3.9 .1535 6.75 ,2657 We4 . . 10.32 .4062 ~/~ ... 25.0 .9843 1,7 .0669 .... 1540 23 6.75 .2657 .... 4130 Z 25.03 .9844 e~/6,~ .... 0670 51 3.97 .1562 5/32 ... .... 2660 H 10.5 .4134 25.4 1.0000 1 SYMBOLS Certain syrnbols or combinations of symbols may appear on your Volvo Penta SXstern drive or on their accessories. It is very important that you understand their meaningor purpose. If any symbol is not cmearly understood, see your Dealer. DR3847 "Safety Warning" Syrnbols ® PO,SONOUS Fire hazard , .R,sko, Be sor,ous,n,ory. care,u, e Follow instructions ~l~’ Contents under pressure "Position indicator" Symbols Shift positions RAISE LOWER (~ FORWARD REVERSE "Condition" Symbols Hour meter Tachometer (~ ® Ammeter O ,~ ¯ Voltmeter W V°ltmeter ~ O,Ifilter ~ Fue, filter ~ Watertemperature AEmergencystop .~ Oi, pressure "instructional" Symbols ~.~ eUse gasoline ~ Read Operator’s Manual ® Gasoline is present before operating product Oil fill (~ DR3847 Lubrication and Inspection Chart :~erv|co Point Every 25 Hours Every 100 Hours or as Specified or as Specked GJmbal Bearing Lubricate seasonally. NOTE: Do not use a power operated grease gun. Seasonally check fluid level in Trim/Tilt Pump reservoir, Check for leaks and proper operation. Universal Joints Lubricate seasonably, NOTE: Do not and Bellows use a power operated grease gun. Drive Unit Drain and refill. Check level occasionally during boating season. U-joint Shaf~ Spiines Lubricate seasonally, Recommendations Use Wheel Bearing Grease, UseVolvo Pente power trim/tilt & steering fluid. Use Wheel Bearing Grease. inspect beltows annually. UseDuraPlus synthetic GL5gear oih Use Molybdenum Grease. NOTES Section 2 Transom Shield Assembly SX Models Table of Contents Anode Replacement .............................. 2=14 Gimbai Housing Assembly ..................................... 2=17 Cleaning and inspection ......................... 2-17 Disassembly .................................. 2-14 Installation .................................... 2-24 Removal ..................................... 2-23 Gimbal Ring Assembly ..................................... 2-10 Disassembly .................................. 2-10 installation .................................... 2-11 Removal ...................................... 2-9 Pivot Housing Assemb|y ...................................... 2-6 Cleaning and inspection .......................... 2-6 Disassembly ................................... 2-6 installation .................................... 2-7 Removal ...................................... 2-5 Service Chart ................................... 2-28 Specifications ................................... 2-26 Trim/Tilt Cylinders installation .................................... 2=4 Removal ...................................... 2-3 Trim Sender installation ............................ 2-14 and 2-20 Removal ............................... 2-9 and 2-14 Safety Warnings Before working on any part of the transom shield assembly, read 1Lhe section called Safety at the end of this manual. When replacement parts are required, use genuine Volvo Penta parts or parts with equivalent characteristics including type, strength and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers. Some screw holes have special Hell-Coil inserts that provide a thread-locking feature, Do not clean Heli-Coilholes with a thread tap. This will damage the Hell-Coil inserts and force their replacement. Volvo Penta Special Tools PiN Description 3850608-5 Retaining Ring Pliers 3850609-3 Drive HandBe 3854349-2 Insert Tool 3854350-O Socket Removal Toom 3854351-8 Rod 3854352-6 Slide Hammer 3854353-4 Bearing Puller Jaws 3854355-9 Remover/Xnstaller 3854356-7 Driver 3854357-5 Gimbal Housing Seam installer 3854358-3 Remover/Installer 3854359-1 Upper Steering Bearing installer 3854360-9 Remover/installer 3854361-7 Steering Arm Puller OwatonnaService Tools OEM 4184 Slide Hammer Order From: OTC Division of SPX Corporation 655 Eisenhower Drive Owatonna, Minnesota 55060 USA Toll free order line: 1-800-533-5338 Or 1-800-533-0492 Sealants, Lubricants and Adhesives Cleaning Solvent Gasket Sealing Compound Loctite primer or equivalent Loctite or equivalent Volvo Penta Grease 3Madhesive or equivalent Loctite or equivalent Wheem Bearing Grease 3M Scotch Grip Rubber Adhesive 1300 2-2 VDfrB/eng 34527 19616 Remove the drive unit following the procedure in Drive Unit Removaland Installation section in this manual. If the complete transom shield assembly is being rebuilt or replaced, remove engine following procedure in Engine workshop manual. Trim/Tilt Cylinder Removal Do not remove trim/rUt hydraulic lines or fill plug unless hydraulic pressure is released from the trim/tilt system,Follow steps 1 and 2 to release hydraulic pressure, Have a drain pan ready to catch fluid that will drain from the disconnected lines. 20673 [~] 1. Fully extend trim cylinder rams. 2~ /~ 2. Wear safety glasses; there may be high pressure in the reservoir and at the line fittings that could spray hydraulic ftuid. Fully open manual release valve (~) and remove fill plug (~) to equalize pressure. Reinstall fill plug and close manual release valve to prevent fluid loss from reservoir. [~ 3. Remove screw, ground wire and retainer from the front of the cylinder. 34528 E4~ 4. Unscrew pivot pin cap © and lift off trim/tilt line cover @. Removescrew and retainer (~) at top of cylinder. Cover fittings with a shop cloth, and disconnect trim/tilt lines. Removeand discard trim/tilt line O-rings ®. r7~ 7. Unscrew the pivot pin Iocknut (~ and remove the flat washer (~. Pull pivot pin out of cylinder, gimbal ring, and cylinder on opposite side. Remove bushing from forward end of trim cylinder and replace if necessary. Remove cylinder and set aside to drain. 20707 8. Repeat steps 3 thru 6 for the remaining cylinder. vDrr~n0 //~ Safety Related 2-3 Trim/Tilt Cylinder installation r-~=3 LLJ 1. Clamp the pivot pin in a soft-jaw vise and remove the remaining Iocknut and washer. CJean the pivot pin, then coat it with Volvo Penta Grease. 2. Replace the cylinder’s bushings if they’re damaged, then slide the pivot pin through the cylinders and gimbal ring. [~ 3. Center the pivot pin, then lightly coat the threaded ends with Gasket Sealing Compound. Instalm both washers and two new Iocknuts. Tighten each nocknut until equal amounts of threads are exposed on both ends of the pivot pin. Tighten both nocknuts to 120-144 in. Ibs. (14-18 N-m). [~ 4. Place a new O-ring on the trim/tiUt cylinder line fittings and attach lines to cylinder. Tighten Uine fittings to 84-108 in. Ibs. (9,5-12,2 N-m). Install oil line retainer (~ and secure with screw. [~ 5. Install trim/tilt line cover ® and pivot pin cap ©. 8. Attach retainer and ground wire to front of trim/tilt cylinder. Tighten screw securely. To f[H and bleed the trim cylinders and trim motor reservoir, see Filling and ~eeding Dry System in Trim/Tilt Hydrau|ic System section of this manual. 20704 34529 ~73 20674A 2-4 VD/TB/eng 34616 34617 4906 Pivot Housing Removal Removethe drive unit following the procedure in Drive Unit Removaland installation section in this manual. [~ 1. Turn drive unit to port. Loosen anchor damp screw @ and s~ide clamp to starboard disengaging the remote controJ shift c,abRe. 2. Removeshift cable from the pivot and gimbal housing. Removethe small and large seals (~). From inside of boat, pull 34531 shift cable out of the sleeve and connector assembly. L~ 3. Disengage the U-joint boot from the lip of the pivot housing and push it inside. Eg~ z~ 4. Wear ,safety g|asses. Use retaining ring pliers to remove the retainer from inside of the exhaust boot, then push the boot inside the housing. [~ 5. Unscrew the nut securing the water hose nipple, and push the nipple through the housing as far as possible. 34768 6. Turn gimbal ring to the starboard and remove the ground strap ®. D2~ 7. Use a 1~ in. hex drive wrench or socket and remove both pivot pins. 34534 vD~,-,~ ~ Safety Related 2-5 Pivot Housing Disassembly [~ 1. Remove and discard the cooling passage O-ring. ~] 2. Unscrew the water drain plug and discard the O-ring. [~] 3. inspect the nylon friction washer on the pivot bosses. Peel them off and discard them if they’re damaged. Remove and inspect the thrust washer ~) underneath. Cleaning and inspection Clean housing in solvent and dry thoroughly. Remove sealer and/or adhesive from the cooling passage opening, U-joint bellows opening, and pivot bosses. Clean screw hones with solvent only. A thread tap would damage the He/i-Coil inserts and force their replacement. e Drain Hole -Clean thoroughly to allow complete water drainage. o O-ring Sea| Groove -Check for sharp edges that wound prevent O-ring sealing water passage. ¯ Mounting Studs -Look for damaged threads and looseness. ¯ Ground Wire -Check wire ends for frayed or loose con nections. Repair or replace all suspect components. Pivot Housing Assembly 1. Coat a new O-ring with Gasket Sealing Compound and place it on the drain screw. Install the screw and tighten it to 50-80 in. Ibs. (6-7 N-m). 34521 34522 g N 2-6 VDRB/eng 34523 12961 34524 L~ 2. Apply 3Madhesive or equivalent to the groove around the water passage, and install a new O-ring seal. E6-’7 3. If the old pivot boss friction washers were removed, make sure a thrust washer (~ coated with Volvo Penta Grease is installed in each pivot. InstalJ two new friction washers and coat them with Volvo Penta Grease. Pivot Housing installation 1. Position the pivot housing in the gimbal ring. Guide the water 34576 tube nipple through the housing, and position the bellows behind their respective openings. 2. Align one gimbal ring pivot pin hole with the hole in the pivot housing. Look inside to see if the thrust washer is still in position and not blocking the hole. Screw in the pivot pin until it seats, but do not tighten it at this time. [~ 3. Align and install the other pivot pin. Tilt the housing up and down to see if it moves freely. Use a 1~ in. hex socket and tighten the pivot screws to 105-120 ft. Ibs. (142-163 N.m). 34579 Hold pivot housing to keep housing from over rotating and damaging bellows and water hose while tightening pivot screws. [~ 4. The drain hole in the nipple must face down when instalJed in the pivot housing. G0-] 5. Pull the water tube through the pivot housing as far as it will go. Screw on the water nipple nut. if the nipple turns with the nut, or if the nipple end does not protrude through the nut when it’s seated, then the square nipple collar is not located properly behind the housing. Loosen the nut and rotate the nipple to reposition it. Make sure the drain hoRe in the nipple faces down. Tighten the nut to 96-120 in. Ibs. (11-14 N.m). 34577 34582 34584 [~ 6. To seal the U-joint bellows against water entry. Apply Gasket SeaBing Compound around the complete inner V-shaped lip of the pivot housing. DE] ~] 7. Pull the U-joint belmows through the opening and seat the Hp in the groove. BelRows must seal the entire circular opening; any flat spot on the lip indicates the bellows has not engaged the V-groove. [~ 8. Pull top of exhaust bellows through the pivot housing. Tilt the pivot housing and push the bottom of exhaust bellows 34586 through the pivot housing seating the bellows channel around the lip of the pivot housing opening, Any fiat spot on the bellows indicates the bellows has not engaged the lip. DE] ~ 9. wear safety glasses. Insert the retaining ring inside the bellows. Position the opening upward as shown for secure attachment. DE] 10. Attach the pivot housing ground wire to the upper threaded hole on the port side of gimbal ring. 34587 Ssfety Re|~,,~l 2-8 34537 Girnbal Ring Removal Remove cylinders and pivot housing foflowing instruc trim/tilt tions elsewhere in this section, E7--’] 1. Turn the gimbal to port and remove the two screws holding the trim sender, Do not attempt to pull out the sender as its leads are secured to the transom shield. 8~ [~] 2. Remove the three screws and lock washers holdiing the lower steering support bracket (~ and pull the bracket off:. If Ws,tight, use a drift punch ~) and mallet to tap on alternating sides of the bracket until its free. ~’~ 3. Remove cotter pin © and steering arm pin (~. Remove ground strap (~) from steering arm. [~ 4. Remove two screws and the plastic gimbal housing cover, L~ 5. Remove two screws and the steering cavity cap. Peel off and discard the foam gasket. 6. Remove ther four Iocknuts and retaining plate from the topof the steering arm. Unscrew the center steering arm bolt ®. m 9 34482 ~935~ 34483 vol~,,g 2-9 IT] 7. Rest Volvo Penta Steering Arm Puller P/N 3854361-7 on top of the two alignment dowels inside the steering arm, andinstall the center bolt. Tighten the bolt to remove the steering arm. Be ready to catch the gimbal ring when the arm comes free. 8. Removethe steering arm from inside the boat. Remove thrust washer ~ from the gimbal housing. Gimba[ Ring Disassembly 1. Removeand discard the O-ring around the upper steering post. E~] 2. Face the large diameter end (E) of Volvo Penta Remover/ installer P/N 3854358-3 toward the gimbal ring. Insert the tool into either tilt bearing and drive it the other tilt out. Remove bearing in a similar manner. [~] 3o Remove both trim/tilt nylon pivot pin bushings. Use Volvo PentaBearing Puller Jaws P/N 3854353-4 and Volvo Penta Slide HammerP/N 3854352-6. [~ 4. insert small end of Volvo Penta Remover/Installer P/N 3854355-9 into bearing, and drive out bearing. Gimbal Ring Assembly [~] 1. Lightly oil the outside of a new lower pivot bearing © and place it in the bore. Use Volvo Penta Remover/Installer P/N 3854358-3 (~ to seat the bearing into the bottom of the gimba[ ring. 2. Apply Volvo Penta Greaseto the outside of two new trim/tilt nylon pivot pin bushings. Use Volvo Penta Remover/ Installer P/N 3854358-3 to seat them in the gimbal ring. ,? 4985 24212 4~ 2-10 VD/TB/eng ES~ 3. Apply Volvo Penta Grease to the inside of both trim/tilt nylon bushings (~). [-’9~ 4. Lightly oil the outside of two new tilt bearings, insert a bearing into the gimbal ring from the outside. Insert the blunt end ot: Volvo Penta Remover/Installer P/N 3854358-3 (~) into bearing. Using a soft face hammer, seat bearing flush to 0.010 in. (0,254 mm) below inner surface of gimbal ring. Repeat procedure l~or installation of the other bearing. ~0~ 5. If bushing ~) around upper steering post is damaged,, it can be removed by splitting it down one side with a sharp tool. [’Not-~ When replacing steering post bushing, check upper bearing inside gimbal housing to see if it also needs replacement. I~] 6. If upper steering post bushing @ was removed, lubricate inside diameter of a new bushing with Volvo Penta Grease, and place bushing on top of steering post. Install steering arm and center bolt. Tighten center bolt until bushing seats, then remove center bolt and steering arm. Gimbal Ring installation [~] 1. Coat a new O-ring ® with Volvo Penta Grease and place it around the base of the upper steering post. 19717A E~ 2. Coat the thrust washer ~) with Volvo Penta Grease and set it over the upper pivot bearing inside the top of the gimbal housing. From inside of boat, position steering arm ® over the thrust washer. DE] 3. Guide gimbal ring steering post up engaging steering arm and install center bolt finger tight. When the gimbal ring is properly centered in the upper bearing, the gimbal studs must be flush or above the top of the steering arm when the bolt is finger tight. If the studs are not at the position described, the upper bearing will be damaged when the center bolt is tightened. E~E] 4. Tighten the center bomt to 64-72 ft. Ibs. (88-98 N-m). EEl 5. Place the washer on top of the steering arm. install four new Iocknuts and tighten them to 13-15 ft. Ibs. (18-20 N-m). EEl 6. Install a new foam seam on the underside of the steering cavity cap. Carefully amign the seal notches with those in the cap. 34512 34513 34514 2-12 VD/TB/eng F~6-"I 7. Install cap and tighten two mounting screws to 60-84 in. Ibs. (7-9 N.m). Align dowels © of cover with gimbal housing h(~ies and set the gimbal housing cover in place. Install two mounting screws and tighten them to 60-84 in. Ibs. (7-9 N.m). 8o Attach ground wire to steering arm inside transom. E~ 9. Apply Volvo Penta Grease to the nylon thrust washer and lower pivot post. Slide nylon washer ® between gimbal ring and gimbal housing. Align pivot post hole of the gimbal ring, gimbal housing, and thrust washer, then slide pivot post through the gimbal ring and gimbal housing until it is seated. EsE] 10. Install the lower steering support bracket. Seat it with a mallet if necessary. Apply upward pressure to gimbal ring a=nd support bracket. Use Jower thrust washers as a gauge to deter mine how many will fit space ® between upper surface of support bracket and lower surface of gimbai ring. I~°t-~ The support bracket has a protruding lip on its upper surface where it fits over the pivot pin. When checking fit, washer insertion must be done at this point only, otherwise too many shims will be measured and installed. These washers will preload gimbal ring. After determining number, add one extra, then install them in position ®. Use a minimum of one but no more than five washers to shim gimbal ring. 11. Attach the trim cylinder ground wires to the two forward screws ~), then install the lock washers. Screw in all three mounting screws and tighten them to 18-20 ft. Jbs. (24-27 N.m). 12. Route the trim cylinder ground wire between the cylinder lines and the gimbal ring. Slide the ground wire onto the ground screw, then install the lock washer. Attach the screw to the port side ® of the gimbal ring and tighten it securely. 3,4590 34518 22784 34588 Trim Sender insteUation rT] Turn gimbal ring to port and attach the trim sender. Tighten the screws to 18-24 in, Ibs. (2-3 N-m)o install trim/tilt cylinders and pivot housing foUowing instruc tions elsewhere in this section. Girnbal Housing Disassembly Removetrim/tilt cylinders, pivot housing, and gimbal ring following instructions elsewhere in this section. Water Hose and Bellows Removal [~] 1. Unscrew clamps ~) and pull off the U-joint and exhaust bellows. 2. Loosen clamp (~) on upper end of water inlet hose and remove hose from water tube. Anode Replacement [~ The sacrificial zinc anode need not be removed unless it’s deteriorated and needs to be replaced. [~ 1. Remove the two screws, lock washers, flat washers, and the anode. ~] 2. Clean the mounting surface, then install the new anode and the attaching hardware. Tighten the screws to 12-14 ft. Ibs. (16-19 N-m). Trim Sender Removal [~ 1. Disconnect rubber connector at wiring harness on engine. Use Volvo Penta Socket Removal Tool P/N 3854350-0 to push terminals out of rubber plug. [~ The use of alcohol or cleaning solvent will make socket installation into the rubber plug easier. 34537 34493 34471 34494 2-14 9266 VD/3"B/eng 34495 34497 [~] 2. Remove the retaining clip from the grommet ©. [~] 3. Push the grommet out with a screwdriver. Pull the wires through the hole, cut tie straps securing wires to the trim/tilt lines, and remove the trim sender. Water Tube Removal [~] 1. Remove the two screws (~) from the "water tube retainer. Pull the water tube and grommet out of the gimbam housing, if the grommet sticks, go to the outside of the transom and push it 34499 through. 2. If the grommet needs to be replaced, slide it off the water tube. it can be reused if undamaged. Hydraulic Lines and Manifold Removal [~1 1. Remove the two clamps (~ that secure the lines to each side of the gimbal housing. 2. Unscrew aH four lines and remove them from the mani-. fold. Remove and discard the fitting O-rings. Removan of the grease extension tube ® may make the servicing of the starboard 34500 side lines easier. Clamp a vise grip pliers close to the bearing bore ~) and rotate the tube to loosen it. Pry against the p~ier head to force the tube out ot; the housing. 1[~] ~ 3. Remove; the Iocknut and washer ® that attach the manifold to the hoiJsing. Since the manifold is sealed by an O-ring, use a small drift (~ to drive it out of the housing from the inside of the boat. 34501 ~] 4. Pull the manifold and lines through the hole as far as possible. Tag one line (~ for reference and note their direction of routing. 5. Unscrewboth lines, then discard the fitting O-rings. Remove the manifomd O-ring and discard it. Steering Bearing, Girnba| Bearing and Sea{ Removal Do not remove the gimbal bearing or upper steeringbearing unless they need to be replaced. Removal of the gimbam bearing and seal do not require disassembay of the transom 345O3 shield. Access can be gained by going through the U-joint be{lows on an assembled transom shield. [~ 1. Use a three-jaw pumler such as Owatonna Tool P/N OEM4184 to pu{{ out the gimbai housing bearing. Spread the tool jaws between the bearing and inner seal, and expand them tightly behind the bearing. Remove and discard the bearing. 2. Pull the inner seal out in a similar manner and discard it. [~ 3. Remove the thrust washer from around the top of the upper steering bearing. Use Volvo Penta Remover/InstaUler P/N 3854360-9 ~) and Volvo Penta Driver P/N 3854356-7 © to remove the bearing, insert the driver into the insta{ler and position the tool underneath the bearing as shown. Drive the bearing up and out of the bracket. Gimbal Housing Cleaning and inspection CUeangrease and sealer from bearing cavity, seal seat, and manifold cavity. Check inner bore diameter for scoring or discoloration that indicates a spinning bearing. e Pivot Bearing - inspect Teflon surface for wear or corrosion. ¯ Gimbal Bearing -RolUers must spin freeay and hub must pivot in all directions; inner diameter must be free of corrosion, ® Hydraulic Manifold -O-ring groove must be free of nicks and burrs; all fluid passages must be clear. ¯ Hydraulic Unes - Lines must be clear and fittings undamaged. ¯ Grease Fitting and Tube -must be unobstructed. ¯ Mounting Studs -must be tight and have no thread damage. ¯ Seal Grooves - Check for corrosion, burrs and damaged edges. ¯ Anode - Check amount of deterioration. Ch,=an parts in solvent and dry thoroughly. L~ Somescrew holes have special Hell-Coil inserts that provide a thread-locking feature. Do not clean Heft-Coil holes with a thread tap. This will damagethe I/eli-Coil inserts andforce their replacement. Locking Heft-Coils are available only from Volvo Penta Parts Dept.. See your parts catalog. Gimbal Housing Assembly Steering Bearing, G/tubal Bearing and Seal Unstellation 1. Face the open end of a new gimbai housing seal toward Volvo Penta Gimbai Housing Seal Installer P/N 3854357-5 and place it on the projecting nose of the tool Lightly coat the metal case with Gasket Sealing Compound. ~ 2. Screw the installer onto Volvo Penta Drive Handle P/N 3850809-3. Drive the seal into the housing until it seats. Coat the seal lip with Volvo Penta Grease. vorr~n~ ~ Safety ReBated 2-17 4959 4960A E~ 3. To ensureadequate lubrication of the gimbal bearing, it must be correctly positioned prior to installation. Rotate the outer band until its slot aligns with the lubrication hole. Scribe a reference mark at this point on the bearing case. DE] 4. Oil the exterior of the bearing case. Place the bearing in the housing with the reference mark ~ facing the extension tube opening. Screw the raised Side (~) of Volvo Penta Gimbal Housing Seal installer P/N 3854357-5 onto Volvo Penta Drive Handle P/N 3850609-3. Drive the bearing in until it seats. Lubricate the bearing with Wheel Bearing Grease through the grease fitting on the starboard side of the housing. E~ 5. To install the upper steering bearing, slide Volvo Penta Remover/Installer P/N 3854360-9 © onto Volvo Penta Rod P/N 3854351-8@, then place a new bearing (~) on the installer. Lightly 9 oil the outside of the bearing. [~ 6. Volvo Penta Upper Steering Bearing Installer P/N 3854359-1 (~) will act as a stop to seat the bearing. When positioned inside the steering arm cavity, the recessed side of the tool must face the bearing as shown. E~ 7. Face recessed side of Volvo Penta Upper Steering Bearing Installer P/N 3854359-1 down, and insert it into the steering arm cavity from inside the boat. Screw puller rod into the installer until it’s flush with the top of the instalJer. Hold the rod and tighten the nut until the bearing seats. Hydraulic Lines and Manifold Installation 1. Coat a new O-ring with Gasket Sealing Compound and place it on the manifold. 2. Lubricate two new O-rings with hydrauJic fluid andpMcethem 345O3 on the hydraulic line tips. E~ 3. Hold the manifold as shown and attach the lines. Make sure the tagged line goes in its proper location. Route both lines parallel and at the angle shown. Line routing is importantotherwise manifold will be difficult or impossible to install. Tighten the fittings to 14-18 ft. Ibs. (19-24 N.m) and discard the reference tag. 2-18 vDrr~e L~ Tagged line must attach to the correct inlet. If lines are switched, trim/tilt mechanismwill malfunction. When properly connected, the lower manifold line will attach to the "UP" inlet on the pump valve body, and the upper manifold line will connect to the starboard inlet on the pump body. ~] [~] 4. Feed the lines through the manifold opening, pulling them from inside the transom if necessary. Seat the manifold ~ over its mounting stud. Use a new Iocknut and tighten nut to 108-132 in. Jbs. (12-15 N-m). rg] 5. Coat new O-rings with hydraulic fluid and place them on hydraulic lines. Attach the lower port line to the manifold ® first, then the upper one. Tighten the fittings to 14-18 ft. Ibs. (19-24 N-m). Attach the short starboard line to the lower port (~ of the manifold. Attach the long starboard line to the upper port (~) the manifold. Tighten the fittings to 14-18 ft. Ibs. (19-24 N-m). 6. Route the lines together down the side of the housing. Install the clamp and screw, tighten the screw securely. 7. If the grease extension tube was removed, install it as fot[ows: a. Remove the grease fitting from the tube. Apply Gasket Sealing Compound I/~ of the grease fitting to the last in. end (~) of the tube. Insert the tube through the outer wail of the housing. b. Spray the tapered end of the tube O and housing hole with Loctite primer or equivalent and allow to air dry. c. Sparingly apply Loctite or equivalent to the tapered end of the tube (D and drive the tube into the housing until it seats. Wipe away any excess adhesive that may enter the bearing cavity or the end of the tube. Install the grease fitting. 34503 34501 34506 Safety ReJated 2-19 34510 Trim SenderInstallation El [~ 1. Apply Volvo Penta Grease to the trim/tilt sender Read grommet. Feed the wires through the opening in the rear of the gimbal housing, and out through the transom plate. Push the grommet into the home until it seats. Do not route trim/timt sender leads under extension tube or hydraunic lines. Leads must be free to move when drive unit steers, otherwise sender or wire will be damaged. E~ 2. Attach the retaining cUip to the grommet inside the 9267 transom plate. E~ 3. use volvo Penta insert Tool P/N 3854349-2 to push the wire sockets into the rubber plug until they seat. The use of alcohol or cleaning solvent will make socket installation into the rubber plug easier. Water Tube Installation 1. ff the grommet was discarded, face the tapered end of a new one toward the hooked end of the tube and slide it up against the flange. DE] 2. From inside the boat, insert the hooked end of the tube through the gimbal housing. Hold the tube vertically, then instaiR the two mounting screws and tighten them to 120-144 in. Ibs. (14-18 N-m). 34468 2-20 vwr~ Water Hose Insta|llation 1. Remove and discard the nipple O-ring. Clean all grease from the nipple making sure the drain hole is clear. If the nipple needs to be replaced, damp it and pull it out of the hose. ~7 2. Coat a new O-ring with Volvo Penta Grease. Slide it onto the nipple and position it in the groove closest to the square at the end of the fitting. Clean excess grease out of drain hole and drain grooveo Donot place an O-ring in the drain home groove. This would prevent water draining out during winterization, and could result in freeze damage. [~ [~ 3. Smide a clamp onto the upper end of the hose. Position the screw head so that it will be behind the port hydraulic lines as shown. Push the hose onto the water tube, then rotate it until the nipple points directly outward. Slide the ground strap clip under the hose clamp. Tighten the clamp securely. [~ Clamp’s screw head must be behind hydraulic lines to prevent it contacting the pivot housing when drive is in a full tilt position. Improper clamp position may limit tilt range, and DR1867 damage clamp and hose. 4. Check the position of the nipple drain hone. If it’s not facing down, loosen the nipple clamp and rotate nipple until the drain hole is facing down. Tighten clamp securely. U-Joint and Exhaust Bellows Installation 1. Coat the outside surface of the gimbaU bearing bore with Gasket Sealing Compound. Sea~er is not required on the outside of the exhaust opening, Clamp’sscrew position is important. If not properJy posi= tioned, steering radius wilm be reduced because of gimbaU ring contacting clamp head when turning. ~] [~ 2. Place champ on the smalm end of the U-joint bellows. There is an internal rib that must engage a corresponding groove around the opening’s surface. Push the belmows on and engage the groove, then rotate the clamp until the screw fitting is in the one or two o’clock position. Slide ground strap clip under hose clamp. Tighten the clamp securely. [~ 3. The large end of the exhaust bellows has an internal rib simiJar to the U-joint bellows. Place clampon this end, Bellows must be positioned with exhaust relief cutout facing down. Push the bellows onto the exhaust tube until it engages the groove. Turn the clamp screw to the three o’clock position. Slide ground strap clip under hose clamp and tighten the damp securely. Install gimbai ring, trim/tilt cylinders and pivot housing following instructions elsewhere in this section, Gimba| Housing and Transom Plate Removal Removeengine, lower exhaust pipe and steering cylinder following instructions in Volvo Penta SX Engine Removal and Installation section in the Engine Workshop Manual ~ The transom shield assembly can be removed without complete disassembly. Since the gimbal housing is attached to the trim lines and pump, decide whether to disconnect trim lines at hydraulic manifold after inner transom plate is removed, or to unscrew trim pump from transom and feed pump and lines through cutout as gimbal housing is removed. 1. Remove the two screws and four nuts and washers securing the transom plate inside the boat. Lift the plate off tile studs. Note that the hydraulic lines route above the uppermost port stud and through a relief in the inner transom plate. ~ ~ 2. Remove the two remaining nuts, washers, and transom bearing plate. Pull the gimbal housing off the transom. Shift Cable Sleeve Replacement E~ 1. Unscrew the shift cable sleeve and connector assembJy. Discard the connector O-ring. 2. Apply Gasket Sealing Compound to a new O-ring. Slide it onto the connector and position it against the hex ~ then coat the connector threads with sealer. ~-~ 3. Install the ,,;leeve and connector assembly, and use a crowfoot adapter to tighten the connector to 46-52 ft. Ibs. (62-71 N-m). ® 4S49 vo~ 2-23 Transom and Exhaust Seal Replacement 1. Remove and discard the exhaust O-ring seal (~) and the large rubber transom seal (~). [~] 2. Appay 3M Scotch Grip Rubber Adhesive 1300to the entire transom seal groove around the gimbal housing. Start at top and firmly push a new seal into the groove. Also apply 3M Scotch Grip Rubber Adhesive 1300 to the seal ends and butt them together © to form a watertight iunction at the top of the gimbal housing. 3. Apply 3M Scotch Grip Rubber Adhesive 1300 in the exhaust groove @, and install a new O-ring seal. Gimbal Housing and Transom Plate installation 1. Thoroughly clean outer transom surface where gimbal housing seam makes contact, if trim pump and lines are already attached to housing, insert them through transom cutout, then instaml gimbai housing. Do not use sealer between housing seal and transom, and do not attach washers or nuts at this time. [~ 2. If trim lines were previously disconnected, attach them to the hydraulic manifold (~). Note: Line from pump "UP" outlet must attach to lower rnanifo|d opening, otherwise trim system wUl not function properly. Route the lines above the alignment tube ® and over the uppermost port stud @ as shown. [~ 3. Lightly coat the six gimban housing studs with Gasket Sealing Compound. DE] 4. Apply a light coat of Volvo Penta Grease to the inside of the transom plate alignment tube. 34667 3465O 18121 2-24 vDrr~v,,g 34854 34655 ~__] 5. Position the two hydraulic lines above the uppermost port stud and mount the transom plate. Place the transom bearing plate (~) over the two bottom studs, flat side against transom. nnstalm three fiat washers O and five new Iocknuts @. Tighten nuts until they just contact plate and transom. Do not tighten nuts at this time. ~] 6. Position ground wire (~ on transom shield stud. install washer and Iocknut. Do not tighten nut at this time. 7. Lightly coat the alignment screw threads with Gasket 34557 Sealing Compound, then screw them completely in only finger tight. Do not tighten the alignment screws at this time. ~ 8. Tighten the six Iocknuts in a cross pattern, starting with the two center nuts. Tighten them to 20-25 ftJbs. (27-3.4 Norn). [~ 9. Tighten the two alignment screws to 12-14 ft. Ibs. (16-19 N.rn). DR1074 34658 Specifications Description Nut Manifold to Transom Shield Shift Cable Sleeve Steering Arm Studs Transom Shield Mounting Trim Line to Cylinder/Manifold Trim/Tilt Pivot Pin Water Nipple Screw Alignment, inner Transom Plate Anode Cover, Steering Arm Cover, Transom Shield Drain~Vent, Pivot Housing Support Bracket, Gimbal Ring Trim Motor Reservoir Trim Sender Water Outlet Bo|t Pivot Housing to Gimbal Ring Steering Arm U,S. Metric 108-132 in. Ibs. 12-15 N-m 46-52 ft. Ibs. 62-71 N-m 13-15 ft. Ibs. 18-20 N-m 20-25 ft. Ibs. 27-34 N-m 84-108 in. Ibs. 9,5-12,2 N-m 120-144 in. Ibs. 14-16 N.m 96-120 in. Ibs. 11-14 N-m 12-14 ft. Ibs. 16-19 N-m 12-14 ft. Ibs. 16-19 N-m 60-84 in. Ibs. 7-9 N.m 60-84 in. Ibs. 7-9 N-m 50-60 in. Ibs. 6-7 N.m 18-20 ft. Ibs. 24-27 N-m 7-13 in. Ibs. 0,8-1,5 N-m 18-24 in. Ibs. 2,0-2,7 N-m 120-144 in. Ibs. 14-16 N-m 105-120 ft. Ibs. 142-163 N.m 65-72 ft. Ibs. 88-98 N-m 2-26 vD~en~ Specifications Loctite or equivalent o Stud, Gimbal Housing 3M adhesive or equivalent ,e Seal, Water Passage Loctite or equivalent ® Lubrication Tube Loctite or equivalent ¯ Stud, Manifold 3M Scotch Grip Rubber Adhesive 1300 ® Seal, Exhaust Opening ¯ Transom Seal Volvo Penta Grease ¯ Alignment Tube, Inner Transom Plate ® Bushing,, Upper Steering Post ¯ Friction Washer, Pivot Housing ¯ Grommet, Trim Sender Lead e Nylon Bushing, Trim Cylinder o O-ring, Upper Steering Post e O-ring, Water Nipple e Pivot Pin, Trim/Tilt Cylinder Lubricants- Volvo Penta Grease =~ Seal Lip, Gimbal Housing ib Thrust Washer, Lower Steering Post ~ Thrust Washer, Pivot Bolt ~bThrust Washer, Upper Steering Bear ing Wheel Bearing Grease ~ Gimbal Bearing, Driveshaft Gasket Sealing Compound ¯ Alignment Screw, Transom Plate ~ Gimbal Housing Lip, U-Joint Bellows =~ Lubrication Tube ~ O-ring, Hydraulic Manifold =~ O-ring, Shift Cable Tube ~P Pivot Housing Lip, U-joint Bellows o Pivot Pin Threads, Trim/Tilt ~b Seal Case, Gimbal Housing =b Studs, Gimbal Housing VD,~enQ 2-27 Service Chart - Sealants, Lubricants, Adhesives and Torque Values ...... 3M Scotch Grip Rubber Adhesive 1300 ~) Volvo Penta Grease © Gasket Sealing Compound @ 3Madhesive or equivalent ~) Loctite or equiva|ent 65-72 ft. Ibs. (88-98 N.m) Wheel Bearing Grease n~) Loctite or equivalent 80-84 in. Ibs. Loctite or equivalent ® 13-15ft. Ibs. (7-9 N-m) (18-20 N’m~4% ~ 120-144in. Ibs. (14-16 N.m) ~"-’~ ~)~ /(~ /(~ 108-132in. Ibs. (12-15 N.m) 46-52 ft. Jbs. "~’-47~ (62-71 N.m) ..=_===._.~.~-~v 84-108in. Ibs. ~ (9,5-12,2 N-m) 20-25 ft. Ibs."~’~#~ / (27-34 N.m) / j;e// .< 105-120ft. nbs. (142-163 N-m) 12-14 ft. fbs..~ (16-19 N.m) ~--~-~18-20ft. lbs. (24-27 N.m} , ~%’~, "~18-24 in. Ibs. f 12,0-2,7 N-m) ® 84-108 in. Ibs. (6-7 N.m) I ~ (9,5-12,2 N.m) 98-120in. robs. " ~ / (11-14 N.m) ® 120-144 in Ibs (~. DR4983(14-16N-m) "-"-’-’J"~ "~"(~ 2-28 vorr~,nQ Section 3 Upper Gear Unit SX Models Table of Contents Cleaning and Inspection .............. 3-12 Special Tools ........................ 3-2 Gear Lash Specifications ...................... 3-38 Checking ......................... 3-26 U=Joint Replacement .................. 3-8 Correcting ........................ 3-27 Upper Gear Unit Pinion Bearing Carrier Assembly ........................ 3-21 Assembly ........................ 3-14 Disassembly ....................... 3-3 Disassernbiy ....................... 3-9 Oil Screen ........................ 3-10 Service Chert ....................... 3-39 Upper and Lower Output Gear Shift Actuator Housing Assembly ........................ 3-17 Assembly ........................ 3-32 Disassembly ....................... 3-7 Disassernbly ...................... 3-30 Drive Unit Installation ....................... 3-33 Assembly ........................ 3-35 Shimming ........................ 3-34 Disassembly ....................... 3-3 Shift Linkage Filling ........................... 3-36 Assembly ........................ 3-13 Removal .......................... 3-3 Disassembly ...................... 3-12 Pressure and Vacuum Check ......... 3-35 Shimming Water Passage Plate Service ........... 3-12 Lower Output Gear ................ 3-18 Gear Teetl~ Contact Pattern ............ 3-40 Pinion Bearing Carrier .............. 3-20 Shift Actuator Housing .............. 3-34 Thrust Plates ..................... 3-11 Top Cover ........................ 3-25 Upper Output Gear ................. 3-19 Vertical Movement Of Upper Driveshaft 3-24 Safety Warnings Before working on any part of the upper gear unit, read the section called Safety at the end of this manual When replacement parts are required, use genuine Volvo Penta parts or parts with equivalent characteristics including type, strength and rnateriai. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers. Several of the following procedures require, use of an arbor or hydraulic press. Always wear safety glasses when using this device to perform these procedures. Volvo Penta Special Tools Spline Socket 3850598-8 Spanner Wrench 3850604-4 Gearcase Holder 3850605-1 Remover/Installer 3850606-g SeamInstaller 3850607-7 Shim Tool Upper 3850701-8 Retaining Ring Pliers 3850608-5 U-Joint Adaptor 3850628-3 Drift 884168-6 Drift 884259-3 Press Tool 884263-5 Press Tool 884265-0 Press Tool 884268-8 Mandrel 884932-5 Mandrel 884933-3 Sleeve 884938-2 Std Handle 9991801-3 Owatonna Service Tools T74-4635-C U-joint Tool OEM 1027 Universal Dial Indicator Set Order From: Owatonna Tool Company Service Tool Division 855 Eisenhower Drive Owatonna, Minnesota 55080 USA ToJa free order line: 1-800-533-5338 Or 1-800-533-0492 Sealants, Lubricants and Adhesives CUeaningsolvent Wheel Bearing Grease Gasket Seaming Compound Teflon Pipe SeaRant Volvo Penta Grease DuraPlus synthetic GL5 gear oil 3-2 VD/l=B/eng Drive Unit Removal To service components of the upper gear unit, remove drive unit from transom shield. Follow the procedure in Drive Unit Removal and Installation section in this manual. Drive Unit Disassernbly EI~ 1. Mount the drive unit assembly in a suitable holding fixture and clamp it securely. Unscrew the lifting eye ~, if one was used, or the dipstick. Discard the O-ring on the dipstick. E~ [~ 2. Remove the rear plastic cover (~, if it hasn’t been removed. Remove the oil level plug © so the oil reservoir vents when draining. Discard the O-ring. 3E~ 3. Place a 4 quart drain pan under the lower gear unit. Remove the lower drain plug (~, discard the O-ring, and let the drive unit drain completely. ~4~ 4. Remove six screws, two on either side (~), and two aft Remove the upper gear unit. Upper Gear Unit Disassembly ~.~ 1. Remove the water tube ~) and grommet @ from the upper unit. Discard the grommet. 34647 34646 34645 34644 34~z6 vorrwe,o 3-3 2. Attach Spline Socket P/N 3850598-8(~ to the Gearcase Holder P/N 3850605-1 (~. Tighten the set screw © securely. [~ 3. Mount the upper gear unit facing either direction, on the homdingfixture. Loosen locking screw ~). Rotate and lift fixture shaft ~) to engageunit upper driveshaft splines. Install and securely tighten the four mounting screws (~). Shift Actuator Housing Removal ~] 1. Remove cotter pin (~ and clevis pin ® retaining shift link (~ to eccentric piston arm ~. Move shift link out of the way. 2. Removefour screws (~) securing shift actuator housing. Removethe housing from the upper gear unit. EEl 3. Note the position of the shift shoe (D during removal, it must be properly positioned during installation or the shift system wi[I not function correctly. 34642 34767 34766 3-4 vDm~W~g 34638 346O3 Pinion Bearing Carrier Removal E6=_~ 1. Remove the four screws ~) securing the pinion bearing carrier to the upper housing, ~T~ 2. Remove the pinion bearing carrier using two screwdriv ers. Be careful not to damage the upper housing or the bearing carrier mounting s~rfaces. [’8~ 3. Save any undamaged pmastic shims, as they may be reused. Remove and discard the O-ring (~. Output Gear Removal [~ 1, Remove the four screws ~) securing the upper gear unit top cover. Remove the cover. ~I0~ 2, Save any undamaged shims under the cover as they may be reused. Remove and discard the cover seal (~. ~l~ 3, Push the holding fixture shaft up to engage the upper driveshaft splines, Align the flat on the fixture shaft with the locking screw @, Tighten the locking screw to prevent the upper gear unit shaft from turning. Remove the LEFT-HAND threaded nut @ on top of the shaft with a 30 mm socket. 34604 ® 346O6 34607 3-5 vD/r~..~ 34808 34611 El 4. Lift upper gear and bearing assembly out of the unit. Removeneedle bearings (~) from center of bearing assembly after noting bearing orientation (top-to-bottom). Remove and save shims (~). They can be reused if they are not damaged. Do not mix needle bearings with those of the lower gear and bearing assembmy. Premature failure will result if they are intermixed. Bearings should be reinstalled in the same top-to bottom orientation as they were removed for longevity. 5. Remove cone clutch © and spring ~. Note the word "’TOP" (~ on the top side of the cone clutch. This must face up during reassembly. [~] ~ 6. Use Spanner Wrench P/N 3850604-4 to unscrew the bearing retainer ring that holds the lower gear and bearing assembly in place. Insert the tool into the unit. Use two upper gear unit cover screws to secure the spring loaded arm to the top of the gear unit. As the screws are turned down, alternate between the two screws every two turns. Seat the screws completely, then tighten them securely, Tighten the holding fixture securely. The bearing retainer ring is tightened to 145-165 ft. Ibs. (197-224 N-m). [~ 7. Attach a 3/4 in. breaker bar to the spanner tool and break the retainer ring free. After it turns easily, detach the spring-loaded arm from the top of the unit. Unscrew the retainer ring and lift it out. Be careful removing the screws. The arm is under tension. [~ 8. Remove the lower bearing and shaft assembly. Remove the shims (~ at the bottom of the unit, The shims can be reused if undamaged. . k k ¯ 346O1 34~0 3-6 VD/TBfeng 34599 34598 [7~ 9. Turn the lower bearing and shaft assembly over. Push up on shaft to disengage upper driveshaft C-clips (~) from ring spacer [8=-] 10. Remove the upper driveshaft C-clips ~) and ring spacer C~ from the shaft. [~ 11. Remove lower gear and bearing assembly. Remove needle bearings (D from the assembly after noting bearing orientation (top-to-bottom). 34609 ~-~ Do not mix needle bearings with those of the upper gear and bearing assembly. Premature failure will result if they are intermixed. Bearings should be reinstalled in the same top-tobottom orientation as they were removed for longevity. Upper and Lower Output Gear Disassembly 1. Place Remover/Installer P/N 3850606-9 (~), large diameter end up, in a press. Place the upper gear and bearing assembly (has extra ring (~ around bearing) into the tool with the gear 3~1Q facing up. Press the ring off the bearing using Press Tool P/N 884263-5 Q. [1=~ 2. Place Sleeve P/N 884938-2 ~), large diameter end up, in press. Place the upper bearing assembly into the tool with the gear facing down.. Press the gear from the bearing using Press Tool PIN 884263-5 (D. 3. Follow the pro,~,edures in the previous step and remove the lower gear from the bearing. [1~ Z~ 4. Wear eye protection. The upper driveshaft may’ be disassembled if needed, by removing the spring C-clip ~) and 34596 spring spacer (~). vwn~,,0 ~ Safety Related 3-7 U-Joint Replacement Both U-Joints can be replaced without removing the pinion bearing carrier from the upper gear unit. Removal ~ 1. Wear eye protection. On the inside of each U-joint arm is a retaining ring. Use a small drift and mallet to remove all eight retaining rings. Discard the old retaining rings and replace them with new ones. DE] 2. Remove the U-Joints requiring replacement. Press out the U-Joints with OwatonnaTool P/N T74-4635-C (~) or equivalent. Pilot the bearing cap with open adaptor ® from Volvo Penta U-Joint Adaptor P/N 3850628-3. Follow the instructions provided by the tool manufacture. DE] ~ 3. Do not press any bearing cap completely through its yoke. When the pressure-side cap is almost through the yoke, removethe U-Joint shaft from the tool and pull off the exposed ° cap with pliers. Rotate the U-Joint 180 and press the cross bar in the opposite direction to remove the remaining cap. 4. Removethe remaining caps and other U-Joint using the Owatonnatool as previously described. Pay special attention to the position of the grease fitting in relation to the U-Joint lobes. installation Removeall bearing caps from a new U-Joint. Use grease fitting and lubricate U-Joint with Wheel Bearing Grease until grease appears at end of all four lobes. This ensures each lobe will receive equal volumes of grease after assembly. r~ 1. Insert U-Joint lobes into center coupler of driveshaft. ° Makesure grease fitting is positioned at a 45 angle to any two lobes, otherwise fittings cannot by reached for lubrication. r~ 2. Install both bearing caps by hand. Slide U-Joint back and forth between caps to be sure they’re aligned. DE] 3. Press bearing caps on with OwatonnaToolP/N T74 4635-C or equivalent. Place open adaptor from Volvo Penta U-Joint Adaptor P/N 3850628-3 in tool and tighten tool until retaining ring groove of one cap completely clears the inside of the coupler. Z~ 4. Wear eye protection. Discard old retaining rings and replace them with new ones. Attach to cap with pliers or hammer. 34595 34637 34636 //~ Safety Related 3-8 5. RemoveU-Joint from tool and rotate it 180°, Press in opposite cap untU the retaining ring of the first cap seats against the yoke. Face the open end of the ring toward the drive shaft and attach it to the cap. if neces~ary,use a punch and hammer to seat the fling in the groove. 6,, Repeat steps 1 thru 5 above for all remaining bearing caps. L,~bricate the U-Joints with Wheel Bearing Grease. 7. Check the U-Joint for freedom of movement. Drive the end caps outward against the clips as necessaryto ensure freedom of movement. ,Pinion Bearing Carrier Disassembly DE] 1. Make a U-Joint Support © by cutting a 1 in. diameter pipe 2"~ in. long. Slide the support through both yokes. ~7~ 2. Rest the pinion bearing carrier on top of a vise and clamp the yoke securely. ~8~] 3. Remove the pinion gear retainer screw (~) using a TX-50 ~rx bit. Discard the screw. Remove the pinion gear retainer L~. L~ 4. Remove the pinion bearing carrier from the U-Joint shaft. Z~ 5. Wear eye protection Remove the seal C-clip from ’the pinion bearing carrier by using Volvo Penta Retaining Ring Pliers P/N 3850608°5. 3476O 34757 34832 w>,~r~.~ ~ Safety Related 3-9 3463O 34694 E~ 6. Place Sleeve P/N 884938-2 (~, large diameter up, in press. Place a rag inside the tool to protect the gear during disassembly. Place pinion bearing carrier into the tool, gear side down. Press out the input gear using Press Tool P/N 884266-8 (~). E~E] 7. Remove the crush sleeve from the input gear shaft and discard it. [~ Pretension sleeves must not be reused. Proper rolling torque cannot be achieved with a used pretension sleeve. EEl 8. Clamp the input gear and bearing in a bearing separator, placing the curved side of the jaws behind the bearing. Remove the gear from the bearing using Press Tool P/N 884266-8 ~). Do not remove the bearing from the input gear unless it is damaged. Removal will destroy the bearing. When replacing any tapered roller bearing, the corresponding bearing race must also be replaced. EE] 9. Place pinion bearing carrier in a press with the seal facing down. Press out the seal and rolmer bearing using Press TooJ P/N 884263-5 @. EEl 10. instaXl Mandrel P/N 884933-3@ on to the end of Std Handle P/N 9991801-3 ~). Place the pinion bearing carrier in press large diameter down. Press out the small bearing race. [~ 11. Place Sleeve P/N 884938-2 0 in a press. Turn the pinion bearing carrier over and pmace it on the tool. Press the large bearing out using the tools in the previous step. Upper Gear Unit Oil Screen Remove the oil screen ~) from the upper unit. Clean and replace as necessary. UnstaUl the oil screen into the oil passage in the unit. Make sure the screen is secure. 34629 34892 W 34691 W %-; 3-10 VD/TB/eng ShimmingThrust Plates E~ 1. Check the width across the thrust plates with a Vernier Caliper. Make sure all space between the shims and the thrust plates are removed. This is a shimmed dimension that should be greater than 5.007 inches (12,72 cm), but not exceed 5.036 inches (12,79 cm). Do not remove the thrust plates unless the dimension is incorrect, ff the dimension is less than 5°007 inches (12,72 cm), add one shim to each side. if more than 5.036 inches (12,79 cm), subtract one shim from each side. 2. To reset the width, pry off four retaining rings and remove the thrust plates. The retaining rings can be reused unless they are broken, Notice that the concave side of each ring faces inside the unit. [~ 3. Underneath each plate is one or more shims. Each shim is the same size .015 in. (0,38 mm). Shims must always be instalHed in pairs, one on each side of the unit. There must always be a minimum of one shim per side, but no more than four per side. ff more than four per side are needed, replace both thrust plates and check the dimension again. 4° To determine if shimming is necessary, compare your measurement with 5.036 (12,79 cm). 5.036 in. required width -5.012 in. measured width 0.024 in. difference in this example, no shims are required. Since shims are added! in pairs, the difference would have to exceed .030 in. (.015 in. x 2) before shims would be needed. Do not exceed 5°036 in. (12,79 cm) when adding shims. Excessive width will cause interference between the upper gear unit and the transom shield. ~2--~ 5. Place correct shims on the thrust plates and insert the plates into the unit. Face the concave side of each retaining ring toward the inside of the unit. Push the ring onto the plate stud. Hold the ring with a 1~ in. box-end wrench. Tap the thrust plate with a soft face hammer until the ring seats against the unit. 32583 34689 34688 34686 wrre~,~ 3-11 Shift Linkage Disassembly [~ 1. Place a flat blade screwdriver in the slotted end of the bellcrank pin. Remove and discard cotter pin ~). DE] 2. Pull out the pin and remove bellcrank assembly ~) and two flat washers ©. [~ 3. Remove and discard cotter pin @ securing shift link ~ to bellcrank assembly ®. Remove flat washer @ then the shift link. Unscrewthe shift fork ® from the end of the link. [~ 4. Remove and discard the cotter pin O securing the cube O to the bellcrank. Remove flat washer (~) then the cube. Water Passage P/ate Service ~] This plate is a water passage plate and is not removed for normal service, if the unit has a restricted water fgow cooling system problem, the plate may be removed to look for debris. A new gasket coated with Gasket Sealing Compound must be used for reassembly. Tighten the four screws O to 60-84 in. lbs. (6,8~9,5 N.m)° Cleaning and inspection Ctean the unit in sotvent to remove a[I sealer from screw holes, gasket surfaces, and O-ring bores. Dry the unit thoroughly. [~ Most threaded holes in the upper gear unit haveHe/i-Coil® inserts. Do not use a thread tap to clean screw holes. Tap will damageHell-Coil insert and make replacementnecessary, Do not replace with standard non-locking He/i-Coils; use only those shown in the appropriate Volvo Penta stern drive parts catalog. ¯ Lock Ring Threads -lock ring must turn freely for full depth. 34684 34710 34709 3-12 vo~l~ e Cooling Passages - check for corrosion build-up tl~at would restrict water circulation. ¯ Pinion Bearing Carrier Bore -remove all sharp edges that wouJd cut O-ring. o Model LD,, Plate -transfer plate to new gear unit when replacing old unit. Gears, Shafts and Bearings -inspect gear teeth for cracks and chips or discoloration. If any gear is damaged all must be replaced. They are replaced as a set. Screw threads on end of shafts must be undamaged. Replace shaft if lock patch is excessively warn. Check for pitting, corrosion and discoloration. ¯ Cone Clutch and Shift Shoe - replace if any signs of excessive wear is found. Shift Linkage Assembly E~ ~ 1. Apply Volvo Penta Grease to the cube shaft ~). Install the cube on the bellcrank arm with the slotted hole. Secure with flat washer and cotter pin ~). Bend the ends of the cotter pin for secure attachment, ~’~ ~ 2. Screw the shift fork ® onto the shift link (~). Adjust the shift fork to a dimension 51~e in. (150,8 ram) +1~ turn measuredfrom the center of the hole (~ in the shift fork to the center line of the shift link end ~). Apply Volvo Penta Grease to the ° g0 bend of the shift link. Determine if the drive unit is a right or left hand rotation drive. The link is installed on the left side of the beJlcrank for right hand rotation and on the right side of the beHcrankfor left hand rotation, install the link. Secure with a flat washer and cotter pin ®. Bend the ends of the cotter pin fo~r a secure attachment. @ 347O7 [~ 3. Apply Volvo Penta Grease to the bellcrank pin. Place the bellcrank assembly (~) inside the unit. insert the pin into the unit from the starboard side. The screwdriver slot must face away from the unit. [~ ~ 4. Place two flat washers ® on the pin between the unit and the starboard side of the belicrank. Push the bellcrank pin all the way through the bellcrank and into the port side of the upper gear unit. install a cotter pin © into the pivot pin between the two washers. Bend the ends of the cotter pin for a secure attachment. Pinion Bearing Carrier Assembly [~ 1. Place the pinion bearing carrier in a press with the large opening up. Lightly oil the outside diameter of the small bearing race with DuraPlus synthetic GL5gear oil and set it in the carrier. Press the race in untim it seats using Mandrel P/N 884932-5 (~), large diameter up, and Std Handle P/N 9991801-3 (~). 2. Turn the pinion bearing carrier over and set it in the press. Lightly oil the outside of the large bearing race with DuraPlus synthetic GL5gear oil and set it in the carrier. Assemble the special tools used in the previous step with the large diameter of MandreJ P/N 884932-5 (~ facing down. Press the race in until it seats. [~ 3. Coat the pinion gear (~) shaft with DuraPius synthetic GL5 gear oil and set it in the press. Protect the gear teeth. Position the merge tapered roller bearing on the input gear and press it until it seats using Press Tool P/N 884283-5 ~). 34706 34705 34681 34682 3468O Safety Related 3-14 VD/TB/eng 34679 34678 ~7 4. PWace a new crush sleeve ® on the input shaft. ~ot-~ A new crush sleeve must be used to achieve proper rolling torque. [~ 5. Oil the ~arge and small roller bearings with DuraPlus synthetic GL5 gear oil. Place the pinion bearing carrier on top of the input gear. Place the small bearing on top of the input bearing shaft. ~J 6. Press the small bearing onto the shaft using Press Tool P/N 884263-5(~ until there is about .040-.060 in. (1,0-1,5 ram) bearing box end play. This is the starting point for determining rolling torque of the pinion bearing carrier. Use caution. Do not press the bearing on too far. if the crush sleeve is distorted by pressing the bearing on too far, proper rolling torque cannot be achieved. The carrier will have to be disassembled and crush sleeve replaced. [~ 7. Coat the outside surface of a new seal with Gasket Sealing Compound. Place the protruding lip (~ of the seal into the recess of Seal anstaller P/N 3850607-7. ~] 8. Press the seal into the pinion bearing carrier until it seats. 34677 34676 34762 34761 VD~n~ 3-15 34712 34704 EEl/~ 9. Wear eye protection. Install seal C-clip into its groove in the pinion bearing carrier using Volvo Penta Retaining Ring Pliers P/N 3850808-5. Make sure the retaining ring seats completely. L-~ 10. coat the seal lips with Volvo Penta Grease. EEl EEl 11. Place the U-Joint yoke support (~) used during disassembly through both yokes and place it in a vise. Carefully insert the U-Joint shaft through the seal and engage the splines of the input gear. EEl 12. Spray the threads of the U-Joint shaft and a new pinion gear retainer screw with Loctite primer or equivalent and allow to air dry. r~ 13. Place the pinion gear retainer @ onto the top of the input gear. Apply Loctite or equivalent to the screw threads. E~ 14. install the screw and tighten a little at a time using Torx Bit TX-50. Turn the pinion bearing carrier while tightening the screw to seat the bearings. Frequently remove the assembly from the vise to check the rolling torque. Stop when the rolling torque reaches 9-14 in. Ibs. (1,0-1,6 N-m). [~ If the rolling torque is exceeded, the pinion bearing carrier will have to be disassembned and a new crush sleeve installed. 34’763 34632 34759 34758 Safety Related 3-16 vwr~6 Assembly of Upper and Lower Output Gears ~ 1. Place the lower gear in a press. Protect the gear face. Lightly oil the inside diameter of the bearing with DuraPlus synthetic GL5 gear oil. 2. Place the bearing, numbered side facing up, on the top, ofthe gear. Press the bearing in place until it seats, using Drift P/N 884168-6 ©. 3. Follow the above procedures and assemble the upper beariing assembly. 34755 4. Place SJeeve P/N 884938-2 (~), large diameter end up, in press. Lightly oil the inside diameter of the adaptor ring (~ with DuraPlus synthetic, GL5gear oil. Place it on top of the sleeve flange side up. 5. Place the upper bearing (~, gear side down on top of the adaptor ring (~). Press the bearing into the adaptor ring until seats using Remover/InstaiJer P/N 3850606-9 @ and a suitablepiece of flat stock. 34754 [~ The following procedures will set gear position for the input, lower and upper output gears. Record all measurements for future reference. Lower Output Gear Shimming [~ 1. Place the lower gear and bearing assembly, gear side down on a suitable work surface. Place Shim Tool Upper P/N 3850701-8 (~) on the assembly as shown. Take a feeler gauge measurement at the outer edge (~) of the bearing. Record this measurement. [~ 2. Add or subtract the shimming allowance © on the gear from the measurement taken in Step 1. This is the amount of shims required to properly position the lower output gear in the upper gear unit. [~ E~ ~ Because of the location of shims in relation to the gear, use the following information when adding or subtracting the etched allowance figure from the measurement in Step 1. ¯ If gear etching is (-12), it is understood to represent inches to the hundreth" 0.012 in. Convert to decimal inch. ¯ If +5, you woumd SUBTRACT the etched number is .005 in. from the feeler gauge measurement taken in Step 1. ¯ If the etched number is -5, you would ADD .005 in. to the feeler gauge measurement taken in Step 1. @ If the etched number is zero (0), you ADD or SUBTRACT nothing to/from the feeler gauge measurement taken in Step 1. Add / Subtract (~ -Feeler Gauge Measurement _+ © - Shimming Allowance Etched On Gear Amount Of Shims Required [~ All mating, thrust and bearing faces must be clean. Shims to be used during assembly must be clean and undamaged° No less than one shim but no more than four shims should be used. Shims to be used must be dean and undamaged. Upper Output Gear Shimming EEl 1. Place the upper gear and bearing assembly, gear side down on a suitable work surface. Place Shim Tool Upper P/N 3850701-8 (~) on the assembly as shown. Take a feeler gauge measurement Record th is at the lower edge (:~ of the adaptor ring. measurement. ~==] 2. Add or subtract the shimming allowance (~) on the gear from the measurement taken in Step 1. This is the amount of sh;ims required to properly position the upper output gear in the upper gear unit. [~=l ~ l~ Because of the location of shims in relation 1:o the gear, use the following information when adding or subtracting the etched allowance figure from the measurement in Step 1. ¯ if gear etching is (-12), it is understood to represent inches to the hundreth: 0.012 in. Convert to ,decimal inch. e If the etched number is +5, you would ADD .005 in. to the feeler gauge measurement taken in Step 1. ¯ If the etched number is -5, .005 in. you would SUBTRACT from the feeler gauge measurement in Step 1. ® if the etched number is zero (0), you ADD or SUBTRACT nothing to/from the feeler gauge measurement taken in Step 1. Add / Subtract @ - Feeter Gauge Measurement -© -Shimming Allowance Etched On Gear Amount Of Shims Required N~t~] All mating, thrust and bearing faces must be clean. Shims to be used during assembly must be clean and undamaged. No less than one shim but no more than four shims should be used. Shims to be used must be clean and undamaged. 34891 34890 Pinion Bearing Carrier Shimming 1. Using a vernier caliper or depth micrometer, measure the actual dimension (~) from the top of the pinion gear to the surface of the pinion bearing carrier. Measure in several places, then take an average. Stay away from the bolt holes to get an accurate reading. [~ 2. A shimming allowance figure ~) is etched on the pinion (input) gear. Add or subtract the shimming allowance to / from the measurementtaken in Step 1. [~ [~ ~ Because of the location of shims in relation to the gear, use the following information when adding or subtracting the etched allowance figure from the measurement taken in Step 1. ® If gear etching is (-12), it is understood to represent inches to the hundreth: 0.012 in. Convert to decimal inch. ¯ ffthe etched number is +5, you would ADD .005 in. to the depth measurement taken in Step 1. ¯ if the etched number is -5, .005 in. you would SUBTRACT from the depth measurement taken in Step 1. o if the etched number is zero (0), you ADD or SUBTRACT nothing to/from the depth measurement taken in Step 1. Add / Subtract (~) -Measurement Of Step +-~) -Shimming Allowance Etched On Gear "’X" -Total 3. Subtract the nominal figure 1 .g71 from Total "X" of Step 2. This figure is the amount of shims required to properly position the pinion gear in the upper gear unit. Subtract "X" -Total Of Step 2 -1o971 in.- NominamFigure Amount Of Shims Required Shims are to be placed between the bearing carrier and the upper gear unit. No less than one shim but no more than five shims shou|d be used. Shims to be used must be clean and undamaged. 3-20 vo,’~,,,~ ®\ i©.,@ 34~35 Upper Gear Unit Assembly Lower Output Gear and Shaft Assembly 3~ 1. Install the spring spacer © onto the splined end of the upper driveshaft with the recessed side facing the helix (~). Install the spring C-clip (~) on the recess next to the helix. 4~ 2. Place the upper driveshaft through the lower output gear assembly. The groove (~) must be on the same side as the bearing. 34956 3. Lightly oil the lower needle bearings @ with DuraPlus synthetic GL5gear oil. install the needle bearings onto the upper driveshaft with the same top-to-bottom orientation as when disassembledto ensure longevity. New bearings can be installed with either end up, Push the bearing anl the way into the gear and bearing assembly. 6~ 4. Place the ring spacer ® on to the upper driveshaft with the recess 0 facing up. 7~_=] [~ 5. Place the two upper driveshaft C-clips (~ into the 34957 groove on the driveshaft. Move the driveshaft down to capture the C-clips in the recess of the ring spacer. 34958 vo,r~,~ 3-21 Lower Output Gear installation ~] [~ 1. Place the required amount of shims ~) determined in a previous step into the upper gear unit. Rest the shims on the ledge at the bottom of the bore as shown. ~] 2. Place the lower output gear assembly into the upper gear unit and rest it on the shims. Do Not let the driveshaft drop down into the unit. [~ 3. Loosen the locking screw (~) and adjust the height of the fixture shaft to engage the upper driveshaft. This will now support the upper driveshaft and retain the C-clips. Failure to support the driveshaft will allow the C-clips to fall out. Removal of the output gear assembly will be required to reinstall the C-clips. [~ 4. Lightly oiR the bearing retainer ring © with DuraPlus synthetic GL5gear oil. install the ring in the upper gear unit. Thread the ring aml the way in by hand until it seats. 5. When fumEy seated, the bearing retainer ring will be below 3d961 the bottom edge of the pinion bearing carrier opening. ~A~2 ~ 3-22 VDf]’B/eng ~-] 6. Install Spanner Wrench P/N 3850604-4 (~) and secure the tension arm (£) with two upper gear unit top cover screws (F~. Tighten the cover screws down evenly, alternating every two turns. Tighten the screws securely. 7. Tighten the, bearing retainer ring to 145-165 ft. Ibs. (1,97-224 N-m). Remove the two retaining screws then remove the wrench. Use caution when removing the retaining screws as the arm is under spring tension. Cone Clutch |nstailation ~-ot-~ Before installing cone clutch, the proper gear contact pattern must be achieved° Refer to checking gear teeth contact pattern in this section. 1. Place the cone clutch spring (~) around the upper drive- shaft. Slide the spring down into the unit until it rests on the spring spacer, ~ 2. identify the end of the cone clutch that is marked with the word "TOP" ®. 1~ 3. Install the cone clutch with the word "TOP" facing UP, onto the upper driveshaft. Slowly let the cone clutch spin down the driveshaft helix until it rests on the spring. 34971 34972 Upper Output Gear Installation E~] 1. Place the predetermined amount of shims (~) to locate the upper output gear into position on top of the upl~er gear unit. E~] 2. Place the upper output gear ~) on top of the unit and seat the assembly. Be careful not to disturb the shims when installing the bearing assembly. [~ 3. Place the upper needJe bearing © on top of the upper driveshaft. Maintain the same top-to-bottom orientation as dur 34945 ing disassembly to ensure longevity. New bearings can be installed with either end up. Push the bearing ain the way into the gear and bearing assembly. Shimming Vertical Movement Of Upper Driveshaff In order to obtain the correct vertical clearance (up and down movementof the upper driveshaft), there are four upper drive- shaft nuts with shoulders of different thicknesses. [~ 1. Apply DuraPlus synthetic GL5 gear oil to the upper 34946 driveshaft threads to prevent galling. Select an upper ddveshaft nut @ and install it on the upper driveshaft. e Nut has a left-hand thread. E~] 2. Tighten the nut to 96-110 ft. Ibs. (130-149 N-m). 34947 3. Push up on the holding fixture shaft to remove the end play in the upper driveshaft. Measure the clearance between tile upper driveshaft nut and the upper output gear bearing (~). The vertical clearance should be 0.002-0.010 in. (0,05-0,25 mm). If tile clearance is high, install a thicker nut. if the clearance is tmN, install a thinner nut. The thickness of the nut can be determined by the number on the top of the nut. 0 2 4 6 .000 in. .008 in. .016 in. .024 in. 3852301-5 3852302-3 3852303-1 3852375-9 4. Retighten the clearance again. nut to the specified torque and measure the [~ if the proper clearance is not obtainable with any of the nuts, make sure the upper gear, bearing and bearing support ring are correctly assembled. If the components are correctly assembled, the bearing is defective and must be replaced. Pinion Bearing Carrier Installation [~ 1. Install the predetermined plastic shims ® that set pinion gear position on the pinion bearing carrier. Do not install an O-ring at this time. Plastic shims will only fit on the pinion bearing carrier and align with the carrier bolt holes in one direction. Misalignment of the holes will destroy the shims and possibly cause the pinion gear to be out of position. [~ 2. Install the pinion bearing carrier into the upper gear unit and secure with four screws ~). Tighten the screws to 12-14 ft= Ibs. (16-19 N-m). Top Cover Shimming 1. Place enough shims ® under the top cover to obtain the desired clearance of 0.002-0.004 in. (0,05-0,10 mm). ~] 2. install the top cover on the upper gear unit and push down lightly. Take several feeler gauge readings to determine an average clearance. Add or subtract shims to obtain the desired clearance of 0.002-0.004 in. (0,05-0,10 mm). 1[~"~ 3. Install the four top cover screws to secure the top cover. Tighten the screws to 16-18 ft. Ibs. (22-24 N.m). 34948 34949 34950 34952 v~v.,g 3-25 Checking Gear Lash This procedure will check the relative clearance between the pinion gear and the upper and lower output gears. Lower Gear [~] ~ 1. Attach a dial indicator to the upper gear unit. Place the indicator tip at the vertical/horizontal midpoint (~) of a lower gear tooth. Proper indicator placement is important for an accurate reading. DR3231 [~] 2. Zero the indicator. With -your finger, gently rotate the gear first in one direction until tooth contact is felt, then in the other direction. Do not turn the gear far enough to rotate the U-joint, just far enough to contact the pinion gear in both directions. Correct gear lash is 0.006-0.011 in. (0,15-0,28 ram). Record your measurements. Upper Gear [~ [~] 1. Reposition the dial indicator to contact the vertical/ horizontal midpoint of an upper gear tooth. ~] 2. Zero the indicator. With your finger, gently rotate the gear first in one direction until tooth contact is felt, then in the other direction. Do not turn the gear far enough to rotate the U-joint, just far enough to contact the pinion gear in both directions. Correct gear lash is 0.006-0o011 in. (0,15-0,28 ram). Record your measurements. Correcting Gear Lash ~ If both readings are different, yet within eachgear’s specified range, gear lash is correct. Gear lash measurements that are inc<)rrect will fall into one of the categories below. Refer to chart and drawing when determining how to change gear lash. Make all shiim changes at Position ~) first, then at ~), ©, (~) and ~ in order. Determine amount of change by either subtracting range mid- L ........ point from reading, or by subtracting reading from range midpoint. A change to shim @ affects gear lash of both upper and lower output gears. A changeto shim ® affects gear lash of upper ® output gear only. A change to shim ~) affects gear lash of lower output gear only. DR5061 One Gear Correct, One Gear Requires Change Add or subtract same amount of shims at each location indicated. Positions Requiring Shim Change ® @ @ @ ® Lower gear less than range rain. Subtract * * " Reshim Upper gear within range ~ Lower gear greater than range max. Add * * Reshim Upper gear within range Upper gear less than range rain. * Add Reshim * Reshim Lower gear within range Upper gear greater than range max. * Subtract Reshim * Reshim Lower gear within range * No Change Required ~t~ Shim to backlash ratio is approximately 2:1. Example: .004 in. shim is equal to .002 in. of backlash. Both Gears incorrect By SameAmount Add or subtract same amount of shims at each location indicated. Positions Requiring Shim Change ~o.~,,o. @ ® @ @ @ Upper gear greater than range max. Subtract Subtract Reshim * Reshim Lower gear less than range rain. Lower gear greater than range max. Add Add Reshim * Reshim Upper gear less than range rain. Lower gear less than range min. * ’~ * Add * Upper gear less than range min. ~ Lower gear greater than range max. * * Subtract * Upper gear greater than range max. * No Change Required Shim to backlash ratio is approximately 2:1. Example: .004 in. shim is equal to .002 in. of backlash. Both Gears incorrect By Different Amounts ~3 Add or subtract different amounts of shims as required at each location indicated. Positions Requiring Shim Change ® © ® ® Upper gear greater than range max. Subtract Subtract Reshim * Reshim Lower gear less than range rain. Lower gear greater than range max. Add Add Reshim * Reshim Upper gear less than range rain. Lower gear less than range min. Subtract Add Reshim * Reshim Upper gear less than range rain. Lower gear greater than range max. Add Subtract Reshim * Reshim Upper gear greater than range max. * No Change Required ~_ot~ Prior to continuing on next page, refer to page (3-40) for checking gear teeth contact pattern. Final Assernbly of Upper Gear Unit 1. Remove the pinion bearing carrier top cover and upper gear assembly from the upper gear unit. Refer to Cone Clutch InstaJlation/ Removal. 2. install upper gear and upper vertical shaft nut as previously described in this section. EEl 3. coat a surface of a new top cover gasket with 3Madhesive or equivalent. Pmace the gasket around the upper output gear assembly. Orient the tab (~) with the hole in it over the off circulating passage ® as shown. Check the position of the shims © to make sure they are in position for cover installation. 4. Install the top cover and secure with four screws @ coated with Gasket Sealing Compound. Tighten the screws to 16-18 ft. Ibs. (22-24 N.m). [~ 5. Coat a new O-ring (~) with DuraPlus synthetic GL5gear oil and place it in the O-ring groove in the pinion bearing carrier. Check the position of the pmastic shims ® to make sure they are in position for carrier installation. 6. install the pinion bearing carrier and secure with four screws (~ coated with Gasket Sealing Compound. Tighten the screws to 12-14ft. Ibs. (16-19 N.m). 7. Instaff U-joints following instructions found elsewhere in this section. Shift Actuator Housing Disassembly EEl 1. Remove shift shoe (~ and spring O from the shift actuator housing. Note the position of the shift shoe for reassembly. 34978 34979 35019 3-30 ® 34983 34984 34~85 2. Remove and discard the shift actuator housing O-ring. ~"] 3° Drive the tension pin (~ into the eccentric piston until the eccentric piston pin (~ can be removed. ~’~ 4. Remove the eccentric piston pin ® with a pair of pliers, 5. Note the eccentric piston’s orientation then remove the piston from the housing. ~’] 6. Turn the piston over and tap out the tension pin G). 34~88 The tension pin must be removed before installation. Do not install a new tension pin without removing the old one from the eccentric piston. Having two pins in the home will make removal of the new one almost impossible. 1~] 7. Remove the shift actuator seal by inserting a screwdriver behind the seal. Twist the screwdriver and remove the seal, Discard the seaJ. 8. ,Clean all parts in solvent and dry with air. Inspect all parts for wear. Replace any defective components. 34987 34989 vo,~e~,~ 3-31 Assembly [~ 1. Coat the outside case of a new seal with Gasket Sealing Compound. Identify the side of the seal that has the larger space (~) between the case and lip. This side must face outwards during installation. [~ [~ 2. Pmace the shift actuator housing in a press with the seal cavity facing up. Place the seaJ in the cavity with the large space ~) facing up. Press the seal in place with Drift P/N 884259-3, large diameter down, until the tool seats on the housing. [~ 3. Coat the seal lips with Volvo Penta Grease. [~ 4. instalm the eccentric piston through the seal and bushing. Orient the piston with the offset screw ® towards the side of the housing with the notch ©. [~ 5. Align hole ~) in the eccentric piston pin with the hole (~) the eccentric piston. Insert the piston pin into the piston until the two holes align. 34992 34993 34997 3-32 VD/’l’B/eng [~=J 6. Install the tension pin (~. Drive the pin in until it’s flush with the top of the piston. [~ 7. Instaim the shift shoe spring ~) into the hole in the eccentric piston, install the shift shoe ® on top of the spring. Orient the shift shoe as shown. Make sure the shift shoe is installed correctly as shown. The shift mechanism will not operate properly if the shift shoe is installed in any other position. 8. Coat a new O-ring O with DuraPlus synthetic GL5 gear oil and install it in the O-ring groove on the shift housing. Installation 1. Set the eccentric piston pin (~) on one of the fiat areas (~ eitther side of the neutral detent (D. 34996 34974 34975 ~97s vD:r~ 3-33 / 35013 [~] 2. install the shift actuator housing into the upper gear unit and secure with four screws (~). Tighten the screws to 60-84 in. Ibs. (6,8-9,5 N-m). ShimmingShift Actuator Housing [-~ 1. Support the eccentric piston arm and remove the shift shoe stop screw ® and all shims ©. [~ ~ 2. Reinstall the shift shoe stop screw ®, without shims. Verify the eccentric piston pin is positioned on one of the flat areas on either side of the neutral detent. The eccentric piston arm will be positioned slightly high or low of horizontal. Tighten the stop screw until it is no longer possible to turn the upper driveshaft. Loosen the stop screw until the upper driveshaft just turns freely. ~] 3. Take a feeler gauge measurement between the housing and the stop screw. 4. Removethe stop screw. Add enough shims © to the screw to come as close as possible to the feeler gauge measurement. Shims come in one size only. Coat the screw threads with Teflon Pipe Sealant. [~ No less than one shim but no more than four shims should be used. [~] 5. Install the stop screw. Support the eccentric piston arm and tighten the stop screw to 10-12 ft. Ibs. (14-16 N.m). The upper driveshaft must turn freely. [~ L~ 6. Attach the shift linkfork @to the eccentric piston arm. The hole (~ on the starboard side is for rotation LEFT-HAND propellers. The hole ® on the port side is for RIGHT-HAND rotation propellers. Secure with pin ~) and cotter pin (~). Bendthe ends of the cotter pin for a secureattachment. 35017 35014 © 350~5 Z~ Safety Related 3-34 Assembly of Drive Unit -=====.=.==~ ~’~ 1. Install intermediate driveshaft (~ with the groove O facing @ upward, onto driveshaft. [~ 2. Install and position water grommet (~ and supply tube (~ into upper gear unit. Check oil filter ~ for proper installation. [=No~ Care must be used on reassembly of gear unit. If machined surface is damaged, leakage may occur. ~ 3. Attach upper gear unit to the lower gear unit. Engage intermediate driveshaft (~) splines and water supply tube (~). 4. Apply Gasket Sealing Compoundto the lower gear unit mounting screws, install four short screws, two on either side (~ of gear unit, and two longer screws (~) aft. Tighten %-16 screw,,~ 2.2-24 ft. Ibs. (30-33 N-m) and 7/lS-14 screws to 32-40 ft. Ibs. (43-54 N-mL Pressure and Vacuum Testing Drive Unit Before filling drive with gear unit oil, it must be pressure and vacuum tested to verify proper sealing during assembly. Remove magnetic drain plug on side of gear unit skeg. install and tighten oil level gauge at top of drive. 34128 34127 ® 34126 34124 V[Yi"g/6ng 3-35 Pressure Testing [~ 1. Attach a pressure tester (such as a Stevens S-34) to skeg drain hole, and pressurize drive to 3-5 PSi (20,7-34,5 kPa). Rotate propeller shaft and U-joint shaft to check sealing, if pressure loss is indicated, use a soapy water solution or submerge drive in water to find source. Make necessary repairs then repeat test. [~ 2. If pressure loss is not indicated, increase pressure to 16-18 PSi (110-124 kPa). Again, use a soapy water solution or submerge in water to find source if drive looses pressure. Make repairs as necessary and repeat test. Drive must hold pressure before making vacuum test, and must not loose more than 1 PSi (6,9 kPa) in 3 minutes. Vacuum Testing 1. Attach a vacuum tester (such as a Stevens V-34) to skeg drain hole, and pull vacuum to 3-5 inches of mercury (10-16,8 kPa). Rotate propeller and U-joint shaft to check sealing, if drive does not hold vacuum, apply a heavy oil to seaJ and gasket surfaces to find source. Make necessary repairs then repeat test. No loss of vacuum should occur on low test. iT] 2. if vacuum loss is not indicated, increase vacuum to 14-16 inches of mercury (47-54 kPa). Again, apply heavy oil to find source if drive will not hold vacuum. Make repairs as necessary and repeat test. Drive must not loose more than 1 inch of mercury (3,4 kPa) in 3 minutes. Drive Unit FilJing [~ Do not fill drive unit with oil until it passes both pressure and vacuum tests. Drives that fail either test wilJ alUow water entry when in use and cause subsequent damage to internal parts. [~] 1. Place drive in a vertical position. Remove the rear plastic cover to altow access to the oil level plug. Remove the oil level plug (~. Also remove the levet indicator gauge at top of drive to help vent the oil reservoir. Discard the plug and gauge seal (~). Replace them with new ones. ~] 2. Remove magnetic drain screw on side of skeg. Discard screw seal and rep0ace with a new one. [~] r~ 3. Fill drive with DuraPlus synthetic GL5gear oil from skeg drain hole. Fill slowly to purge trapped air. Stop filling when the oil level reaches the bottom of the oiJ level hole. Do not overfill. Filling drive too quickly may form air pockets that will cause an inaccurate oil level reading. Running drive with improper oil level can resuUt in immediate internal damage. 35O5O i" 21798 21141 3-36 21~ VD/TB/eng E2~ ~ [~ 4. When oil reaches proper level, stop filling and screw in the level plug and gauge. Tills will create an air lock to prevent excessive oil loss while drain plug is installed. Apply Gasket Sealing Compound plug, and tighten to 60-84 in. to the fill Ibs. (6,8-9,5 N-m). Apply Gasket Sealing Compound plug to the fill and gauge. Tighten them to 48-72 in. Ibs. (5,4-8,1 N-m)o 5. Install the drive unit and adjust the shift system following the instructions under Drive Unit Removal end installation, Volvo Penta SX Models. [’6-’] 6. If the drive unit is not to be installed, install the slhift linkage access cover and secure with three screws ©. Tighten the screws to 108-132 in. Ibs. (12-15 hi-m). rT~ 7. After drive has been run, recheck oil level. Add make-up oil through gauge opening to bring oil up to the proper level somewhere in the range (~) on the dipstick. 34112 @ L____ F--] 33836 Specifications Description U,S= Metric Bearing retainer ring 145465 ft. Ibs. 197-224 N-m Nut Upper driveshaft 96-110 ft. Ibs. 130-149 N.m Screw Fill and drain 60-84 in. Ibs. 6,8-9,5 N-m Lower to upper gear unit 3/8-16 22-24 ft. robs. 30-33 N.m 7/1e-14 32-40 ft. Ibs. 43-54 N.m Oil level gauge and plug 48-72 in. Ibs. 5,4-8,1 N-m Pinion bearing carrier 12-14 ft. Ibs. 16-19 N-m Shift actuator housing 60-84 in tbs. 6,8-9,5 N-m Shift linkage access cover 108-132 in. Ibs. 12-15 N-m Shift shoe stop screw 10-12 ft. lbs. 14-16 N-m Top cover 16-18 ft. Ibs. 22-24 N.m Water passage cover 60=84 in. Ibs. 6,8-9,5 N-m Loctite primer or equivalent ¯ Pinion gear retainer screw Loctite or equivalent ® Pinion gear retainer screw Wheel Bearing Grease ¯ U-Joints Volvo Penta Grease ¯ Seal lips ¯ Shift linkage pivot points DuraPius synthetic GL5gear oil ¯ Threads, upper driveshaft ¯ O-ring, pinion bearing carrier ® O-ring, shift actuator housing Gasket Sea|ing Compound ¯ O.D. all metal case seans ¯ Gauge, gear unit oil Hevel ¯ Screws, water passage plate ® Screws, pinion bearing housing ® Screw, drain and fill ® Screws, lower to upper gear unit ® Screws, shift actuator housing ® Screws, shift linkage access cover ¯ Screws, top cover Teflon Pipe Sea|ant ® Shift shoe stop screw 3M adhesive or equivalent ¯ Gasket, top cover 3-38 vo,’re,,,~ Service Chart -Sealants, Lubricants, Adhesives and Torque Values 96-110 ft. (130-149 Ib " N.m) DR5023 Volvo Penta Grease (~) Gasket Sealing Compound © Teflon Pipe Sealant @ DuraPlussynthetic GL5 gear oil (~) Loctite or equivalent ® 3M adhesive or equivalent ~) Wheel Bearing Grease Drive UniJt Oil Capacity @: 71 oz. {2100 cc) ® ,t. (197-224 N-m) DR5023 3-39 Checking Gear Teeth Contact Pattern -Upper Gear Unit 1. in order to achieve long gear life and smooth running with minimum noise, you must obtain proper gear tooth contact pattern. The contact pattern will give you a visual clue as to where the teeth are meshing with each other. The proper pattern on theupper gear unit will be checked on the driven gears, (upper and lower) on their respective convex sides. [~ 2. Paint (3) teeth on both the upper and lower driven gears their convex sides with gear marking compound as shown. You can access the gears through the hole of the shift mechanism. The teeth should be completely covered with marking compound, (light coating) from heel to toe and crest to root. [~ Cone clutch should not be installed at this time. [~ 3. insert a piece of wood (approximate size, 1 in. x 2 in. x in.) through the shift mechanismhole and into the driven gear cups. Load gears and turn input gear (6) times in the direction engine rotation (clockwise as viewed from front of the drive). This procedure will require the assistance of another person to turn input gear. Gear Terminology Toe -,# Heel~,,/" ~Root Paint Convex S~de 3-40 vo~.,~ ~,3~ Dismantle the gear set and compare the contact pattern to that of the picture. 4 This picture shows the desired pattern for the drive side of the forward and reverse gear. The drive side is the convex side of the gear. The dye pattern should be nearly oval in form and be positioned half way up on the gear tooth, it should be displaced towards the smalJ end of the tooth (towards the gear cup) but not running off the end of the tooth. ~=~ 5. If the dye pattern reflects a contact pattern as shown in figure 4, the shim thickness behind the double bearing box must be reduced. The drive gear then moves towards the driven gears. The driven gears must be shimmed the same amount to maintain the correct backlash. See condition A under item 7. [~ 6. If the dye pattern reflects a contact pattern as shown in figure 5, the shim thickness behind the double bearing box must be increased. The driven gears must be shimmed the same amount to maintain the correct backlash. See condition B under item 7. VUT~,,g 3-41 Dye Pattern Not Correct 7. To move the pattern add or subtract shims at each location indicated. To maintain gearlash use the samethickness shim on each adjustment. Conditions A. Moving pattern from the heel toward the toe i A B C D E L .......... subtract add subtract subtract * B. Moving pattern from the toe toward the heel A BCDE add subtract add add * @ * When adjusting shim thickness under point C, a clearance of 0.002-0.10 in. (0.05°0.25 ram) must be maintained under the vertical shaft nut. See page3-24, Shimming Vertical Movement Of Upper Driveshaft. When adjusting shim thickness under point C, a clearance of 0.002-0.004 in. (0.05-0.10 ram) must be maintainedunder the top DR~61 cover. See page 3-25, Top Cover Shimming. [~ Gear backlash and contact patterns must be satisfied in consecutive steps, so you must recheck backlash before recheck ing the contact pattern. Clean aii marking compound from gears prior to final assembly. NOTES NOTES Section 4 Lower Gear Unit SX Models Table of Contents Anodes Installation ....................... 4-18 Removal ........................... 4-4 Testing and Replacement ............ 4.21 Vertical Driveshaft Bearing Removal and Installation ....... 4-8 Driveshaft and Gear installation ....... 4=13 Driveshaft and Gear Removal .......... 4-6 Retainer Installation ................ 4-13 Retainer Removal ................... 4=6 Setting Initial Rolling Torque ......... 4-13 Setting Rnal Roiling Torque .......... 4-15 Gear Lash Checking ......................... 4-15 Correcting ........................ 4.15 Lower Gear Unit Disassembly ........................ 4-3 installation ........................ 4-18 Assembly ......................... 4.10 Removal ........................... 4-3 Pinion Bearing Installation ................ 4-12 Bearing Removal ................... 4-8 Shimming .......................... 4-9 Pressure and Vacuum Testing .......... 4.19 Propshaft Bearing Housing Removal .......................... 4.3 Retainer Installation ................ 4.17 Seal and Bearing installation .......... 4-4 Seal and Bearing Removal ............ 4-4 Initial Shimming ................... 4-14 Rnal Shimming ................... 4.17 Propshaft Bearing Installation ................. 4.5 Bearing Removal ................... 4-5 Propshaft Gear and Bearing Bearing Cup Installation ............. 4-12 Bearing Cup Removal ................ 4.7 Installation ....................... 4-11 Shimming ........................ 4-11 Rolling ~rque Setting Final ...................... 4-15 Setting Initial ..................... 4-13 Sealants, Lubricants and Adhesives ...... 4-2 Service Chart ....................... 4.23 Special Tools ........................ 4-2 Specifications ...................... 4-22 Upper Gear Unit Oil Screen ............ 4-10 Drive Uniit Filling .................... 4.20 Safety Warning,.; Before working on any part of the lower gear unit, read the section called Safety at the end of this manual. Several of the following procedures require use of an arbor or hydraulic press. Always wear safety glasses when using this device to perform these procedures. Volvo Penta Special Tools PIN 3850609-3 3850610-1 3850611-9 3850612-7 3850707-5 3850613-5 3850614-3 3850615-0 3850616-8 3850617-6 385061 6.4 3850619-2 3850620-0 3850621-8 3850622-6 3850623-4 3850624-2 3850625-9 3850626-7 3850627-5 3850598-8 3850599-6 3850600-2 3850601-0 3850602-8 3850603-6 Description Drive Handle Drive Handle Puller Bridge Puller Jaws Propeller Shaft Bearing Housing Remover/Instal ler Alignment Plate Support Pinion Nut Holder Remover Propshaft Bearing Installer Spline Socket Guide Plate Installer Bearing Cup installer Pinion Bearing Remover Rod Remover/installer Bearing Remover Shimming Ring Seal Installer Spline Socket Pinion Shim Fixture Shim Fixture Spanner Wrench Gear Lash Extension Retainer installation Tool Sealants, Lubricants and Adhesives Gasket Sealing Compound Volvo Penta Grease Loctite primer or equivalent Loctite or equivalent 3M adhesive or equivalent DuraPlus synthetic GL5gear oil 34133 34132 2O54O Lower Gear Unit Removal [~ 1. With the drlive unit in the fual tiJt downposition, place ;~ 4 quart oil drain pan under the gear unit. L-~ 2. Remove the oil level dipstick so the oil reservoir can vent while draining. [~ 3. Remove lower oil fill/drain plug. Clean off magnet and let drive unit drain completely before removing the lower gear unit. [~ 4. Use the trim/tilt systemto raise drive unit to the full tilt up position. Z~ Be prepared to support the lower gear unit. When the h~st screw retaining the lower gear unit to the upper gear unit is removed, the lower gear unit will be free to drop down. L~ [~] 5. Remove six screws, two on either side ~ and two aft ®. Pull off lower gear unit assembly and mount it into a suitable holding fixture. [~] 6. Mark the location of the trim tab (if one is used) with 34130A felt-tipped marker for future reference. Remove the trim tab screw and trim tab. LowerGear Unit Disassembly Propshaft Bearing Housing Removal [~ 1. Removescrew (~ and inner propshaft bearing housing retainer (~. ~ 2. Remove propshaft bearing housing set screw (~ using Torx T-27 bit. vwr~..0 ~ Safety Related 4-3 214~ 21492 Anode Removal [~ ~ 3. Remove anode retainer screws ~) and retainer (~). Use a Torx T-30 bit for the small screw, and a Torx T-40 bit for the two larger screws. Remove anode © and inspect it; if anode is % its original size (1~ deteriorated), replace it. ~] 4. Using Volvo Penta Propeller Shaft Bearing Housing Remover/ 0nstaller P/N 3850707-5, unscrew propshaft bearing housing counter-clockwise. 21483 Care must be used to prevent damaging the propshaft bearing housing threads. Damaged bearing housing threads can damage the internal gear unit threads. [~ 5. Remove, clean and inspect shim @ it may be reused if it’s not damaged. Discard O-ring (~. Propshaft Bearing Housing - Seal and Bearing Removal [~ 1. Use a punch and hammer to remove propshaft seal from housing. Seal will be damaged during removal and must be repRaced. 20789 [~ 2. Attach threaded rod ® (from Volvo Penta Puller Bridge P/N 3850611-9) to Volvo Penta Two Jaw Puller ~) P/N 3850612-7. Slide Volvo Penta Guide Plate (~) P/N 3850619-2, stepped side facing up, onto threaded rod. Insert Puller into housing, expand jaws tightly behind bearing cup, and pull out cup. Propshaft Bearing Housing -Seal and Bearing installation [’~ 1. Clean and inspect propshaft bearing housing. Assemble Volvo Penta Rod screw P/N 3850623-4 (~, Guide Plate P/N 3850619-2 @ and Seal installer P/N 3850627-5 as shown. Face Rip of seal toward tool, and slide seal onto installer. Apply Gasket 33853 Sealing Compound to metal casing of seal. Press seal into bearing housing until it seats. Apply Volvo Penta Grease to the seal lip. 4-4 VD/’rB/er~g 21488 20760 E~ [~ 2. Apply a light coat of DuraPlus synthetic GL5gearoil to the bearing cup. Using Volvo Penta Rod screw P/N 3850623-4 (~ and Bearing Cup installer P/N 3850621-8, press bearing cup hlto housing until it seats. Propshaft Bearing Removal ~0~] 1. Pull out and inspect propshaft. 2. To remove propshaft bearing, screw propeller nut onto shaft to prevent thread damage. Support bearing and press 20797 propshaft down and out of bearing. Be ready to catch shaft when bearing comes free. Propshaft Bearing Installation [~ Apply a light (:oat of DuraPlus synthetic GL5gear oil to the LD. of the bearing. Slide bearing onto propshaft with taper facing the threaded propefler nut end. Rest Volvo Penta Bearing Installer P/N 3850617-6 (~ on the open jaws of a press support. Position raised lip of Installer up; it must contact nose of bearing. To prevent spline damage, slide Volvo Penta Spline Socket P/N 3850618-4 (~ onto propshaft. Insert propshaft into Installer, and 20796 press propshaft into bearing until it seats. Vertical Driveshaft 8rid Water Tube Guide Removal ~-~ 1. Remove vertical driveshaft and inspect splines, if dam aged, repRace driveshaft. Remove inlet water tube ~ and grommet (~. Discard grommet. E!=-~ 2. Remove anode (~) and inspect it; if anode is % its original size (I/3 deteriorated), replace it. 34128 VDGB/eng 4-5 [~ 3. Remove inlet water tube guide. Inspect seals (~ and ~) the guide. If seals or guide are damaged, replace guide assembny. [~ 4o Remove and replace oil passage O-ring ©. Vertical Driveshaff RetainerRemoval DE] using Spanner Wrench P/N 3850601-0 (~, unscrew retainer and O-ring (~). Discard O-ring. Vertical Driveshaft and Gear Removal 33808 [~ 1. Screw Volvo Penta Pinion Nut Holder P/N 3850615-0 (~ onto Volvo Penta Drive Handle P/N 3850609-3 ~), and slide Volvo PentaAlignment Plate P/N 3850613-5 ~) onto handle. [~ 2. Insert pinion nut holder pilot into drive gear while turning driveshaft to align pinion nut with holder. Slide Spline Socket P/N 3850598-8~ onto driveshaft. 33806 34793 33821A ~] 3. To remove pinion nut, turn driveshaft counter-clockwise. 4. Removeand retain pinion nut and pinion. ~"~ [~] 5. Lift out: vertical driveshaft assembly, then remove propeller shaft gear assembly. The 19 pinion roller bearings may fall out of the retainer; remove and retain the roller bearings. Propshaft Gear - Bearing Cup Removal 1. Use a three-j’aw puller such as OwatonnaTool P/N 0EM4184 to remove the bearing cup and shims. ~-~ The shims will be damaged during removal and must be replaced on reassembly. 33818 33842 214.35 !, 20795 33848 2. Do not remove propshaft gear bearing unless you intend to replace it. Removal process may damage bearing. Use a bearing separator to support the bearing, insert Volvo Penta Bearing Remover P/N 3850625-9 ~) and Volvo Penta Drive Handle P/N 3850810-1 (~) into gear, then press gear out of bearing= ~] 3. Do not remove oil slinger from gear unless you intend to replace it, Removal process may damage oil slinger. Use a bearing separator to support the oil slinger, and press gear out of oil slinger. Pinion Bearing Removal 1. Use Volvo Penta Two-Jaw Puller P/N 3850612-7 © and Volvo Penta Puller Bridge P/N 3850611-9 (~), to remove vertical driveshaft bearing cup (~) and shims. The shims will be damaged on removal of bearing cup and must be replaced. [~ DE] 2. To remove pinion bearing, apply Volvo Penta Grease to the bearing rollers and place them in the bearing case. Use Volvo Penta Rod P/N 3850623-4 ®, Guide Plate P/N 3850619-2 @ and Pinion Bearing Remover P/N 3850622-6 ®. [~ ~ 3. Wear Saf~y Glasses. Install remover into pinion bearing. Using a hammer, drive pinion bearing down and out of gear unit. Clean and inspect gear unit. Vertical Drlvesheft Bearing Removal and lnstal|ation Do not remove vertical driveshaft bearings unless you intend to replace them. Removal process may damsge bearings. [~ 1. Note size, position, and direction of taper of the verticam driveshaft bearings for reinstaJnation. Using a bearing separator and press, remove bearings. 33799 21433 33798 338OO Safety Related 4-8 VDJl"B/eng ~ 2. Apply a light coat of DuraPlus synthetic GL5gearoil to the I.D. of the small bearing. Protect threads of vertical driveshaft by installing a pinion nut O onto vertical driveshaft. Slide bearing onto vertical driveshaft with taper facing pinion end. Rest Volvo Penta Bearing Installer P/N 3850617-8 (~) on open jaws of a press support. Position raised lip of Installer up; it must contact backside of bearing. Insert vertical driveshaft into Installer, and press verticaR driveshaft into bearing untiJ it seats. ~ 3. Apply a light coat of DuraPlus synthetic GLhgear oil to the LD. of the targe bearing. Smide bearing (~) onto vertical driveshaft with taper facing away from small bearing. Rest Volvo Penta Bearing Installer PiN 3850617=6 (~ on open jaws of a press support. Position raised lip of installer up; it must contact nose of bearing. Insert vertical driveshaft into Instalmer, and press verticam driveshaft into bearing until it seats. Pinion Shimming This procedure determines the amount of shims required to properly position the pinion in relation to the propshaft gear. Record the fo||owing shimming measurementfor the final gear lash check. ~] 1. Clamp Spline Socket P/N 3850598-8 © into a vice and slide vertical driveshaft into socket. Install small bearing cup (~ onto bearing. Slide Pinion Shim Fixture P/N 3855098-4 ® onto vertical driveshaft with the three slots @ facing threaded end of vertical driveshaft. ~] 2. Install pinion and pinion nut. Tighten pinion nut to 150-1 £K) ft. Ibs. (203-217 N.m). Rotate shim fixture to seat bearing for shimming purposes. 3. Check all three shots with feeler gauge and record each reading. Average the three recorded feeler gauge readings by adding them together, then dividing by three. Example: Slot no. 1 = .011 in. .028 in. + 3 = .0093 in. Slot no. 2 = .009 in. (Round off to .009 in.) Slot no. 3 = .008 in. Total .028 in. 33810 33809 33850 I 33813 VD/T~deng 4~9 32563 33801 4. Remove pinion gear and discard the nut. [~ 5. Add or subtract the shimming allowance number etched on the gear from the number found in Step 3. If the number is etched +5, you would add .005 in. to the number, if the etched number is -5, you would subtract .005 in. from the number. If the number is zero (0), you would add or subtract nothing from the number. Example: 33802 .009 in. figure from Step 3 +.005 in. figure etched on gear .014 in. shims required 6. Record dimension (example: .014 in.) for the pinion bearing shim. No less then one shim but no more then three shims should be used to obtain the average recorded shim thickness. 33803 Upper Gear Unit Oil Screen Removethe oil screen (~) from the upper gear unit. Clean and replace as necessary, install the oil screen into the oil passage in the upper gear unit. Make sure the screen is secure. Lower Gear Unit Assembly [~ 1. The selected pinion shims (~) are installed into the gear unit under the lower small bearing cup. 33849 ~] [~ ~ 2. Apply a light coat of DuraPlus synthetic GL5gear oil to the small bearing cup. Wear Safety Glasses. Install bearing cup © on top of shims with cup taper facing up. Use Volvo Penta Rod P/N 3850623-4 (~), Guide Plate P/N 3850819-2 ® and Bearing Cup installer P/N 3850621-8 ® to install bearing cup. Place Cup installer on cup, then seat Guide Plate (~) onto gear unit. Use hammer to seat bearing cup. Safety Related 4-10 VD/]~eng Propshaft Gear -Bearing Installation ~t~ This procedure determines the amount of shims required to properly position the propshaft gear in relation to the pinion. Record the following shimming measurement for the final gear lash check, ~ 1. Apply a light coat of DuraPlus synthetic GL5gearoil to the propshaft gear and oil slinger. Align the pins @ of oil slinger with the hoaes of the propshaft gear. Use Volvo Penta Support P/N 3850614-3 (~) and Volvo Penta Propshaft Bearing Installer P/N 3850617-6 (~ to press oil sJinger onto gear untiJ seated. ~] 2. Apply a light coat of DuraPlus synthetic GL5gear oil to the bearing. Slide new bearing onto propshaft gear with taper facing away from gear. Position nose of Volvo Penta Remover~Installer PiN 3850624-2 (~ onto bearing, and press bearing onto gear until it i,,~ seated. Propshaft Gear Shimming ~] 1. Place gear and bearing (~ on a flat surface. Place the bearing race (D on top of the bearing. Rotate the race to seat the bearings. Position Shim Fixture P/N 3850600-2 ~ on top of the gear and bearing assembly, recessed side facing down. ~__] 2. Using a depth micrometer, measure the distance from the top of the shim fi×ture @ to the end of the gear shaft. Subtract .500 in. from this measurement. Examp|e: I Subtract: .597 in. measurement to end of gear shaft -.500 in. thickness of shim fixture .097 in. actual dimension ~] 3. Add or subtract the shimming allowance number etched on the gear from the actual dimension in Step 2. If the etched number is +5, you would ADD .005 in. to the actual dimension in Step 2. Jf the etched number is you would SUBTRACT -5, .005 in. from the actual dimension in Step 2. if the etched number is zero (0), you add or subtract nothing from the actual dimension in Step 2. Example: C Add/Subtract: .097 in. actual dimension in Step 2 .000 in. etched number (0) on gear .097 in. total 33847 34788 34794 4. Subtract the total figure in Step 3 from a nominan dimension of .106 in. This new totat is the number of shims required to position the propshaft gear. Example: .106 in. nominal dimension .097 in. total from Step 3 .009 in. total shims required Propshaft Gear - Bearing Cup installation [~ 1. Semect the correct number of shims to equaJ your recorded measurement.Place shims into recess of bearing cup bore. No less then one shim but no more then three shims should be used. E~ 2. Apply a light coat of DuraPlus synthetic GLSgear oil to the bearing cup. Place bearing cup on top of shims in lower gear unit. ScrewVolvo Penta Remover P/N 3850618-8 (~ onto Volvo Penta Drive Handle P/N 3850809-3 (~). Slide Volvo PentaAlignment Plate P/N 3850813-5 © onto handle. 3. Use a wooden 2x4 or 2×8 to cushion forward gear unit edge. Drive bearing cup in until seated. Pinion Bearing installation [~ 1. Apply Volvo Penta Grease to the roller bearings and install bearings into pinion bearing race. 2. Apply a light coat of DuraPlus synthetic GL5 gear oil to pinion bearing. Install pinion bearing ~) onto Volvo Penta Instalmer PIN 3850620-0 (~). Slide Volvo Penta Guide Plate P/N 3850619-2 (D onto Volvo Penta Rod P/N 3850623-4 (~). insert rod into gear unit andscrewinto installer (~). [~ 3. Turn Volvo Penta Rod P/N 3850623-4 until pinion bearing is seated, then unscrew and remove tools. [~ if Installer turns in bearing, screw Volvo Penta Pinion Nut Holder P/N 3850615-0 (~ onto Volvo Penta Drive Handle P/N 3850609-3 (D and slide Volvo Penta Alignment PUate P/N 3850613-5@ onto handle. Insert into gear unit and hold pinion installer. 20778 20777 21431 20772 4-12 VD/TB/eng ® 1 1 1 ~:" ®/ 20730 33841 33817 Vertical Driveshaft and Gear installation [~] 1. Install propshaft gear and bearing assembly (~ into gear unit. Position pinion above propshaft gear in gear unit pinion pocket. Engage pinion teeth O with propshaft gear teeth, install vertical driveshaft ~) into gear unit and engage pinion splines. insert vertica~ driveshaft carefully so pinion bearing rollers aren’t dislodged. 9~ 2. Apply a light coat of DuraPlus synthetic GLSgear oil to the 33816 upper bearing cup. Place cup in housing, and push down until it seats on vertical driveshaft bearing. Vertical Drivashaft Retainer Installation [~ 1. Screw in vertical driveshaft retainer using Spanner WrenchP/N 3850601-0 (~), and seat upper vertical driveshaft bearing cup. ~] 2. Apply Loctite primer or equivalent to the threads on the vertical driveshaft and let air dry. Apply Loctite or equivalent to the threads. Install a new pinion nut onto verticam driveshaft. 34795 Screw Volvo Penta Pinion Nut Holder P/N 3850615-0 ® onto drive handne P/N 3850609-3 O, slide Volvo Penta Alignment Plate P/N 3850813-5 @ onto handle, then insert into propeller shaft gear. ~-~" 3. Install Spline Socket P/N 3850598-8 ~) onto vertical driveshaft and tighten pinion nut to 150-160 ft. Ibs. (203-217 N-m). ® Setting initial Rolling Torque [’N-~ This procedure will ensure bearing life by setting the vertical driveshaft rolling torque. Turn gear unit so that propshaft boH’e is vertical. This will ensure the propshaft gear will not 33821A interfere with the pinion rolling torque measurement. Record the following shimming measurement for the final roiling torque setting. 4-13 1. Turn vertical driveshaft several times to ensure bearing is seated before each torque reading. EEl 2. Tighten vertical driveshaft retainer (~ to achieve a vertical driveshaft rolling torque of 2-4 in. Ibs. (0,22-0,45 N-m). Record rol|ing torque setting. initial Propshaft Bearing Housing Shimming This procedure determines the amount of shims required to preload the propshaft bearings, and also ensures bearing life by setting the vertical driveshaft/propshaft rolling torque. 33827 1. ApplyDuraPlus synthetic GL5gear oil to the threads of the propshaft bearing housing. Use Volvo Penta Grease to hold ShimmingRing (.160 in.) P/N 3850626-7 (~), and place Shim on housing. Do not install O-ring at this time. 2. Screw in propshaft bearing housing. Attach torque wrench to Volvo Penta Propeller Shaft Bearing Housing Remover/ ° installer P/N 3850707-5 © at a 90 angle, and tighten housing to 80 ft. Ibs. (108,5 N-m). Record the following shimming measurementfor the final 21486 gearlash check. [~ 3. Determine depth of propshaft bearing housing. Measure from gear unit hub edge ~) to top of each bearing housing rib ~). Record and average the measurements. Example: Rib no. 1 = .403 in. 1.208 in. + 3 = .4026 in. Rib no. 2 = .407 in. Rib no. 3 = .398 in. 20810 Total 1.208 in. 4. Roundoff division figure (example: .403 in.), and add .160 in. (Shimming Ring P/N 3850628-7) to rounded off number (exampie: .403 in. + .160 in. = .563 in.). This result will be used later to determine the amount of shims required for the propshaft bearing housing. [~ 5. Unscrew propshaft bearing housing and remove bearing housing Shimming Ring P/N 3850626-7 (~). Setting Final Roiling Torque ~] Install propshaft and bearing housing. Use Volvo Penta Propeller Shaft Bearing Housing Remover/Installer P/N 3850707-.5 ® and Spline Socket P/N 3850598-8 ~) to turn vertical driveshaft ancl tighten bearing housing. This will set final rolling torque for the lower gear unit. Set rolling torque at 14-23 in. Ibs (1,58-2,60 N.rn) for 1.51 and 1.60 gear ratio drive units and 11-18 in. Ibso (1,24-2,03 N-m) for 11.66 and 1.85 gear ratio drive units. Gear Lash Checking ~ 1. Install a Volvo Penta propeller without the thrust washer. Install the brass spacer and prop nut. Tighten the prop nut by handuntil the propshaft does not rotate freely, 1~’] 2. Slide Gear Lash Extension P/N 3850602-8 ® onto drive- shaft splines. ~=J 3. Clamp or hold base of dial indicator onto machined surface of gear unit. Position dial indicator perpendicular to flat surface of gauge arm. Dial indicator must contact groove O on gauge arm for an accurate reading. Rotate gauge arm and dial indicator should read between .005-.012 in. (0,13-0,30 ram). If reading between .005-.012 in. (0,13-0,30 mm)is obtained, remove propeller and continue to page 4-17 Final Propshaft Bearing Housing Shimming. Correcting 1. ~f dial indicator reading is less then .005 in. (0,13 ram) or more then .012 in (0,30 mm), all shimming operations must be remeasured. If corrections are made in the rechecking of the shimming operations, and a gear lash of .005-.012 in. (0,13-0,30 mm) obtained, continue to page 4-17 Final Propshaft Bearing Housing Shimming. 33840 26587 33828 2. if all rechecked shimming operations are the same as the originan recorded shimming operations, and the recorded gear lash is stimn less then .005 in. (0,13 ram) or more then .012 in. (0,30 ram), continue with the following procedure: Subtract the gear lash measurement from .012 in. (upper limit of correct gear lash range), and divide by two. .012 in. Upper limit of correct gear lash range -.004 in. Gear lash measurement .008 in. Result .008 in. + 2 = .004 in. correction needed Round off to nearest thousandths of an inch (i.e..004 in.) needed. This example requires the addition of .004 in. shim under the lower driveshaft bearing cup, and .0~t in. shim removed from behind the propeller gear bearing cup. The optimum gear lash measurementis .0085 in.. Subtract .005 in. (lower limit of correct gear lash range) from the incorrect gear lash measurement, and divide by two. .015 in. Gear Rash measurement -.005 in. Lower limit of correct gear lash range .010 in. Result .010 in. + 2 = .005 in. correction needed Round off to nearest thousandths of an inch (i.e..005 in.) needed. This example requires the removal of .005 in. shim from under the lower driveshaft bearing cup, and .005 in. added behind the propeller gear bearing race. The optimum gear lash messute ment is .0085 in. Final Propshaft Bearing Housing Shimming ~__,~] 1. Determine depth of propshaft bearing housing. Measure from gear unit hub edge (~) to top of each bearing housing rib ~). Record and average the measurements. Example: Rib no. 1 = .443 in. 1.335 in, + 3 = .445 in. Rib no. 2 = .447 in. Rib no. 3 = .445 in. Total 1.335 in. Subtract this figure from first recorded measurement (example: .563 in. -.445 in. = .118 in.). The result will be the amount of shims required for the propshaft bearing housing. A .118 in. shim is required for the propshaft bearing housing in this example. ~] 2. Apply DuraPius synthetic GL5 gear oil to O-ring © and threads of propshaft bearing housing. Apply Volvo Penta Grease to the selected shim ring to help hold it in place, then attach shim @ to bearing housing, install assembly into gear unit. ° ~] 3. mnstali torque wrench at a 90 angle to Volvo Penta Propeller Shaft Bearing Housing Remover/installer P/N 3850707-5. Tighten bearing housing to 200-225 ft. Ibs. (271-305 N.m). Recheck final total rolling torque to make sure it hasn’t changed. ~’==ot~ If finaU rolling torque is too high (more than 23 in. tbs. (2,,6 N.m) for 1.51 and 1.80 gear ratio drive units and 18 in. ibs (2,03 N.m) for 1.66 and 1.85 gear ratio drive units), remove the propshaft bearing housing shim ring and instalm the next size larger shim ring. Recheck finan rolling torque. 2(}815 If ~nal roiling torque is too low (less than 14 in. Ibs. (1,58 N-m) 1.51 and 1.60 gear ratio drive units and 11 in. Ibs. (1,24 N-m) for 1.66 and 1.85 gear ratio drive units), remove the propshaft bearing housing shim ring and install the next size smaller shim ring. Recheck final rolling torque. ~’~ot~ Prior to continuing, refer to page 4-24 Checking Gear Teeth Dye Pattern. Propshaft Bearing Housing -Retainer Installation 20553 E~] 1. Apply Loctite primer or equivalent to set screw, let dry, then apply Loctite or equivalent. Tighten set screw no more th~Ln 42-60 in. ibs. (4,8-6,8 N-m). ~t~ Bearing housing lip will be distorted or broken if set screw is tightened more than recommended. vD/~°,~ 4-17 33838 33837 2. Apply Gasket Sealing Compound to the bearing housing retainer screw. Make sure retainer and retaining screw are correctly oriented in the Retainer Installation Tool P/N 3850603-6 ~). Position retainer and screw ® inside exhaust chamber ©. [~ 3. Use a 1/4 in. drive and 3/8 in. socket to instatl retainer screw. Tighten the retaining screw to 20-25 ft. Ibs. (27-34 N-m). Removethe installation tool with a twisting motion and remove it from the exhaust chamber. AnodeInstallation 21494 [~ 1. When installing, curvature of anode @ must match curve of propshaft bearing housing. Position anode in lowest position allowed by mounting holes. Apply Gasket Sealing Compound to the long pointed screw (~), and install into bracket ®, wave washer ~) and anode. Hand tighten screw. [~] 2. Apply Gasket Sealing Compound to the washered screws ®, and instalm into bracket. Tighten to 12-14 ft. Ibs. (16-19 N.m). Tighten anode screw (~) to 60-84 in. Ibs. (6,8-9,5 N-m). LowerGearUnit Installation DE] [~ 1. Apply 3Madhesive or equivalent to the seal lip O on the bottom of the water tube guide and to the inside of the watertube grommet O. 29374 ~] 2. Install water tube guide ~) and four screws. Apply Gasket Sealing Compound to each screw, and tighten to 10-12 ft. nbs= (14-16 N-m). Apply DuraPlus synthetic GL5gear oil to a new vertical driveshaft retainer O-ring (D and new oil passageO-ring ~. anstaml O-rings into grooves. 29375 ® 4-18 33~s VD/3=B/eng 34128 34127 3. install anode and secure with two screws (~). Tighten tile screws to 60-84 in. lbs. (6,8-9,5 N-m). ~ 4. Install coupler ~)with the groove ® facing upward, onto vertical driveshaft. [~ [~ 5. Install and position water grommet (~) and supply tube ® into upper gear unit. Check oil filter (~ for proper installation. Care must be, used on reassembly of gear unit. if machined surface is damaged, leakage may occur. [~ 6. Attach lower gear unit to upper gear unit. Engage coupler ~) spUnes and water supply tube ®. ~3~ 7. Apply Gasket Sealing Compound to the lower gear unit mountingscrews. Install four short screws, two on either side (~ of gear unit, and two longer screws ~) aft. Tighten ~-16 screws to 22-24 ft. Ibs. {30-33 N.m) and 7As-14 screwsto 32-40 ft. Ibs. (43-54 N-m). 8. Install trim tab (~) (if equipped}. Tighten mounting screw 34124 14-16 ft. Ibs. (19-22 N-m). Pressure and Vacuum Testing Drive Unit Before filling drive with gear unit oil, it must be pressure and vacuumtested to verify proper sealing during assembly. Remove magnetic drain plug on side of gear unit skeg. Install and tighten oil level gauge at top of drive. 34131 v0~ 4-19 Pressure Testing 1. Attach a pressure tester (such as a Stevens S-34) to skeg drain hole, and pressurize drive to 3-5 PSI (20,7-34,5 kPa). Rotate propeller shaft and U-joint shaft to checksealing. If pressure less is indicated, use a soapy water solution or submerge drive in water to find source. Make necessary repairs then repeat test. EEl 2. if pressure loss is not indicated, increase pressure to 16-18 PSI (110-124 kPa). Again, use a soapy water solution or submerge in water to find source if drive looses pressure. Make repairs as necessary and repeat test. Drive must head pressure before making vacuum test, and must not loose more than 1 PSI (6,9 kPa) in 3 minutes. Vacuum Testing EEl 1. Attach a vacuum tester (such as a Stevens V-34) to skeg drain hole, and pull vacuum to 3-5 inches of mercury (10-16,8 kPa). Rotate propeller and U-joint shaft to check sealing. If drive does net hold vacuum, apply a heavy oil to seal and gasket surfaces to find source. Make necessary repairs then repeat test. No loss of vacuum should occur on low test. EEl 2. if vacuum loss is net indicated, increase vacuum to 14-16 inches ef mercury (47-54 kPa). Again, apply heavy oil to find source if drive will net hold vacuum. Make repairs as necessary and repeat test. Drive must not loose more than 1 inch of mercury {3,4 kPa) in 3 minutes. Drive Unit Filling [~ Do not fill drive unit with oil until it passes both pressure and vacuum tests. Drives that fail either test will allow water entry when in use and cause subsequent damage to internal parts. EEl I~] 1. Place drive in a vertical position. Remove the rear plastic cover te aUlow access to the oil level plug. Remove the eli level plug (~. Also remove the level indicator gauge at top ef drive to help vent the oil reservoir. Discard the plug and gauge seal ®. Replace them with new ones. EEl 2. Remove magnetic drain screw on side of skeg. Discard screw sear and replace with a new one. EEl EEl 3. Fill drive with DuraPius synthetic GL5gear oil from skeg drain hole. Fill slowly to purge trapped air. Stop filling when the oil level reaches the bottom ef the ell level hole (~). Do not overfill. Filling drive too quickly may form air pockets that will cause an inaccurate oil level reading. Running drive with improper oil level can result in immediate internal damage. 34125A 217gg 4-20 VO/’rB/eng ~ [~ 4. When oil reaches proper level, stop filling and screw in the level plug and gauge. This will create an air lock to prevent excessive oil loss while drain plug is installed. Apply Gasket Sealing Compound plug, and tighten to 60-84 in. Ibs. to the fill (6,:8-9,5 N-m). Apply Gasket Sealing Compound plug and to the fill gauge. Tighten them to 48-72 in. Ibs. (5,4-8,1 N-m). [~ 5. After drive has been run, recheck oil level. Add make-up oia through gauge opening to bring oil up to the proper Ueven within range © on the dipstick. Anodes -Testing and Replacement Anodeerosion or disintegration in salt or brackish water indicates they’re performing their function. Anodes should be inspected and/or replaced at intervals, or corrosion of the drive will increase. The lower gear unit has anodes located in three places: at the front and rear of the gear unit above the anti-ventilation plate, and on the propshaft bearing housing. [’Not~ If any anode has been reduced to two-thirds its original size (one-third eroded), it must be replaced. Test for proper installation of the anode. Set an ohmmeter to the low ohms scale. Connect one ohmmeter lead to a good ground, and the other to the anode. Be sure anode surface is clean to make good contact. Ohmmetershoumd indicate a very low reading (zero). If not, remove the anode and clean the mounting screws, the anode, and the area where the anode is installed. Install and retest the anode. Do not paint or otherwise coat the anodes. This will prevent them from functioning properly. If anode appears to be corroded on its surface, but is not deteriorating, it should be repnaced. Specifications __ = Description U.S. Metric Propshaft bearing housing 200-225ft. Ibs. 271-305 N-m Nut Pinion gear 150-160ft. Ibs. 203-217 N-m Screw Anode 60-84in. I bs. 6,8-9,5 N-m Anode retainer 12-14 ft. Ibs. 16-19 N-m Fill and drain 60-84in. I bs. 6,8-9,5 N.m Lower to upper gear unit %-16 22-24ft. Ibs. 30-33 N-m zAe-14 32-40 ft. Ibs. 43-54 N-m Oil level gauge 48-72 in. Ibs. 5,4-8,1 N.m Retainer, propshaft bearing housing 20-25 ft. Ibs. 27-34 N-m Set screw, propshaft bearing housing Trim tab to gear unit 42-60 in. Ibs. 14-16ft. Ibs. 4,8-6,8 N-m 19-22 N-m Water tube guide 10-12ft. Ibs. 14-16 N-m Loctite primer or equivalent e Lower vertical driveshaft (pinion nut} threads e Set screw, propshaft bearing housing Loctite or equivalent e Set screw, propshaft bearing housing Volvo Penta Grease e Seal lips e Shim ring, propshaft bearing housing DuraPlus synthetic GL5 gear oil o Threads, propshaft bearing housing e O-ring, forward oil passage ® O-ring, vertical driveshaft bearing re tainer Gasket Sealing Compound ¯ O.D. all metal case seals ¯ Gauge,gear unit oil level ¯ Screw, anode ¯ Screws, anode retainer ¯ Screw, drain and fill ¯ Screws, lower to upper gear unit ¯ Screw, propshaft bearing housing re tainer ¯ Screws, water tube guide 3Madhesive or equivalent ¯ Seal lip on water tube guide 4-22 vwr~.,0 Service Chart .. Sealants, Lubricants, Adhesives and Torque Values DR4998 CA_.)Volvo Penta Grease (~ Gasket Sealing Compound © Volvo Penta Grease ~) OuraPlus synthetic GL5 gear oil Loctite or equivalent ~) 3M adhesive or equivalent O Drive Unit Oil Capacity @: 71 oz. (2100 ml) t¢~ /~ 10-12 ft. Ibs. ~" ~ .L~ (14-16 N.m) \e I//.. ,oo,.o,,,.. (~ L’~~~ (~ (203-217 hi.m)" I (19-22 N.m) 32-40 ft. Ibs. 60-84 in. Ibs. (43-54 N.m) 16,8-9,5 N.m) g (4,8-6,8 N.m) 22-24 ft. Ibs. t ~ 60-84 in. Ibs. ~~ I~ (6,8-9,5 Nom) 60-84 in. lbs.~ /1~ (6,8-9,5 N.m) /-1/1/ . 0-25 ft. Ibs. jf -~j ==~\ .11// f ~ \ ~(27-34N.m) (16-19 N.m) ~, ~’ D~200-225 ft" ‘bs" vorr~o,= 4-23 DR4998 Checking Gear Teeth Dye Pattern -Lower Gear Unit 1. in order to achieve long gear life and smooth running with minimum noise, you must obtain proper gear teeth contact pattern. The contact pattern will give you a visual clue as to where the teeth are meshing with each other. The proper pattern on the lower gear unit will be checkedon the propshaft gear on the convex sides. ~] 2. Paint (3) teeth on their convex sides with gear marking compoundas shown. The teeth should be completely covered with marking compound, (light coating) from heel to tow and crest to root. For right hand rotation drives, the convex side should be painted. For left hand rotation drives, the concave side should be painted. DE] 3. Then reassemble drive as previously outlined. Turn the vertical drive shaft in the direction of rotation. While turning, brake the propeller shaft movement to simulate load. ~nvex de Paint 4-24 vom~e~ 4. Removethe bearing carrier and the propshaft, and inspect thepropshaft gear contact pattern. 5. Checkthat the contact pattern on the surface of the driive side matches figure 3. The pattern should be positioned in the middle of the tooth but displaced towards the small end. E~ 6. ff the contact pattern corresponds to that of figure 4 (contact pattern running off the tool, you must add shims of equal amountsof thickness to the prop shaft bearing and vertical shaft bearing. E~ 7. ff the contact pattern corresponds to that of figure 5 (contact pattern running off the heel), you must subtract equal amountsof shim thickness from the prop shaft and vertical shaft bearings. 8. Gear backlash and contact patterns must be satisfied in consecutive steps, so you must recheck backlash before 1;he contact pattern. Clean al| marking compound from the gearsprior to final assembly. m vwr~,,0 4-25 NOTES Section 5 Drive Unit Removal and Installation SX Models Table of Contents Check and Adjust Trim Sending Unit ................... 5-7 Shift and Throttle Cable installation ................... 5-7 Shift Cable installation ............................ 5-8 Throttle Cable Installation ........................ 5-11 Drive Unit installation ..................................... 5-4 Rernoval ....................................... 5-2 Safety Warningls Before beginning work in this section, read Safety chapter at end of this manual. Proper installation is important for the safe, reliable operation of all mechanical products. The procedures we recommend and describe in these instructions are effective methods to be folrowed when installing Volvo Penta stern drive products. Some of these methods require the use of tools specially designed for the purpose. The special tools should be used when and as recommended. Drive Unit Removal Specia| Tools Required: ® Hoist Capable of Lifting at Least 500 lb. (227 kg), or Drive Unit Dolly ¯ Lifting Eye (1~-13 thread) ¯ Drive Unit Holding Fixture The boat must be out of the water on a trailer, or in a cradle, for removamof the drive unit. Whena drive unit dolly is used for removal, omit steps 1 and 2. [~ 1. Remove oil level indicator from upper gear housing. [~ 2. Fully thread a lifting eye into upper gear housing oil indicator hole. [~ 3. Remove and retain the three shift linkage access cover screws (~ and cover ®. 4. Remove jam nut © from shift cable. Remove cotter pin and washer (~ from cube ®. Unthread the cube from the shift cable. 5. Loosen screw ® securing cable anchor clamp ~). Slide the anchor to starboard to unfasten the shift cable. Turn the drive unit to port and remove the shift cable. 3~38 5-2 VD/’rB/eng [~S-"~ 6. Remove wasl~er and retain end cap (~), lock nut (~ and flat 0 from trim/tilt pivot rod. [~ 7. Use a soft hammer to lightly tap trim/tilt pivot rod out of trim/tiLt cylinder. ~B’~ [~ 8. Support hydraulic cylinders (~) while removiing pivot rod. Carefully mower each hydraulic cylinder after pivot rod is, removedto prevent damage to hydraulic lines. 9. If bushings come out with pivot rod, be sure to retain groundingdips for installation (one (1) clip for each side). E,~ ~ 10. Attach a hoist capableof lifting at [east 500 lb. (;.P27 kg) to lifting eye, or use a dolly to hoUd drive unit. Removeand discard six lock nuts (D Volvo Penta P/N 3853329-5. D0~ 11. Pull drive unit away from transom shield and support driveshaft ~) and universal coupler ~). 25728 35061 / 35082 35064 v~m~e,o ~ Safety Related 5-3 34064 Installation of Drive Unit JT] 1, Remove oil indicator plug and gasket, install a lifting eye into the oil level hole. A drive unit cart may also be used if access is blocked by a swim platform. 2. Apply a light coat of Volvo Penta Grease to tapered end (~) of pinion bearing carrier. [~ 3. inspect molded rubber seal ring for proper fit in its groove. inspect and lightly lubricate U-joint bellows lip ® with Volvo 34060 Penta Grease. 4. Slide alignment tool © through gimbal bearing (~). The alignment tool must slide through the gimbai bearing and into engine coupler with ease. if the alignment tool binds going into engine coupler, the front engine mount(s) must be adjusted either "up" or "down, or side-to-side" as required, until alignment tool slides in and out of engine coupaer with ease. [~ 5. Remove and retain the three shift linkage access cover screws (~) and cover 3405g I~ 6. Shift drive unit into gear by rotating the eccentric piston arm (~) either up or down. [~] 7. Apply Gasket Sealing Compound to the six studs. 34422 5-4 34056 TBND/eng 2743A ’ES~ 8. Lubricate the driveshaft Grease. splines with 35058 Molybdenum I 34055 J 9. Lightly lubricate the two driveshaft O-rings ® with Dura- PlusTM Synthetic Motor Oil, SAE 30. Grease in the O-ring grooves canhydraulically lock the O-rings and cause difficulty starting llhe d~riveshaft into the gimbal bearing. 10. Grease both U-joint Grease. fittings O with Wheel Bearing Eg~ 11. Lubricate the outer surface of the universal coupler (~ with Volvo Penta Grease. DR2023 ~0~] 12. Slide driveshaft and universal coupler (~ into U-joint bellows. ~1~] 13. To align the driveshaft spiines, rotate propeller shaft until the driveshaft spiines engage the flywheel coupler. ~2~ 14. Slide drive unit onto the six studs until it is completely seated against the pivot housing. Install six Iocknuts ® (three on each side) Volvo Penta P/N 3853329-5. ~3~ [~ 15. Tighten the nuts in two steps. Use a 3/8 in. drive, % in. swivel socket to tighten nuts to an initial setting of 25 ft. Ibs.( 34 N-m). Start with the center nut and work in a crisscross patterr to secure the drive unit to the pivot housing. Use the same crisscross pattern to tighten all six Iocknuts to a final setting of 50 ft. Ibs. (68 N-m). % DR1074 5-5 VD;’TB4eng 34699 34701 16. If a drive unit cart has been used, remove it at this time for installation of the trim/tilt cylinders. Apply Vo/vo Penta Grease to the trim/tilt pivot pin (~). Prior to installing bushing, be sure ground dip is installed properly. [~ 17. install bushings in trim/tilt cylinder end and in upper housing boss (E). Usecare when installing trim/tilt pivot pin or bushings can 347G2 be damaged. EEl 18. Align trim/tilt cylinder end with upper housing boss. Slide trim/tiff pivot pin (~) through trim/tiff cylinder and upper gear housing. Prior to installing bushing, be sure ground clip is installed properly. [~] 19. install bushings in trim/tilt cylinder end and in upper gear housing boss (E). 34O48 [~ 20. Align and slide pivot pin through trim/tilt cylinder end. mnstali flat washer and Iocknut. EEl 21. A two step tightening procedure is required. First tighten each [ocknut until equaR amounts of thread are exposed on both ends of the trim/tilt pivot pin. Then tighten each Iocknut to 10-12 ft. ~bs. (14-18 N.m). [~ 22. Install and secure Iocknut cover protectors onto pivot pin. 18442A 5-6 VO,,q’B/eng 15036 Check and Adjust Trim Sending Unit Push trim/tilt switch to the down position. Drive unit must be in a full trim-in position before adjusting the trim sending unit. [~ 1. Turn steering wheel to full port for access to trim gauge sending unit. Loosen trim gauge sending unit screws © on starboard side of gimbal ring. [~ 2. Rotate trim gauge sending unit as required to achieve a full down reading on the trim gauge. 3. Tighten trim gauge sending unit screws © to 24 in. Ibs. (2,7 N-m). Shift and Throttle Cable installation 1. If the remote control shift and throttle cables are installed in the remote controls, proceed to Shift Cab|e Installation. 2. If the remote control shift and throttle cables have not been installed, the following procedure will permit you to order lIhe correct length remote control shift and throttle cables. ~0~ 3. Measure the proposed route of the remote control shift and throttle cables. All bends must have a radius greater than 6 inches (15,2 cm). ¯ Remotecontrol shift cable: Add ~)+(~ plus 20 in. (50,8 cm), round up to next cable length. o Remote control throttle cable: Add @+®+(~ plus 4 in. (10,1 cm), (® is to center of throttle pin}° Round up to next cable length. ® ® ® 34045 34044 Shift Cable|nstallation Remote control type cables. shift and throttle cables must be SAE [~ 1. if the throttle cable is attached to the throttle arm and anchor bJock, remove it from both. The throttle cable must be disconnected from the throttle arm prior to shift cable installation and adjustment to prevent "’loading" the control box and adversely affecting shift adjustments. E~ 2. Note position of small seal ~) and large seal (~) of the shift cable. Remove and retain jam nut, small seal, and large seal from the shift cable. J~ 3. Apply a light coat of Volvo Penta Grease to the end of the remote control shift cable casing. Slide shift cable through transom sleeve and connector assembly until it appears on the outside of the transom. ~] 4. For ease of installation of shift cable, turn drive unit to port. Reinstall the retained large seal (~) and small seal (~)onto shift cable in the sameposition as noted in step 2. [~] 5. Loosen cable anchor clamp © and slide to starboard. [~ 6. Slide shift cable through pivot housing and drive unit. [~ ~ 7. Slide anchor clamp in, engaging the shift cable anchor groove. Tighten anchor clamp screw securely. 34041 .© 34039 34037 34O38 Safety Related 5-8 34427 34421 El [~ 8. Rotate eccentric piston arm to extend belicrank (~. Removecotter pin, flat washer, and cube (~. [~ 9. Thread cube halfway onto remote control cable end. 10. Rotate shift lever back to neutral detent position, then move remote control handle to its neutral detent position. "Pdrn cube IN or OUT until it aligns with center of belncrank slot ®. [~ ~ 11. Install flat washer and cotter pin. Bend prongs of cotter pin for a secure attachment. |nstai| jam nut ~) and tighten 34424 securely against cube to keep cable from turning in cube. [~ 12. For |eft-hand rotation propeJ|ers, the bellcrank link must be installed into the starboard hole (~) of the eccentric piston arm. [~ 13. For right-hand rotation propellers, the bellcrank link must be installed into the port hole 0 of the eccentric piston arm. 34426 344.20 vwnv~ ~ Safety Related 5-9 r-R"! L_U ~ 14. To reposition betlcrank link, remove cotter pin (~ and pin from clevis. Removecotter pin ~), washer, and linkage from bellcrank. [~ [~ ~ 15. Install linkage into opposite side of beilcrank. install washer and cotter pin ®. Bend prongs of cotter pin. Position clevis on starboard side of eccentric piston arm and install pin and cotter pin ~). Bend prongs of cotter pin for a secure attachment. [~ 16. Reinstall shift linkage access cover and secure with three original screws ©. 34423A ///~ 34112 Safety Related 5-10 VD/TB/eng Throttle Cable Installation ~o=~ Move remote control handle to the NEUTRAL detent position. Turn propeller shaft and shift into the forward gear detent position, and then pull HALFWAYBACK towards NEUTRAL This positions the control for proper throttle cable adjustmont. Failure to follow this procedure can bind the shift linkage in the control, and produce "hard shifting". 1. Align internal bosses (~) of trunnion with throttle cable groove (~). Press trunnion on throttle cable until seated. ~ot~ Engine anchor block brackets may have 2 sets of anchor biock holes. The top set is for 4V (4 barrel) carburetor models, and the bottom set is for 2V (2 barrel) carburetor models. ~7=7~~ 2. Install open end ® of trunnion in anchor block. Install screw in anchor block and position throttle cable assembly in selected set of holes. Locknut @ must be against the ancllor bracket, tighten it securely. ~ Z~ 3. Throttle arm connector ® must have a minimum G,f 9 fuji turns or 1/4 in. of throttle cable thread engagement, install throttle arm connector onto the throttle cable. Pull connector ® DR4977 forward to remove all end play from remote controm throttle cable, then turn the connector in until hole aligns with the throttle arm if throttle arm connector hoJe cannot be adjusted to aJign with the throttle arm, check for proper cable installation in the remote control box’. 9~ ~ 4. Carburetor Models: Install connector onto throttle arm. nnstaiR washer and cotter pin @. Spread prongs of cotter pin (~1 for a secure attachment. Tighten jam nut (~) against connector. rl~ ~ 5. F3 Models: install connector onto throttle arm. Install DR4978 and tighten throttle arm Iocknut (~) for a secure attachment. Tighten jam nut (~ against connector. ® @ DR4979 ® VO/’rB/eng ~ Safety Related DR4980 5-1 1 NOTES 5-12 v~w Section 6 Trim/Tilt Hydraulic System SX Models Table of Contents Description, Trim/Tilt System ........................ 6-3 Diagnostic Chart ................................. 6-16 Filling and Bleeding Dry System ..................... 6-32 Ground CJip Replacement .......................... 6-33 Hydraulic Operation -Fluid Schematics ................ 6-5 |mpact ....................................... 6.14 Manual Release Valve (Lower Drive Only) ............ 6-12 Manual Release Valve {Raising or Lowering Drive) ..... 6-13 Running in Forward Gear (and Shallow-Water Drive)... 6-10 Running in Reverse Gear ......................... 6.11 ’Thermal Expansion Valve ........................ 6.15 Trim-In/Tilt-Down (Bow Down) ..................... 6.8 Trim-in Relief Valve .............................. 6.9 Trim-Out/Tilt-Up (Bow Up) ........................ 6.6 Tilt-Up Relief Valve .............................. 6-7 Reservoir -Checking, Riling and Bleeding .............. 6.3 Specifications, Hydraulic Pressure ................... 6-33 System Hydraulic Tests ............................ 6-19 Trim/Tilt Cylinders ............................... 6-29 Disassembly .................................. 6-29 Reassembly ................................... 6-30 Trim/Tilt Motor .................................. 6-22 Assembly of Assembly of Disassembly Disassembly Installation installation Installation Gear Unit .......................... 6-24 Manifold ........................... 6.26 of Gear Unit ........................ 6-24 of Manifold ......................... 6-25 of Gear Unit ......................... 6.28 of Motor and Reservoir ................. 6.28 of Trim/Tilt Motor ..................... 6-28 Pressure Testing Manifold ........................ 6-27 Removing Motor and Draining Reservoir ............ 6-22 Separation of Gear Unit and Manifold ............... 6-23 Separation of Reservoir and Motor ................. 6-23 Troubleshooting -General ......................... 6.18 Troubleshooting With In-Line Pressure Testes’ . ......... 6.18 Valve Body Component Description ................... 6-4 Volvo Penta Special Tools P/N Description 3854362-5 Retaining Ring Pliers No. 1 3854363-3 Tilt Cylinder Seal Protector 3854364-1 Seal Installer 3854365-8 Spanner Wrench 3854366-6 Adapter, Pressure Tester 3854367-4 Hydraulic Cylinder Rod Holder 3854368-2 Trim/Tilt In-Line Pressure Tester Miscellaneous Stevens Gearcase Tester No. S-34 or Equivalent Cleaning Solvent Sealants, Lubricants and Adhesives Loctite or equivalent Liquid Neoprene Loctite primer or equivalent Volvo Penta Grease Volvo Penta power trim/tilt & steering fluid or Dexron/i Automatic Transmission Fluid Safety Warnings Before working on any part of the trim/tilt system, read the section called Safety at the end of this manual. When replacement parts are required, use genuine Volvo Penta parts or parts with equivalent characteristics inc|uding type, strength and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passen gers. 6-2 VD/TB/eng System Description The trim/tilt unit consists of a valve body, oil pump, and electric motor assembly connected to two hydraulic cylinders. A trim sending unit is mounted to the starboard side of the gimbal rin, g and connected to a dash mounted trim gauge. To operate the trim/tilt, push the switch to the desired bow-ul~ bow-down position. Holding the switch in the desired position will activate the system until the switch is released. Holding the switch in the bow-up position, the electric motor drives the hydraulic oil pump forcing oil into the base of the hydraulic cylinders. The force developed by the cylinder moves the drive unit through an unlimited trim range. The dash mounted trim gauge indicates the bow position that is controlled by the trim angle of the drive unit. Continued operation in the bow-up direction tilts the drive unit to the full tilt-up position. (The trim gauge indicates full bow-up position when in the tilt range.) Holding the switch in the bow-down position, the drive unit will move down through the tilt range into the trim range. If the trim switch is not released the drive unit will move through the trim range to the full bow-down position. Reservoir -Checking, Riling and Bleeding [~] Z~ Do not remove fill plug (~) unless drive unit is in the full tilt-up position. Raising the drive unit reduces the pressure and fluid level in the reservoir. Failure to raise drive unit would cause a dangerous hydraulic fluid spray when the fill plug is remov~o ~-] ~ 1. Raise drive to the full tilt-up position. Wear safety glasses. Cover fill plug with a shop cloth, and slowly unscrew plug. ~-~ 2. Fluid should be level with bottom of fill plug hole when trim system is properly filled. Use only Volvo Penta power trim/tilt & steering fluid, or De×ton II automatic transmission fluid. Add as required. 3. install fill plug and tighten securely. Cycle drive up and down a minimumof five times. Return drive to the full tilt-up position and recheck fluid level. Repeat this procedure until no more fluid is required. ~-~ In situations where air has entered pump and hydraulic lines because of low fluid level, or any part of system has been disassembled, it will be necessary to bleed (purge) air from system. To remove air from hydraulic system, cycle trim/tilt system a minimum of five times, adding fluid as required. Total oil capacity with cylinders extended is 54 fl. oz. (1597 rnl). w~.~ //~ Safety Related 6-3 Valve Body Component Description [~ Manual release valve -This valve ~) allows manual lowering and raising of the drive unit without electrical power. When this valve is turned counterclockwise, the drive unit will lower by its own weight. The tilting motion may be stopped at any point by closing this valve. This valve must be fully open to raise the propulsion unit, and must be fully closed to maintain a tilt or trim position while static or running in forward gear. ~-~ Trim-in/tilt-down outlet -This valve body outlet <~) is con nected by hydraulic lines to the rod end (low volume side) of the trim/tilt cylinders. [~ Trim-out/tilt-up outlet -This valve body outlet © (marked "UP") is connected by hydraulic lines to the high volume side of the hydraulic cylinders. [~ Thermal expansion relief valve -This valve (~) is located inside the manual release valve and prevents hydraulic lock=up in the full tilt-up position caused by thermal expansion of the hydraulic oil. It opens only under unusually high pressure conditions; 2500 --+ 250 PSi (17,238 kPa). Inlet check balls -The oil pump inlet check balls ~) rest in seats (~) on either side of the oil pump gears @. The check balls allow oil from the reservoir to the pump when open. When closed, they prevent oil from the pump returning to the reservoir. [~ Manual release check ball and retainer -The manual release check ball ® and retainer (~ are positioned in a seat (~ next to the trim-in/tilt-down check valve. The check ball allows fluid from the reservoir into the valve body, and the retainer limits its move ment. Trim-out/tilt-up check valve -This valve (~ opens under pressure to allow oil to flow to the high volume side of the cylinders during UP operation, it maintains oil in the high volume chamber of the cylinders to hoBd a tilt or trim position while running in forward gear. This valve also allows oil to return to the trim/tilt pump during DOWNoperation after it has been opened by the pump control piston, it’s positioned in a seat (D connected to the "UP" port. Trim-in/tilt-down checkvalve -This valve (~ opens under pressure to allow oil to flow from the pump to the low volume chamber of the cylinders during DOWNoperation. It also allows oil from the low volume side of the cylinders to return to the pump during UP operation after it has been opened by the pump control piston. This valve prevents raising of the drive unit during reverse gear operation (reverse lock), it also prevents oil flow from the cylinders during high-pressure impact conditions. It’s componentsare identical to the trim-out/tilt-up check valve ~). 20244 20292 ® 20290 6-4 VD/TB/eng ~] Filter screen-if unit is so equipped, this is a serviceable part held in place in the valve body by the gear housing. It filters oil returning to the reservoir from the manual release valve passage. 5~ Pump control piston -The pump’s oil pressure moves the control pistons (~) to open the trim-in/tilt-down check valve when operating in the UP mode, and open the trim-out/tilt-up check valve when operating in the DOWN mode. The check balls (~ either allow or prevent fluid flow through the pistons, depending on direction of fluid flow. Both pistons free- float in chambers ~) in the pump gear housing ®, and the parts are identical. ~] Tilt-up relief valve - This valve (~) controls the maximum oil pressure in the system during UP operation. It also limits the pressure that can be developed at the full tilt-up stall position to a maximumof 1400 + 200 PSI (9653 kPa). ~] Trim-in relief valve - This valve O regulates oil pressure in the system during the DOWN returns from the operation. More oil high volume side of the trim/tilt cylinders than can go into the low vol,ume side of the cylinders, due to the rod volume. The excess oil passes through the trim-in relief valve and maintains oil pressure on the DOWN side at 600 -200 PSI (4137 kPa). Filter and coupler - This serviceable filter @ is located under the motor, and filters oil moving from the reservoir to the pump. The coupler ~) connects the motor armature to the pump drive gear. Hydraulic Operation -Fluid Schematics To understand the operation of the hydraulic unit, you must be familiar with the valve operation and oil flow in the ten different operating modes illustrated on the following pages: [~ Runniing in Reverse Gear Trim-Out/Tilt-Up (Bow Up) Tilt-Up Relief Valve r~ Manual Release Valve (Lowering Drive Only) Trim-in/Tilt-Down (Bow Down) [~ Manual Release Valve Trim-in Relief Valve (Raising or Lowering Drive) [~ Impact Running in Forward Gear (and Shallow-Water Drive) [~ Thermal Expansion Valve 17586 20291 17597 wrr~o,~ 6-5 Return Pressure Trim-Out/Tilt-Up (Bow Up) 1. The oil pump (~) pressurizes the passage leading to the high volume side of the trim cylinders. The reservoir check ball (~) seats to prevent fluidentering the reservoir, and the trim-out/tilt-up check valve © opens under hydraulic pressure and allows fluid through. As oil exits the valve body, it fills the manual release passage. Fluid, however, is prevented from leaving this passage by the O-ring around the valve tip, and by the internal thermal expansion valve ~). 2. The trim-in/tilt-down piston (~) is also in the pressurized passage. Oil pressure moves the piston away from the trim-out/tilt-up check valve and unseats the check ball inside the piston. Fluid passes through the piston and enters the passage leading to the trim-out/tilt-up piston ®. Pressure seats the check ball inside this piston and prevents oil from passing through. The piston moves under pressure, contacts the trim-in/ tilt-down check valve ®, and opens it. t 3. Hydraulic lines connect the valve body to the transom shield manifold ~) which directs fluid to both trim cylinders. As the high volume trim chambers ® fill, oil is pushed out of the low volume chambers. This low pressure oil returns to the valve body, and passes around the manualrelease valve ~D. Fluid passes through the held- open trim-in/tilt-down check valve and returns to the oil pump for recirculation back to the trim cylinders. 4. Since the amount of oil returning from the trim cylinders is insufficient to fill the high volume chambers, supplementary oil is drawn through the pump filter ~). it enters past both the inlet check ball (~) and the manual release check ball(~, and joins fluid returning to the pump. Return Pressure ® Tilt-Up Relief Valve 1. Whenthe trim pump is operated in the bow-up direction, and the trim cylinders have reached their full tilt-up position, drive unit movementceases. The stoppage of drive movementcauses fluid pressure to suddenly increase a significant amount, if the pump continues to operate in the bow-up direction, ail pump valves will return to the position that allowed upward drive movement. Fluid pressure must now be relieved to prevent excessive current draw and motor stalling. © DR2630 2. The tilt-up relief valve ~) contains a strong spring that holds the valve closed during normal operation. Under increased hydraulic pressure, the valve opens and permits discharge of totalpump output back into the reservoir. Make-up oil is drawn through the pump filter @ past the inlet check bal~ (~) and manual release check ball 3. As long as the pump operates with the drive in the full tilt position, fluid will continue a circuitous flow from the pump, to the relief valve, to the reservoir, and back to the pump. There is no return flow from the trim cylinders since they’re fully extended and the impact relief valves (~) are closed. @ Trim-In/Tilt-Down (Bow Down) 1. The oil pump @ pressurizes the passage leading to the low volume side of the trim cylinders. The reservoir check ball (K) seats to preventfluid entering the reservoir, and the trim-in/tilt-down check valve ® opens under hydraulic pressure and allows fluid through. As oil exits the valve body, it passes around the manual release valve ®. 2. The trim-out/tilt-up piston ® is also in the pressurized passage. Oil pressure moves the piston away from the trim-in/tilt-down check valve and unseats the check ball inside the piston. Fluid passes through the piston and enters the passage leading to the trim-in/tilt-down pis ton (~). Pressure seats the check ball inside this piston and prevents oil from passing through. The piston moves under pressure, contacts the trim-out/tilt-up check valve © and opens it. Return Pressure DR2631 3. Hydraulic lines connect the valve body to the transom shield manifold ~) which directs fluid to both trim cylinders. As the low volume trim chambers(t~) fill, oil is pushed out of the high volume chambers. This oil returns to the valve body, passes through the held-open trim-out/tiltup check valve, and returns to the oil pump for recirculation back to the trim cylinders. 4. Since the amount of oil returning from the trim cylinders is greater than that needed to fill the low volume chambers, the returning oil is under somepressure and closes the inlet check ball ®. All returning oil passes through the oil pump. Since the pump’s output volume exceeds the cylinders requirements, the resulting oil pressure increase is great enough to open the trim=in relief valve ®. Excess oil not required to fill the trim cylinders is returned to the reservoir. 6-8 Vl)/TB/eng ® Trim-In Relief Valve 1. When the pump is operated in the bow-down direction and the trim cylinders have reached their full tilt-down position, drive unit movement ceases. The stoppage of drive movementcauses fluid pressure to suddenly increase a significant amount. If the pump continues to operate in the bow-downdirections all pump valves will return to the position that allowed downward drive movement. Fluid pressure must now be relieved to prevent excessive current draw and motor stall. 2. When trimming in, excess fluid displaced by the retracting rods pressurizes the system and opens the relief valve ®. When the piston bottoms, the valve remains open and permits discharge of total pump output back into the reservoir. Make-up oil is drawn through the pump filter O past the inlet check ball (~. ~ Return ~| Pressure DR2832 3. As long as the pump operates with the drive in the full downposition, fluid will continue a circular flow from the pump, to the relief valve, to the reservoir, and back to the pump. There is no return flow from the trim cylinders since they’re fully retracted and pump hydraulic pressure is not sufficient to open the impact relief valves (~. ~Pressure Running in Forward Gear (and Shallow-Water Drive) 1. Propeller thrust in forward gear causes the drive unit to push against the trim/tilt cylinders, pressurizing the high volume side of the cylinders and the oil to the trim-out/tilt-up check valve ©, thermal expansion valve ~), and manual release valve O. 2. All of these valves, plus the trim/tilt cylinder piston O-rings (~) and the impact relief valves (~, must hold pressure to maintain the drive unit in a set trim position. There is no oil flow in the trim/tilt system while running in forward gear. Pressure Running in Reverse Gear 1. Propeller thrust from operating in reversegear creates a force that pulls on the trim/tilt cylinders, pressurizing the oil on the low volume side of the pistons and in the hydraulic lines to the manual release valve O, trim-in/tilt-down check valve ® and manual release check ball (~. 2. For the drive unit to maintain a fixed trim position, these valves plus the piston O-rings (~, impact relief valves (~, cylinder end cap O-ring (~ and piston rod O-ring ~) must hold pressure. No oil flow occurs in the trim/tilt systemwhile operating in reverse gear. Return Pressure DR2636 ManuaJ Release Valve (Lower Drive Only) 1. The weight of the drive unit applies a force to the trim/tilt cylinders, and pressurizes the oil in the high volume side of the cylinders, the trimout/ tilt-up check valve ©, thermal expansion valve (~), and the manual release valve (~). 20p.ening the manual release valve one full turn ¯ 1= == lets o=! flow past the valve top, through the filter screen ~) to the oil reservoir, thus lowering the drive. 3. To fill the expanding low volume chambers of the trim/tilt cylinders, make-up oil is drawn through the filter (~) past the manual release valve check ball ~) to the Jow volume side of thecylinders. 4. The drive may be lowered completeJy or stopped at any position in the trim/tilt range byclosing the manual release valve. With the valve open only one full turn, the drive may only be lowered, and it cannot be moved in the opposite direction (raised}. 5. ShouJd the trim pump be operated with the release valve one turn open, and the drive completely lowered, oil will be pumped back into the oil reservoir either through the trim-in relief valve ® when trimming down, or past the open manual release valve and through the filter screen (~) when trimming up. No drive movement will occur. 6-12 vwr~e.= Return ~ Pressure DR2635 Manual Release Valve (Raising or Lowering DrivE;) 1. Fully opening the manual release valve until it contacts the retaining ring lets oil flow both to and from the oil reservoir and the trim/tilt cylinders. 2. Lowering Drive: The weight of the drive pressurizes the high volume cylinder chambers, the manual release valve (~), the thermal expansion valve @, and the trim-out/tilt-up check valve ©. Whenthe release valve is fully opened, oil flows out of the high volume chambers, through thelines and into the manual release valve cavity. Part of this fluid volume enters the line leading to the trim/tilt cylinders and provides fill oil to the expanding low volume chambers. Excess oil not required to fill the trim/tilt cylinders leaves themanual release valve cavity and returns to the reservoir through the filter screen ~). Spring pressure holds the trim-out/tilt-up check valve closed, and prevents oil from passing through it. 3. Raising Drive: When the manual release valve is fully openedand the drive is manually raised, the low volume cylinder chambers, trim lines and the manual release valve cavity are pressurized. Oil is forced out of the low volume chambers and into the manual release valve cavity where all returning oil enters the passage and line leading to the high volume trim/timt chambers. Springpressure holds the trim-out/tilt-up check valve © closed to prevent any fluid loss. Since oil volume from the low volume chambers is not sufficient to fill the expanding high volume chambers, makeup oil is drawn through the rioter screen ~) and past the manual release check bah (~), and joins oil returning from the cylinders in the manual release valve cavity. 4. Should the trim pump be operated while the manual release valve is fully open, oil will be pumped to the manual release valve cavity where it will be returned to the reservoir through the filter screen (~). No drive movementwill OCCUr, @ impact 1. Whenthe drive strikes an underwater object while moving forward, the movement of the drive unit to the rear applies a substantially high force to the trim/tilt cylinders and quickly extends the rods. 2. The oil pressure in the high volume side of the trim/tilt cylinders and in the hydraulic lines to the manual release valve O, thermal expansion valve @, and trim-out/tilt-up check valve ©, suddenly drops. 3. The oil in the low volume side of the trim/tilt cylinders and in the connecting lines to the manual release valve O, trim-in/tilt-down check valve ® and manual release check ball O is suddenly pressurized. 4. With the trim-in/tilt-down check valve and manual release check ball both closed allowing no oil flow, the high pressure oil must flow through the impact relief valves ~) to the highvolume chamber, dissipating the energy of the impact. Return Pressure 0 DR2637 5. Since the volume of the cylinder rod takes up someof the space at the top of the cylinder, less oil transfers from the low volume side of the cylinders than is required to fill the space in the high volume side of the cylinders, and some air is introduced to the high volume side after an impact. 6. To lower the drive unit to the normal trim range, the trim/tilt unit must be operated in the bow-downdirection. 7. Normally, one or two cycles of the trim/tilt unit through the full trim/tilt range will purge the accumulatedair from the high volume side of the trim/tilt cylinder and connecting hydraumic lines. 8. The oil pressure at the low volume side of the trim/tilt cylinders will normally be about 1800 PSi (12,411 kPa) minimum when the impact relief valves open. 6-14 vwr~,~ @ Thermal Expansion Valve 1. ’When the drive unit is in the full tilt-up position, that position is maintained by the piston O-~’ings (~), the impact relief valves (~), the trimout] tilt-up check valve ©, the manual release valve O, and the thermal expansion valve ~). 2. if the trim/tilt unit is exposed to a large increase in temperature, the oil pressure in this part of the system can increase substantially. The back side (or spring side) of the trim-out/tilt-up check valve is also exposed to this high pressure. ~Pressure @ © 3. Under some conditions, the high pressure behind the trim-out/tilt-up check valve could prevent the trim-in/tilt-down piston (~) from opening the valve when attempting to tilt the propulsion unit down. 4. The thermal expansion valve, set at 2500 PSI (17,238 kPa), relieves this excess pressure and prevents lock-up in the full tilt-up position. The thermal expansion valve outflow is vented to the oil reservoir through filter (~). = VD/r~eng 6 1 5 Trim/Tilt Diagnostic Chart Some problems and possible causes have been listed below. Remember, some malfunctions may have more than one cause. If the problem you are troubleshooting is described below, check all of the possibilities (identified by a boxed number) that are listed. System Problem Static leak-down and/or trim-in creep in forward gear: [~] ~] ~ [~] Trim-out/tilt-up creep in reverse gear (no reverse lock): DE] [~ E~] ~ [2~] Leaking, both up and down (trim-in/out creep): !-~ Slow or no trim-out/tilt-up, motor runs: [~] E~] [~ E~ E~ ~] E~ [~ E~ [2~] No trim-ouSt.t-up, doesmotor not run: EEl Slow or no trim-in/tilt-down, motor runs: [~ [~ ~ [~ ~ ~ [~ No trim-in/tilt-down, motor does not run: [~ ~ ~ [’~ No trim/tilt up or down, motor runs: [~ E~ E~] No trim/tilt up or down, motor runs fast: [2~] No trim/tilt up or down, motor does not run: [2~ ~] [2~] No tilt-down from full tilt-up position; motor stalls: [~] Erratic operation, jumpy motion, pulsing/hissing fluid sound: [~ Continual use or loss of hydraulic fluid: Possible Cause r~ Air or low/no oil in reservoir. Fill reservoir and cycle trim/tilt unit. ~] Air in hydraulic system. Cycle unit through entire range three to five times. Fill reservoir. [~ ~ Manual release valve loose or leaking. Remove and check condition of plastic seal ring, O-rings, and seats. They cannot be worn or damaged and must be dirt-free. Tighten valve to 45-55 in. Ibs. (5-6 N-m). Safety Related 6-16 VD/TS/eng Possible Cause - Continued [~ Thermal expansion valve sticking, or spring damaged. Dirt under check ball. E~ Trim-out/tilt-up check valve sticking, damagedseal tip, dirt under seal, leaking O-ring, or damaged spring. E~ Pump contro~ piston sticking, dirt under check balls or in small oil passages in control piston. Check piston condition and working surface in valve body. Check ball seat and oil passage holes. [~ Trim/tilt cylinder internal leak. Check for damaged piston seal, impact relief valves, or dirt under relief valves. L~ Trim-in/tilt-down check valves sticking. Check for damaged seal tip, dirt under seal, leaking O-ring, or damaged spring. E~ Manual release check ball leaking. Check for damage to ball or seat, remove dirt. Trim-in relief valve leaking. Check seal tip condition, seat condition, and spring. Check for evidence of sticking or presence of dirt. [~ Tilt-up relief valve leaking. Check for valve sticking, damaged seal tip, dirt under seal, damaged spring, or valve body O-ring damage. Pump coupling broken. See if pump turns freely. Check motor for bent shaft or pump binding. Check for dirt or mechanical damage. L’~ Tripped 10 or 50 amp circuit breaker. Reset circuit breaker. L~ Motor inoperative= Replace motor. Relay control box malfunction. Replace control box. D~] Switch circuit malfunction. See Trim/Tilt Switch -Test Procedure, in the Electrical Systems Workshop Manual. [~ External oil leak. Check hydraulic lines and connections, cylinder rod and seal, valve body to motor O-ring, valve seals in valve body. See Disassembly of Valve Body. [1~] Pump-to-manifold oil Uine attachment reversed. "UP" oil line incorrectly attaches to upper fitting of transom shield manifold. Troubleshooting - General in many cases an inspection or test of the "easy things" first will reveal the problem quickly and save valuable troubleshooting time. 1. Visual inspection: Look for indications of external oil leaks. Repair as necessary. Check reservoir oil level. Do not remove finn plug unless the drive unit is in the fuUl tilt-up position. Fill as required, see Reservoir -Fil|ing and Bleeding. ~-~ L~ 2. Check manual release valve (~: it must be closed and tightened to 45-55 in. Ibs. (5-6 N.m). 3. Battery: The battery must be fully charged for some of the following tests. A fully charged battery will have a specific gravity of 1.260 to 1.280. Troubleshooting With In-Line Pressure Tester [~ The Volvo Penta Trim/Tilt in-Line Pressure Tester P/N 3854368-2 provides a method for checking the performance of the trim/tilt unit. The pressure tester can measure running pressure, stall pressure, and pressure leak-down. The tester can isolate the trim/tilt cylinders from the valve body to help locate a component causing leak-down. EEl The trim/tilt in-line pressure tester consists of a pressure gauge and adapter ~), a tester body and shut-off valve assembly ©, and a hydraulic line assembly ~). [~ The tester body is designed so the hydraulic port stamped "’A" (~) is always connected to the gauge. Hydraulic port stamped "B’" ® opposite the valve ~) can be shut off by closing the valve. If you suspect that a valve or cylinder is leaking, the tester may be connected to the trim/tilt valve body four different ways to isolate and test componentsof the trim/tilt circuit. 15840 ®© ® 3807 Safety Related 6-18 VD/TB/eng How to instal| Tester Follow steps 1 through 5 below to prevent high pressure oil spray and excessive fluid loss when hydraulic fitting is loosened or removed. Spray’ could cause eye injury. 1oRaise the drive unit to its full tilt-up position. 2. Block the drive unit in full tilt-up position. 3. Fully open manual release valve for a few seconds to allow hydraulic pressure to equalize. Then fully close valve to minimize fluid loss when disconnecting lines. Z~ 4 Wear safety glasses. Carefully open fill plug to release any residual pressure from the reservoir. Cover the plug with a shop cloth. Z~ 5. Wear safety glasses. Some residual pressure may be present in the trim/tilt system when the hydraulic line is loosened. Always wrap a shop cloth around the hydraulic fitting before loosening. This will trap any high-pressure oil as the fitting is loosened. 6. Catch any oil with a shop cloth and drip pan. E’~ Z~ Before disconnecting any hydraulic lines, [abel the port {"UP") line for identification. Wear safety glasses when making all line disconnections, Trirn/Tilt System Hydraulic Tests (Test No. 1 = Complete Circuit, Trim-out/Tilt-upJ This test will provide running and stall PSI for the trim-out/tilt-up circuit. E3~ 1. Disconnect port ("UP") hydraulic line from pump valve body. E4~ 2. Connect tester hydraulic line (~) to "UP" outlet in pump valve body, and to outlet "A" on tester body. E4~ 3. Connect port pump hydraulic line ¯ to opening "B" in tester body. 4. Open tester shut-off valve one to two turns. Do not open more than two turns; valve retaining ring may unseat and cause hydraulic fluid spray. 15836 16127 v~.ng ~ Safety Related 6-19 5. Run drive through a complete trim-out/timt-up cycle. Record running and stall PSI and compare to specifications. Test Results: If trim fails to meet specifications, perform Test No. 2. ITest No. 2 -Isolation, Trim-out/Tilt-up Pump Cimuitl This test will isolate the pump valve body trim-out/tilt-up components from the trim cylinders, it will help determine whether defective components are in the pump valve body, or in the trim/tilt cylinders. 1. Follow Steps 1-6 under How to install Tester and connect the tester as described in Test No. t. 2. Run the drive to the full tilt activate the position. Momentarimy trim switch in direction to relieve the DOWN pressure on gauge. 3. Completely close the tester shut-off valve. 4. Run pump in the trim-out/tilt-up direction and record the stall PSI. Release the trim switch and check the leak down rate and final PSI. Compare the results to the specifications. Test Results: 1. if the pressure gauge shows a stall PSi less than specifications, or a beak down rate greater than specifications, the problem lies within the pump valve body. 2. If the stall PSI and Jeak down figures are within specifications, the problem is with either or both trim/tilt cylinders. Do not disconnect any lines if pressure still registers on gauge. This may cause a hazardous spray of high pressure hydraulicfluid. To relieve pressure, momentarily activate trim in opposite direction of last use. Watch gauge to make sure it registers zero before removing lines. [Test No. 3 - CompleteCircuit~ Trim.in/Tilt-downJ This test will provide running and stall PSi for the trim-in/tilt-down circuit. 1. Disconnect starboard hydraulic line from pump valve body. //~ Safety Related 6-20 VD/TB/eng 2. Connect tester hydraulic line (~ to starboard pump oul:let, and to opening "A" on tester body. [~ 3. Connect starboard pump hydraulic line (~ to opening "B" on tester. 4. Open tester shut-off valve one to two turns. Do not open more than two turns; valve retaining ring may unseat and cause a hydraulic fluid spray. 5. Run drive through a complete trim-in/tilt-down cycle. Record running and stall PSi, and compare to specifications. Test Resuks: if trim fails to meet specifications, perform Test No. 4. C~ No. 4 - Pump Circuit~ isolation, Trim-in/Tilt=down This test will isolate the pump valve body trim-in/tilt-down components from the trim cylinders, it will help determine whether defective components are in the pump valve body, or in the trim/tilt cylinders. 1. Attach the tester as described in Test No. 3. 2. Run drive to thE,= full down position. Momentarily activate trim switch in the UP direction to relieve pressure on gauge. 3. Completemyclose the tester shut-off valve. 4. Run pump in the trim-in/tilt-down direction and record the ,,;tall PSL Release the trim switch and check the leak down rate and final PSi. Compare the results to specifications. Test Results: 1. If the pressure gauge shows a stall PSi less than specifications, or a leak down rate greater than specifications, the problem lies within the pump valve body. 2. If the stall PSI and leak down figures are within specifications, the problem is with either or both trim/tilt cylinders. v~r~.., Z~ Safety Related 6-21 Servicing Trim/Tilt Motor RemovingMotor and Draining Reservoir 1. Raise drive unit to the full tilt-up position. ¯ if operative-use trim/tilt system. [~ ¯ if not operative- back out release valve (~) until it contacts snap ring, and slowly manuamly lift drive until cylinders are fully extended. L~ Raising the drive unit reduces the pressure in the reservoir. Failure to raise the drive would cause a dangerous oil spray when the fill plug is removed. 2. Block drive unit in the full tilt-up position. Failure to support the drive would almow its weight to pressurize the trim/tilt system and cause a hydraumic fluid spill. Place a container below the pump to catch any overflow oil after removingfill plug. 3. Fully open manual release valve for a few seconds to allow hydraulic pressure to equalize. Then fully dose valve to minimize fluid loss when disconnecting lines. [~ ~_ 4. Wear safety glasses. Carefully remove fill plug (~. There coumd be some residual pressure remaining in reservoir. DE] 5. identify port hydraulic line © (port valve body outlet is marked "UP") and remove. Pmace Bine in container to catch fluid° 6. Removestarboard line and place in container to catch fluid. Place plugs in valve body to prevent dripping of residual fluid. [~ L~ 7. Disconnect cables at battery, or turn battery disconnect switch to "OFF." Remove green ~) and blue ~) wires from terminal board. Remove tie strap and tape around wires. Take out screw at top of terminal board, and detach board from reservoir. ~5840 15837 15835 //~ Safety Related 6-22 15834 VD;3"B/eng ~ i , 15833 15883 E5=-] 8. Unscrew two lag screws ® holding pump assembly to transom. L~ 9. Drain any oil remaining in reservoir. Turn manual release valve in until seated. it’s necessary that the outside surface of the trim/tilt unit be completeEy free of dirt prior to disassembly. Wipe with a cleaner if necessary. Always use a lint-free cloth when handling trim/tilt components. Separation of Reservoir and Motor 7E~ 1. Take out four screws securing reservoir to manifold. Discard O-ring in reservoir. [~ 2. Remove three screws securing motor to manifold. Discard O-ring on motor. ~9~ [~] 3. Remove and inspect filter. Clean or replace as ne(:essary. Pull out motor drive coupling and inspect for wear or damage. Separation of Gear Unit and Manifold Mating surt~aces between pump and manifold are critical ¯ for sealing, and cannot be scratched or gouged. Use extreme care during disassembly and reassembly procedures. ~ [~ Some housings may require the drilling of 1/8 in. (3,18 ram) homes (~) at the points indicated, to allow for removal of tilt-up and trim-in relief valves. ~ [~ Remove four Allen screws mounting gear housing to manifold by turning each screw no more than one turn, then proceeding to another screw. Gear housing is under spring tension; back out screws equally and in small amounts. Lift g, ear housing off manifold. Be sure both pump control pistons ® and check bails are retained in gear housing. Lift filter (~ (if equipped) out of manifold. 15881 15885A ,,4/ 16104A 20227 15943A 15944A 17516 Disassembly of Gear Unit r~ 1. Remove both pump control pistons (~) with needle- nose pliers. Take out check ball ~) under each piston. [~ [~] 2. Remove the tilt-up relief valve © by inserting a suitable tool through the hole behind it and pushing it out. Removeand discard the valve O-ring (~. r~ [~] 3. Remove trim-in relief valve (small diameter valve) by inserting a suitable tool through the hole behind it and pushing it out. Discard the valve O-ring (D. 4. inspect check balls, springs and valve components. Replace worn or damaged parts. 5. Clean out all metal particles if it was necessary to drill valve removal holes. Thoroughly clean gear housing with solvent, then blow dry with compressed air. Keep all components clean and dust free. Dirt or lint can cause blocked passages, sticking valves, and prevent O,rings from sealing. Use only Volvo Penta power trim/tilt & steering fluid to lubricate parts during reassembly. Assembly of Gear Unit 1. Place a new O-ring on the trim-in relief valve piston (~) and apply Volvo Pents power trim/tilt & steering fluid to both parts. Set the spring and seat in the gear housing, then push in the piston until it seats. / tul 20263 17515 2022 ~7514 6-24 VD,q’B/eng 17513 18035 20281 ~8~ 2. Place a new O-ring on the tilt-up relief valve piston © and apply Volvo Penta power trim/tilt & steering fluid to both parts. Set the spring and seat in the gear housing, then push in the piston until it seats. Make sure piston does not cock in bore. L~ 3. set a check ball ® in each bore, then insert the pump control pistons. Disassembly of Manifold Before removing pump gears, mark the exposed end of m each with an indelible pen. This will identify the direction they should be installed. If one or both gears are installed upside down, they wiml bind and adversely affect operation. Pump pressure will be reduced and motor current draw will be increased. 1. Lift out the two pump drive gears and check for abnorrnal wear, chipped teeth, etc. Remove the two reservoir inlet check balls. Hydraulic pressure is required to remove the two trim/tilt check valves. Any attempt to pry them out with a sharp object will damage the machined surface that seals the gear housing. L~ [~ ~ 2. Fill the unmarked hydraulic line opening with Volvo Penta Grease. Cover check ball hole (~) on underside manifold, then screw a %s in. fine thread bolt into the unmarked opening, if valve does not come completely free, add more grease and screw bolt in again. D4-~ 3. Lift spring, valve and seat out of manifold. Discard valve O-ring ®. ®/ w~.~ 6-25 4. Repeat the procedure in Step 2 to remove the remaining check valve, insert grease and bolt into opening marked "UP." There is no check balO hole to cover on underside of manifomd. [~] DE] 5. Remove manual release check ball and retainer by pushing against check ball with a suitable tool (~ and forcing check ball ® and retainer © out of manifold. Discard retainer O-ring. [~ 6. Remove retaining ring from manual release valve opening, then unscrew release valve (~. Discard all O-rings. [~ ~ The thermal expansion valve ® is located inside the tip of the manual release valve, and is not serviced separately, if either the manual release or thermal expansion valve do not function properly, they are replaced as an assembly. 7. Thoroughly clean the manifold with solvent making sure to remove all grease from the check valve passages. Blow out and dry with compressed air. Keep all components clean and dust free. Use only Volvo Penta power trim/tilt & steering fluid to lubricate parts during reassembly. Assemblyof Manifold 1.0nstail new O-rings and plastic seal ring on the manual releasevalve. Lubricate valve and O-rings with Volvo Penta power trim/tilt & steering fluid, then screw in valve until it seats. Tighten to 45-55 in. Ibs. (5-6 N.m). Do not e×cessively tighten valve; tip can be damaged and valve will leak. [~ ~ 2. install valve retaining ring, Make sure it seats completely in groove, [~ 3. Place small check ball in manual release make-up oil passage ®. [~ 4. install a new O-ring on the check ball retainer. Lubricate both parts with Volvo Penta power trim/tilt & steering fluid. Press in retainer @ unti0 it’s flush with the manifold surface. Do not press retainer in below manifold surface. This would restrict or prevent check baBI movement, and not allow the manual release circuit to function properly. I~ 5. Place a spring in each check valve bore. Inspect both valve tips for damage,then set valves on top of springs. Place a new O-ring on each check valve seat, arid apply Volvo Penta power trim/tilt & steering fluid to both parts. Carefully center seat over valve tip, and press each seat in until it seats, if seat is difficult to install, place a proper diameter socket over seat, and gently tap it into place. 15916A 15917A 16007A Safety Related 6-26 VDFrB/eng 17511 20255 20256 Pressure Testing ManifoJd ~.~ 1. Use a 1%2 × 1,~ in. screw and a %2 in. fiat washer to retain tile trim-out/tilt-up check valve ®. Place screw and washer in gear housing mounting hole nearest check vaJvv. Make sure O.D. of washer does not cover hoJe in center of valve seat. Hole must be uncovered so vamve tip can project through and seat. ManifoJd will not pass pressure test if hole is covered. L~ 2. Attach Volvo Penta Adapter P/N 3854366-6 to a Stevens 17536 Pressure Tester S-34. Make sure a lubricated hydraulic line O-ring (~) is on the adapter tip. 3. Screw pressure tester adapter into opening marked "’UP’" O. Pressurize manifold to 30 PSI (207 kPa), and check for leaks using a soapy water solution or by submerging manifold in a container of Volvo Penta power trim/tilt & steering fluid. 4. Use a 1%2 × 1~ in. screw and -%2 in. flat washer to secure 1;he trim-in/tilt-down check valve (~ and manual release check ball retainer (~. Pnace screw and washer in hole nearest check valve. Make sure O.D. of washer does not cover hole in center of vaJve 20257 seat (see Note in Step 1). DII~ 5. Screw pressure tester adapter into unmarked port. Pressurize manifold to 30 PSi (207 kPa). Check for leaks with soapy water or by submerging manifold in a container of Volvo Penta power trim/tilt & steering fluid. A leak at opening @ can be corrected by instaIHng a new check ball, and gently seating it with a punch. 60 Before continuhg the assembly, correct leaks by replaciing suspect components. 17531 Rnstal[ation of Gesr Unit 1. Place the two check balls (~ in the reservoir inlet passages. Lubricate and install the oil pump gears. Marked end of each gear must be positioned up away from housing. If one or both gears are incorrectly installed, pump witl bind or not allow motor to seat on manifoJd surface. Motor current draw will be increased, and pump operating pressure will be reduced. To check for proper gear position, insert drive coupler into each gear. Coupmer should not bottom out in gears. [~ [~] 2. Place filter (~) in manifold (if so equipped), then gear housing on manifold. Install four Allen screws. Tighten screws one turn at a time in the sequence shown to be sure tilt-up relief valve seats properly. Tighten screws to 35 in. Ibs. (4,0 N-m). |nstallation of Motor and Reservoir 1. insert motor drive coupling into pump gear. Rotate coupling by hand to check pump for binding. if pump cannot be turned by hand, loosen gear housing mounting screws and check again, if pump now turns freely, cause of binding must be discovered and corrected before proceeding with assembly. Failure to correct binding will result in poor or no pump operation, and reduced operationaa nile. [~ 2. InstaJl reservoir oil filter with foam gasket © toward the motor. 3o Prime the pump by purging air. Fill circular cavity within filter to top of casting with trim fluid, then rotate pump coupler one direction with screwdriver. Continue turning coupner until all air bubbles stop coming out of check ball opening. This step will ensure immediate pump operation. 4. Place a new O-ring on the trim motor. Rotate motor body until screw holes align with holes in manifoJd (motor holes will align only one way). Turn coupler until its slot aligns with armature shaft blade, and install motor. Tighten screws to 35-52 in. Ibs. (4,0-5,9 N-m). 5. Place a new O-ring on the reservoir. Align the screw holes and install the reservoir. Tighten the screws to 35-52 in. Ibs. (4,0-5,9 N.m). installation of Trim/Ti|t Motor 1. Attach trim/tilt unit to transom with two lag screws. 20246 20227 20670 6-28 w~ 2. Connect hydraulic line tagged "port" to "UP" opening in trim/tilt unit. Connectremaining line to unmarked outlet. Tighten fittings securemy. Tagged line must attach to correct opening. If lines are switched,trim/tilt mechanism wil| not function properly. L~ z~ 3. insert the terminal board into the retaining notch on the reservoir and tighten the mounting screw securely. Attach the green lead (~) to the top screw of the terminal board, and connect the blue lead (~) to the second screw from the bottom. Coat screws and terminals with Liquid Neoprene. Hold wires togetherwith electrical tape and a tie strap. Reconnect the battery cables. 4. Fill trim/tilt systemwith hydraulic fluid and purge air following the procedure in Filling and Bleeding Dry System. Servicing Trim/Tilt Cylinders Disassemblyof Trim/Tilt Cylinder 1. With the drive unit in the full up position and blocked, open the manual release valve all the way. This will equalize hydraulic pressure in the cylinders. Close the manual release valve. [~ot~ Failure to equalize the pressure may cause dangerous spray of hydraulic fluid when the trim/tilt lines are opened. 2. Wear safety glasses. Carefully open fiJn plug to release any residual pressure from the reservoir. Cover the plug with a shop cloth. 3. Follow the instructions in the respective Transom Shield section of this workshop manuaJ and remove the trim/tilt cylinders from the transom shield. 4. Before disassembJing trim/tilt cylinder, drain remaining fluid from it by extending and retracting rod. Wear safety glasses. Turn cylinder ports down and place a container under both ports before piston is moved. Hydraulic fluid expelled from cylinder canresult in injury to you and others nearby, ~-~] 5. Remove cylinder pivot bushings if they are to be replaced. To remove cylinder" end cap, clamp cylinder in a soft-jaw vise. Using Volvo Penta Spanner Wrench P/N 3854365-8, unscrew cap. A light tap with a mallet is often more effective than force to removean end cap that is stuck. J~] 6. Unscrew end cap until held by one thread, then extend rod. Piston is more easiay withdrawn if end cap is left threaded one turn in cyRinder’ until rod is fully extended. Unscrew end c,ap and remove piston. 15835 32841 25877A 25876A vor~ ~ Safety Related 6-29 25875 6234 EEl 7. To replace internam O-ring and scraper in end cap, piston rod eyelet must be removed. ThoroughJy degrease rod and holder. Cmampthe piston rod assembly in a vise using Volvo Penta Hydraulic Cylinder Rod Holder P/N 3854367-4 (~). EEl 8. Remove eyelet by turning counterclockwise using the trim/tilt rod (E) that secures trim/tilt cyminders to gearcase, if rod slips in special tool, a piece of paper or thin card will increase grip on rod. [~ ff eyelet cannot be removed as above, heat eyelet shank with torch or heat lamp untiJ warm. EEl 9. Puln end cap off rod, then pry scraper out of end cap and discard. [~l ~ 10. Remove both external and internal O-rings from end cap and discard. I~ 11. Carefully remove two split-ring retainers © and O-ring (~) from piston and discard. Do not remove or disassemble piston; there are no service parts. ff troubleshooting indicates impact valve leakage, hold piston rod with Volvo Penta Hydraulic Cylinder Rod Holder P/N 3854367-4 and loosen large piston screw untiO relief bails unseat. W/ash parts with solvent, and bmow out with air. Tighten piston screw securely upon reassembly. Reassemblyof Trim/Tilt Cylinder 1. Clean all hydraulic cylinder components in fresh solvent. Blow dry with compressed air. It is essential that all componentsare kept absolutely clean and dust free. Any dirt on internal components could cause scoring of the cylinder bore. Lubricate all internal components with Volvo Penta power trim~tilt & steering fluid or Dexron II automatic transmission fluid. i& 13330 25874 13333 6-30 w~,w COR RECT 25873 2. Face scraper lip toward tool, and use Volvo Penta Seal Installer P/N 3854364-1 or socket to install new scraper in end cap. 7EZ-~ 3. Insert a new O-ring inside end cap, and place a new O-ring around end cap. Lubricate O-rings with trim fluid. Eg~ E~ 4. Place a new O-ring @ on piston and lubricate it with trim/tilt fluid. Position split-ring retainers @ on either side of O-ring making sure ends match as shown. The retainers are fragile and easily distorted or broken. Take care while installing them. 5. Lubricate internal O-ring, scraper, and piston rod. Place Volvo Penta Tilt Cylinder Seal Protector P/N 3854383-3 on end of rod, then slide end cap onto rod. [~] 6. Thoroughly dean threads of piston rod and eyelet to remove old sealant. Use Loctite primer or equivalent on threads. aamp rod in a vise with Volvo Penta Hydraulic Cylinder Rod Holder P/N 385436’1-4 ~). Apply Loctite or equivalent to threads of rod and eyelet, and securely tighten eyelet on piston rod. 7. Clamp cylinder trunnion in soft-jaw vise. Lubricate cylinder bore, piston, and O-ring with trim fluid. Compress split-ring retainers with your fingers and push piston rod into cylinder bore. 8, Push piston rod all the way down into the cylinder. Fill the chamber with Volvo Penta power trim/tilt & steering fluid. CORRECT DNCORRECT iNCORRECT DR1737 13337 13338 25872 vD,~.,~ 6-31 [~ [~ 9. Thread end cap into cylinder and tighten using Volvo Penta Spanner Wrench P/N 3854385-8. Tighten end cap to 25-30 ft. Ibs. (34-41 N-m}. Rotate eyelet hole until it’s parallel to trim/tilt rod hole Jn base of cylinder. 10. Attach trim/tilt cylinders to transom shield following procedure in Transom Shield section. Attach cylinders to drive unit following procedure in Drive Unit Removal and Installation section° 11. Fill and bleed reservoir and trim cylinders following Trim Motor and Reservoir procedure in Filling and B|eeding Dry System. Filling and Bleeding Dry System If trim components have been disassembled, or are known to be empty, follow this filling and bleeding procedure. Trim Cy|inders 1. Move trim rods to their fully retracted (down) position. 2. Unscrew cylinder end caps and fill the low-volume chambers with Volvo Penta power trim/t~ & steering fluid.Install cylinder end caps and tighten to 25-30 ft. Ibs. (34-41 N-m). 3. install trim cylinders and securely attach hydraulic lines. Trim Motor and Reservoir 1. Mount motor and reservoir assembly on transom. Securely attach hydraulic trim lines. 2. Removereservoir fill plug. Fill reservoirwith Volvo Penta power trim/tilt & steering fluid until level reaches bottom of fill hole. 3. While continuing to fill reservoir, activate trim in "UP"direction. Make several stops as drive raises to give fluid time to reach bottom of plug hole. Continue this fill-stop-fill sequence until trim rods are fully extended and drive is in full tilt position. 4. Add fluid until it’s level with bottom of fill hole, then install and tighten plug. 5. Run drive through a minimum of five up and down cycles to purge air. Stop drive at full tilt position to make a final check of fluid level. Top off reservoir as necessary. 25868 25867 Ground Clip Replacement Removal 1. If trim cylinder is attached to drive unit, removethe Iocknut protector and one nut and washer from rear shaft. Pull shaft out of cylinder rod eye. ~] 2. Pull out bushing and grommet, then take out ground clip. installation 3~ 1. insert ground clip into cylinder rod eye, then push in bushing and grommet. 2. To attach cylinder to drive unit, push trim/tilt shaft back through rod eye. Install flat washer and new elastic Iocknut. Tighten locknut to 10-12 ft. Ibs. (14-16 N-m). Install Iocknut protector. 25856 Hydraulic Pressure Specifications ~ ~, ~ ~ ~ Mode Normal Pressure Notes Trim-out/tilt-up running Tilt-up stall Tilt-up staml/leak-down Trim-in/tilt-down running "i~=im-install Trim-in stall~leak-down Impact Valve Opening 225-275 PSi (1551-1896 kPa) 1200-1600 PSi (8274-11,032 kPa) 200 PSI (1379 kPa) maximum 400-800 PSi (2758-5516 kPa) 400-800 PSi (2758-5516 kPa) 200 PSi (1379 kPa) maximum 1800 PSI (12,411 kPa) minimum 48 amps max. 92 amps max. 5 minutes rain. 60 amps max. 66 amps max. 5 minutes rain. - NOTES Section 7 Propellers Table of Contents Boat Bottom Condition ...................................... 7-5 Painting ....................................... 7-5 Boat Trailers ..................................... 7-5 Boat Trim ....................................... 7-5 High Altitude Operation ............................ 7-6 Propellers Application Charts ............................... 7-6 Left Hand Rotation Models ........................ 7-4 Hub Replacement ............................... 7-3 Removal and Installation .......................... 7-3 Selection ...................................... 7-2 Test Wheel Chart ................................. 7-6 Safety Warnings Before working on any part of this section, read the section called Safety at the end of this manual. When replacement parts are required, use genuine Volvo Penta parts or parts with equivalent characteristics including type, strength and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers. Propeller Selection Selecting the correct propeller for each engine/boat combinationwill ensure good engine service life and boat performance by permitting the engine to operate within the recommended RPM range. A propeller must be carefully selected to match the engine/boat combination, its intended application, and the anticipated load of the boat. Selection of the wrong propeller will reduce engine service life, affect boat performance, and may cause serious engine damage. [=1"] It’s important to remember that propeller pitch and diameter determine engine RPM at full throttle. To determine the propeller best suited for each application, use a tachometer of known accuracy to check engine RPM. The propeller which allows the engine to obtain the maximum percentage of available horsepower ~), and run near the top limit of its full throttle operating range® with the lightest load the boat will carry, is suited for your application, in most cases, selecting a propeller in this manner will prevent the maximum RPM dropping below the low limit of the operating range when the boat has a maximum load. There are instances when the propeller selected cannot cover the complete range of boat applications, for example, from water skiing to high speed performance. In such cases, it may be necessary to change propellers to suit each particular situation. e © Propeller prevents engine RPM from attaining the specified "Full Throttle Operating Range." Engine is laboring, install lower pitch propeller. ¯ (~) Propeller allows engine RPM above the specified "Full Throttle Operating Range."Engine is overspeeding, install higher pitch propeller. ® 100% 90% 80% 70% 60% 50% 4O% 30% DR3406 7-2 vDfrB/eng Remember,if ftjlt the engine operates below the recommended throttle RPM range, the engine is laboring and power and efficiency are being lost. if the engine operates above the recommendedfull throttle RPMrange, engine speed is excessive and additional power and efficiency are not being gained, in either case, serious engine damage may result. Changing pn)pellers on some Volvo Penta SXmodels may require readjusting the trim tab. Propeller Hub Replacement A rubber hub in the propeller is the shock absorber which minimizes the chance of damaging the propeller, lower gearcase, or drive train components during shifting or striking an underwater object, if the hub should become and slip, can be damaged it replacedby an authorized Volvo Penta service dealer or propeller station. Propeller Removal and Installation ~.~ To avoid accidental starting of engine, be sure remote control is in NEUTRAL position and ignition key is removed. Protect your hands from sharp edges of propeller blades by wearing gloves when removing or installing the propeller. Removal EEl1. Remove pin ®. Remove ®. Place cotter keeper b=ock of wood between propeller blade and anti-ventilation plate. 2. Removepropeller nut ©, spacer @, propeller (~), and thrust bushing (~). 3. Wipe propeller shaft clean. Inspect for monofilament line; removeif present. Installation 1. Coat the propeller shaft splines sparingly with Volvo Penta Grease. 2. Place thrust bushing ® on propeller shaft with inner tapertoward gearcase to match taper on shaft. Slide propeller (~) onto shaft, engage bushing, and seat propeller against propeller sh~=ft taper. EEl 3. nnstaJl the spacer ® on splines of the propeller shalit. Place a block of wood between the propeller blade and antiventiUation plate. [~3 [~ 4. Install and tighten propeller nut © to 70-80 ft. Ibs. (95-108 N-m). DR2498 23927 6804 w~.w ~ Safety Related 7-3 ~J 5. Index keeper on propeller nut until aligned with cotter pin hole ® as shown. DE] 6. Install cotter pin and bend ends to secure. [~ Propeller spacer, nut, keeper and cotter pin must be installed as shown. Failure to install all could result componentsin loss of the propeller when boat is operated in REVERSE. Left-Hand Rotation Models All Volvo Penta SXmodelshave a drive capable of both right and left-hand rotation. Left-hand rotation is accomplished in the drive unit upper gear housing. The propeller, propeller shaft and vertical driveshaft are the only parts that rotate to the left. The engine always rotates to the right. Setting a Volvo Penta SX drive for left-hand rotation is done by changing the position the shift linkage at the rear of the upper gear housing from the left side of the shift housing to the right side, and installing a 1eft-hand rotation propeller. For more information see Upper GearUnit in the appropriate section in this workshop manual. ~] [~ Right-hand rotation propellers rotate clockwise to propel a boat forward. Right-hand propellers are considered standard rotation propellers. To identify a right-hand rotation propeller, note the angle ~) of the blade as viewed from the port side. This propeller is used on single engine boats or on the starboard engine of a twin engine boat. [~ [-5=] Left-hand rotation propellers rotate counterclockwise to propel a boat forward. Left-hand propellers are considered counter-rotation propellers. To identify a left-hand rotation propeller, note the angle © of the blade as viewed from the port side. This propeller is used ONLY on the port engine of a twin engine boat. 6602 6598 DR2933 DR2934 DR2@31 7-4 VD/TB/eng Never interchange a right-hand rotation pro- pellet with a left-hand rotation propeller. This would result in the boat being propelled in reverse when the motors are operated in forward gear, and forward when the engines are operated in reverse gear. After having the propellers, remote control or shift cables serviced, shift into FORWARD or REVERSE idle the boat at speed to determine if moves in the direction indicated by the position of the control handle, if the boat moves OPPO- SiTE the direction indicated by control handle, check for correct propeller, and check installation and adjustment of the remote control and shift cables. Failure to perform the above test could re- suit in loss of boat control. Condition of Boat Bottom The condition of the boat bottom affects the boat’s performance considerably. Marine growth (slime, barnacles, of" other foreign matter), which will accumulate in fresh or salt water, will cut down on performance and speed. The boat bottom should be cleaned periodically in accord ance with manufacturer’s recommendations. Bottom Painting if your boat is in water where marine growth is e problem, the use of an anti-fouling paint will reduce the growth rate. See your dealer for an anti-fouling paint that is suitable for your area. ® Tin base anti-fouling paint (TBTA or TBTF~) is recommendedwhere its use is permitted. Copper base anti-fouling paint may be used, but will require more frequent inspection and replacement of sacrificial anodes. DO NOT PAINT any part of the drive unit with copper base anti-fouling paint. Tributyl "]’in Adipate or Tributyl Tin Fluoride ~ot~ Copper base anti-fouling paint should never touch the transom shield or drive unit. Always leave a I/~ in. (12 mm) gap between bottom paint and drive assemblies. Painting the drive unit with copper base paint will accelerate galvanic corrosion. ¯ Vinyl-butyl base anti-fouling paint is a recommended alternative. ¯ DO NOT USE any graphite base antifouling paint. Never paint anti-corrosion anodes, or their effectiveness will be lost. See the Volvo Penta Parts Catalog for anode kits that provi;de further corrosion protection for the outdrive assembly. Boat Trailers It is extremely important that the trailer fits the boat properly. Loss of boat performance and speed may be due to improper trailer support and excessive tie-down pressure which has caused the boat bottom to hook. The boat should rest firmly on the trailer with maximum tie-down pressure applied at the bow and transom only. Boat Triim The power trim/tilt system allows for trimming the drive unit in or out to compensatefor a major change in boat loading and weight distribution. Z~ Safety Related High Altitude Operation A performance loss at altitudes above 5000 ft. can be expected. If you are boating above 5000 ft. elevation for a short term, a lower pitch propeller will restore some of the lost performance. Long term use above altitudes of 5000 ft. may require a --T change in gear ratio. Contact your Volvo Penta deamer regarding installation of a high altitude gear set. [~ To avoid permanent engine damage, be sure that a boat modified for high altitude operation is propermy identified. Return it to its original gear ratio if operated for prolonged periods at or near sea level. _J L_ Test Wheel Chart Dimension Dimension Mociels Right-Hand Rotation Left=Hand Rotation (~ (inches) (~) (inches) 3.0 GL, GS and 4.3 GL GS 3850452 3850663 2 1/2 11%6 5.7 GL, 5.0 and 5.8 FL and Fi 3850453 3850664 2 7/8 11 3/16 Test wheels are a load producing device only. They are not intended to be used to determine power output. Always use the correct test wheel for the particular engine being tested. Satisfactory testing cannot be accomplished if an incorrect test wheel is used, and in some cases engine damage may result. Never allow the engine to exceed the maximum recommendedRPM. Propeller Application Charts Propellers listed in the Volvo Penta Propeller application guide are to be used to pick a starting point when determining the best propeller to be used with a boat and engine combination. The boat should be run with a light load and trimmed for best boat speed (maximum the trim angle without ventilating propeller). Record maximum engine RPM from a known good tachometer. Once the engine RPM is known, the propeller should be changed to get the engine RPM as close to the upper end of the RPM range as possible. A two (2) inch increaseor decreaseof propeller pitch wUl result in a changeof engine RPIVl at wide open throttle of about 300 RPM. Use this figure for making final propeller selections. Volvo Penta manufacturesseveral different styles of propellers. Some propellers may have applications on several types of boats. Consutt your Volvo Penta Parts catalog or Accessory CataEog for descriptions of the different propellers. This will help you chose the correct propeller for your application. 7-6 vDrrB/ong Safety Section Part A Marine Products and Safety of People Who Use Them... S-2 Stern Drive Shift System .......................... S-3 Stern Drive Throttle Control System ................. S-4 Stern Drive Steering System ....................... S-5 Stern Drive Fuel, Electrical System .................. S-7 Part B Marine Products and Safety of People Who Fix Them .. S-11 Handling Stern Drives ........................... S-11 Handling Lead Acid Batteries ..................... S-12 Gasolinel Handle with Care ....................... S-13 Hazardous Products ............................. S-14 VD/T~.o ~ Safety Related S-1 Part A -Marine Products and Safety of People Who Use Them Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure... ® Product user is informed... ¯ Products are safe and reliable... It’s up to you, the people who... ¯ Install accessories... ® Service and maintain the boat... ¯ Service and maintain the stern drive... ...to keep the products safe and reliable. This section talks about safe boating and how you can help keep it safe. Some things you may know ¯ . ¯ but others you may not. First! A word about fasteners.., plain.., special. ,. all screws, nuts, washers and bolts. Do Not Substitute Fasteners They look the same, but.., are they? ~ ~ The Same Size? The Same Strength? The Same Material? The Same Type? Standard or Metric Thread? DR3113 Don’t substitute unless you know they are the same in all characteristics. Second! ¯ Special locking screws and nuts are often used to attach steering, and remote control componentsto the stern drive. ¯ Whenyou remove any part from the stern drive, keep track of special screws and nuts. Don’t mix with other parts. ¯ Whenreassembling the stern drive, use only the special screws and nuts intended to hold steering, and control cables, plus related parts. ¯ Service with parts of know quality that meet Marine industry (BIAJABYC) Standard. S-2 VD/TB/e~ Stern Drive Shift System The Shift System starts here at the remote c.ontroi lever... . .. and ends here at the propeller. DR3114 What’s Most important? Whencontrol lever is in Forward, "W" Neutral or Reverse "position"... ... Shift mechanismmust ma¢cn control lever "position". DR3114 What Could Happen? ¯ If... Neutral t~ If... Forward Forward Reverse or Reverse DR3114 .... propeller is still powered(turning) ... boat will move opposite unknownto operator, or engine wilt to direction intended by operator. start in gear, boat will moveunexpectedly. How Can Loss of Shift Control be Minimized? in pre