Workshop Manual A

Sail boat drive 2(0)

130S-A, 130SR-A, 130S-B, 130SR-B,

 
130S-C, 130SR-C, 150S-A, 150SR-A,
150S-B, 150SR-B, 150S-C, 150SR-C
 Sail boat drive

130S-A, 130SR-A, 130S-B, 130SR-B, 130S-C, 130SR-C

150S-A, 150SR-A, 150S-B, 150SR-B, 150S-C, 150SR-C

Contents

Safety information .............................................. 2 Lower gear, renovation ...................................... 52

General information............................................... 5 Disassembly....................................................... 52
Repair instructions................................................. 6 Assembly............................................................ 57
Special tools ....................................................... 9 Gear wheels 130S, shimming............................. 58
Other special equipment.................................... 12 Gear wheels 150S, shimming............................. 60
Design and function ........................................... 13 Pinion gear 130S, shimming............................... 63
Gear change principle........................................ 13 Pinion gear 150S, shimming............................... 65
Upper gear housing............................................ 14 Final assembly.................................................... 74
Lower gear housing............................................ 15 Upper and lower gear housing, assembly ........ 78
Repair instructions ............................................. 16 Pressure testing..................................................... 82
Upper and lower gear housing, disassembly .. 16 Rubber bushing, change....................................... 83
Upper gear, renovation ....................................... 18 Painting.................................................................. 84
Disassembly....................................................... 18 Shimming, quick reference guide ..................... 85
Inspection........................................................... 26 Shim calculation, lower gear housing 130S........ 85
Gear mechanism, renovation............................. 28 Shim calculation, lower gear housing 150S........ 86
Upper gear, assembly......................................... 30 Shim calculation, lower gear housing................. 87
Upper gear, final assembly................................. 46 Shim table, upper gear housing.......................... 88
Shift mechanism, adjustment............................. 49 Troubleshooting .................................................. 89
Technical data ..................................................... 91
Torque.................................................................... 92

1
 Safety information

Introduction Check that the warning or information labels on

This workshop manual contains technical data, de- the product are always clearly visible. Replace
scriptions and repair instructions for the Volvo Penta labels which have been damaged or painted
products or product versions noted in the table of over.
contents. Check that you have the correct Workshop
Manual for your engine.
Never start the engine without installing the air
Read the available safety information, “General cleaner filter. The rotating compressor turbine in
Information and Repair Instructions” in the work- the turbocharger can cause severe injury. For-
shop manual before you start to do any service eign objects entering the intake ducts can also
work. cause mechanical damage.

Important Never use start spray or similar products as a

In this book and on the product you will find the fol- starting aid. They may cause an explosion in
lowing special warning symbols. the inlet manifold. Danger of personal injury.
WARNING! Warns for the risk of personal inju-
ry, major damage to product or property, or se- Avoid opening the coolant filling cap when the
rious malfunctions if the instruction is ignored. engine is hot. Steam or hot coolant can spray
out and the system pressure will be lost. Open
IMPORTANT! Is used to call attention to things the filler cap slowly, and release the pressure in
which could cause damage or malfunctions to the cooling system if the filling cap or tap has to
product or property. be opened, or if a plug or coolant hose has to
be removed when the engine is hot. It is difficult
NOTE! Is used to call attention to important informa- to anticipate in which direction steam or hot
tion, to facilitate work processes or operation. coolant can spray out.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out
Hot oil can cause burns. Avoid skin contact
when operating or servicing the engine.
with hot oil. Ensure that the lubrication system
is not under pressure before carrying out any
work. Never start or operate the engine with
Make it impossible to start the engine by cutting
the oil filler cap removed, otherwise oil could be
system current with the main switch(es)­and
ejected.
lock it (them) in the off position before starting
service work. Set up a warning notice at the en-
gine control point. Stop the engine and close the sea cocks before
As a general rule all service operations must doing any work on the cooling system.
be carried out with the engine stopped. Some
work, such as adjustments, need the engine to
be running, however. Approaching an engine Only start the engine in a well-ventilated area.
which is operating is a safety hazard. Remem- When operated in a confined space, exhaust
ber that loose clothing or long hair can fasten fumes and crankcase gases must be ventilated
in rotating parts and cause serious personal from the engine bay or workshop area.
injury.
If work is done adjacent to a running engine, a Always use protective glasses or goggles when
careless movement or a dropped tool can lead carrying out work where there is a risk of splin-
to personal injury in the worst case. Be careful ters, grinding sparks, acid splashes or where
with hot surfaces (exhaust pipes, turbos, charge other chemicals are used. Your eyes are ex-
air pipes, starting heaters etc.) and hot flu­ids in tremely sensitive, injury could cause blindness!
pipes and hoses on an engine which is running
or which has just stopped. Reinstall all protec-
tive parts removed during service ­operations
before starting the engine.

2
 General instructions

degreasers and wash residue.

Batteries must never be exposed to open
Avoid getting oil on your skin! Repeated expo-
flames or electric sparks. Never smoke close to
sure to oil or exposure over a long period can
the batteries. The batteries generate hydrogen
result in the skin becoming dry. Irritation, dry-
gas when charged, which forms an explosive
ness and eczema and other skin problems can
gas when mixed with air. This gas is easily
then occur. Used oil is more dangerous than
ignited and highly volatile. A spark, which can
fresh oil from a health aspect. Use protective
be caused by incorrect battery connection,
gloves and avoid oil soaked clothes and rags.
can cause a single spark which is sufficient to
Wash regularly, especially before eating. There
cause an explosion with resulting damage. Do
are special skin creams which counteract dry-
not shift the connections when attempting to
ing out of the skin and make it easier to clean
start the engine (spark risk) and do not lean
off dirt after work is completed.
over any of the batteries.

Always ensure that the Plus (positive) and

Most chemicals intended for the product (e.g.
Minus (negative) battery cables are correctly
engine and transmission oils, glycol, petrol
installed on the corresponding terminal posts
(gasoline) and diesel oil) or chemicals for work-
on the batteries. Incorrect installation can result
shop use (e.g. degreasers, paints and solvents)
in serious damage to the electrical equipment.
are hazardous. Read the instructions on the
Refer to the wiring diagram.
product packaging with care! Always follow the
safety precautions for the product (for example
Always use protective goggles when charging
use of protective mask, glasses, gloves etc.).
and handling the batteries. Battery electrolyte
Make sure that other personnel are not inad-
contains sulfuric acid which is highly corrosive.
vertently exposed to hazardous chemicals, for
Should the battery electrolyte come into contact
example in the air. Ensure good ventilation in
with unprotected skin wash off immediately us-
the work place. Follow the instructions provided
ing plenty of water and soap. If you get battery
when disposing of used or leftover chemicals.
acid in your eyes, flush at once with a generous
amount of water, and get medical assistance at
once.
Exercise extreme care when leak detecting
on the fuel system and testing the fuel injector
Turn the engine off and turn off the power at the
nozzles. Use eye protection. The jet from a fuel
main switch(es) before carrying out work on the
injector is under very high pressure, and has
electrical system.
considerable penetration ability; fuel can force
its way deep into body tissues and cause seri-
Clutch adjustments must be carried out with the
ous damage. Danger of blood poisoning (septi-
engine stopped.
cemia).
The existing lugs on the engine/reversing gear
should be used for lifting the assembly.
All fuels, and many chemicals, are flammable.
Always check that the lifting devises are in good
Do not allow naked flame or sparks in the vi-
condition and that they have the correct capac-
cinity. Petrol (gasoline), some thinners and hy-
ity for the lift (the weight of the engine plus the
drogen gas from batteries are extremely flam-
reversing gear and extra­equipment).
mable and explosive when mixed with air in the
The engine should be lifted with a customized
correct ratio. No Smoking! Ensure that the work
or adjustable lifting boom for safe handling and
area is well ventilated and take the necessary
to avoid damaging components on top of the
safety precautions before starting welding or
engine. All chains or cables should be parallel
grinding work. Always ensure that there are fire
to each other and should be as square as pos-
extinguishers at hand when work is being car-
sible to the top of the engine.
ried out.

Make sure that oil and fuel soaked rags, and

used fuel and oil filters are stored in a safe
place. Rags soaked in oil can spontaneously ig-
nite under certain circumstances. Used fuel and
oil filters are polluting waste and must be hand-
ed to an approved waste management facility
for destruction, together with used lubrication
oil, contaminated fuel, paint residue, solvents,

3
General instructions

If other equipment connected to the engine has Remember the following when washing with
altered its center of gravity, special lifting devis- a high pressure washer: Never aim the water
es may be needed to obtain the correct balance jet at seals, rubber hoses or electrical compo-
and safe handling. nents. Never use a high pressure washer for
Never do any work on an engine which just engine cleaning.
hangs from a lifting­devise. Never work alone
when removing heavy engine components,
Only use the fuels recommended by Volvo
even when using lifting devices such as lock-
Penta. Refer to the Instruction Book. Use of
ing tackle lifts. When using a lifting device two
fuels that are of a lower quality can damage the
people are usually required to do the work, one
engine. On a diesel engine poor quality fuel can
to take care of the lifting device and another to
cause the control rod to bind and the engine
ensure that components are lifted clear and not
to overrev with resulting risk of damage to the
damaged during the lifting operations.
engine and personal injury. Poor fuel can also
When you work aboard a boat, always make
lead to higher­maintenance costs.
sure that there is enough space for disassem-
bly where you are working, with no risk of per-
sonal injury or material damage.

WARNING! Components in the electrical and

fuel systems on Volvo Penta products have
been designed to minimize the risks of explo-
sion and fire. The engine must not be run in
areas where there are explosive materials.

WARNING! Fuel delivery pipes must not be

bent or straightened under any circumstances.
Damaged pipes must be replaced.

4
 General instructions

General information

About this Workshop Manual Spare parts

This workshop manual contains technical data, de- Spare parts for electrical and fuel systems are sub-
scriptions and repair instructions for the standard ject to various national safety requirements such as
version of sailboat drives 130S-A, 130SR-A, 130S-B, the US Coast Guard Safety Regulations. Volvo Penta
130SR-B, 150S-A, 150SR-A, 150S-B and 150SR-B. Original Spares comply with these requirements. No
The workshop manual can illustrate tasks done on damage whatever, occasioned by use of non-original
any of the drives noted above. This means that the Volvo Penta spares for the product, will be compen-
illustrations and photographs which clarify certain de- sated by the warranty offered by Volvo Penta.
tails might not correspond with other drives in some
cases. The repair methods are similar in all important
respects, however. If this is not the case, this will be
noted and important differences will be shown sepa-
rately. The gear design, gear ratio and serial number
are always noted on the type plate. The data on the
type plate must always be given in all correspon-
dence about a gear.

The Workshop Manual is produced primarily for the

use of Volvo Penta workshops and service techni-
cians. This assumes that people who use the Manual
have basic knowledge of marine drive systems and
can do the tasks of a mechanical or electrical nature
associated with the trade.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on
product data which was available up to the date on
which the manual was printed. Any material changes
introduced into the product or service methods after
this date are notified by means of Service Bulletins.

5
General instructions

Repair instructions

The working methods described in the Workshop

Manual apply to work carried out in a workshop. For
Our common responsibility
this reason, the drive is removed from the boat and Each engine and drive consists of a large number of
installed in a fixture. Renovation work which does not collaborating systems and components. Any devia-
need the drive to be lifted out can be done in situ, tion of a component from its technical specification
with the same work methods, unless otherwise speci- can dramatically increase the environmental impact
fied. of an otherwise good engine with attached drive. For
this reason, it is extremely important that specified
wear tolerances are maintained, that systems with
The warning signs which occur in the workshop adjustment facilities are correctly adjusted and that
manual (please refer to “Safety information” for their Volvo Penta Original Spares are used for the engine
meanings) and drive. The times specified in the engine mainte-
nance schedule must be followed, in the same way
WARNING!
as the drive bellows, zinc anodes and oil changes
etc. are changed.
IMPORTANT!
Remember that most chemical products, incor-
NOTE! are not comprehensive in any way, since we rectly used, damage the environment. Volvo Penta
can not of course foresee everything, because ser- recommends the use of biodegradable degreasers
vice work is done in highly varying circumstances. whenever drive components are de-greased, unless
For this reason, all we can do is to point out the risks otherwise specified in the workshop manual. When
which we believe could occur due to incorrect work in working aboard a boat, be careful to ensure that oils,
a well-equipped workshop, using work methods and wash residue etc. are processed for destruction, and
tools tested by us. are not inadvertently discharged with bilge water into
the environment.
All operations described in the Workshop Manual
for which there are Volvo Penta Special Tools avail-
able assume that these tools are used when carrying
Torque
out the repair. Volvo Penta Special Tools have been The tightening torques for vital fasteners, which
specifically developed to ensure the most safe and should be tightened with a torque wrench, are listed
rational working methods possible. It is therefore the in the workshop manual, “Technical data, Tighten-
responsibility of anyone using other tools or other ing torque” and specified in the work descriptions
working methods than we recommend to determine in the book in bold face. All torque specifications
that there is no risk of personal injury or mechanical apply to clean screws, screw heads and mating
damage or malfunction as a result. faces. Torque data stated apply to lightly oiled or dry
In some cases special safety precautions and user threads. If lubricants, locking fluids or sealants are
instructions may be required in order to use the tools needed on a fastener, the type of preparation to be
and chemicals mentioned in the Workshop Manual. used will be noted in the job description.
These rules must always be observed, so there are Where the tightening torque for a fastener is printed
no special instructions about this in the workshop in plain text, the general tightening torques should be
manual. used. The torque specification is a target value and
The majority of risks can be prevented by taking the fastener does not need to be tightened with a
certain elementary precautions and using common torque wrench.
sense. A clean work place and a clean drive will
eliminate many risks of personal injury and engine
malfunction.
Above all, when work on hydraulic systems, lubri-
cation systems, bearing seals and sealed joints is
done, it is extremely important that no dirt or foreign
particles are able to get in, since this would otherwise
cause malfunctions or shortened repair life.

6
 General instructions

Torque-angle tightening Always follow the manufacturer’s ­instructions­for use

regarding temperature range, ­curing time­and any
In torque/angle tightening, the fastener is tightened other instructions for the product.
to the specified torque, and tightening then continues
Two different basic types of preparation are used on
through a pre-determined angle. Example: for 90°
the drive. These are:
angle tightening, the fastener is turned a further 1/4
turn in one sequence, after the specified tightening RTV preparations (Room Temperature Vulcanizing).
torque has been achieved. These preparations are used when two flexible flang-
es, such as oil pan – engine block, are fitted together
without a gasket. RTV is visible when a part has been
Strength classes disassembled; old RTV must be removed before re-
Screws and nuts are sub-divided into different sealing the joint. Old sealant should be removed with
strength classes. Classification is indicated by mark- gasket scraper 885 516 and denatured alcohol.
ings on the screw head. A marking with higher num- Anaerobic agents. These agents cure in the ­absence
ber indicates stronger material. For example, a screw of air. These preparations are used when two solid
marked 10-9 is stronger than one marked 8-8. For components, such as valve housing – engine block,
this reason, it is important when screws are disas- are fitted together without a gasket. Common uses
sembled that the screws are put back in their original are also to lock and seal plugs, stud threads, taps, oil
locations on re-assembly. If a screw must be replaced pressure monitors etc. Hardened anaerobic prepara-
check in the spare parts catalogue to make sure the tions are glassy and for this reason, the preparations
correct bolt is used. are colored to make them visible. Hardened anaero-
bic preparations are highly resistant to solvents. Old
Sealants etc. sealant should be removed with gasket scraper 885
516.
Several different types of sealants, locking fluids and
The surface should then be degreased with dena-
assembly compounds are used on the drive. The
tured alcohol.
properties of the preparations differ, and they are
intended for different strengths of fastener, tempera- The following anaerobic preparations are mentioned
ture, resistance to oil and other chemicals, and for in the workshop manual:
the different materials and gap thicknesses found in Sealant (red), part no. 840 879
the engine. Sealant (brown), part no. 116 1370
Thread locking fluid, part number 116 1053
To ensure service work is correctly carried out it
is important that the correct sealant and assembly The following assembly paste is used on the drive:
paste is used on the fasteners where the prepara- Grease, part number 828 250. Used on seal rings
tions are required. and screws on the lower gear.
In this Volvo Penta Workshop Manual the user will
find that each section where these agents are ap-
plied in production states which type was used on the
drive.
The same preparations should be used in service
work.
When sealants and locking fluids are used, it is im-
portant that the surfaces are free from oil, grease,
paint and rust-protection, and that they are dry.

7
General instructions

Safety rules for fluorocarbon

rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings, for example.
When fluorocarbon rubber is exposed to high tem-
peratures (above 300 °C), hydrofluoric acid can be
formed, which is highly corrosive. Contact with the
skin can result in severe chemical burns. Splashes in
your eyes can result in severe chemical burns. If you
breathe in the fumes, your lungs can be permanently
damaged.

WARNING! Observe the greatest care in work-

ing on engines which might have been exposed
to high tempera­tures, such as overheating
during flame cutting or a fire. Seals must never
be cut with a flame torch during disassembly,
or burned in uncontrolled circumstances after-
wards.

• Always use chloroprene rubber gloves (gloves

for chemicals handling) and goggle­s. Handle the
removed seal in the same way as corrosive acid.
All residue, including ash, can be highly corro-
sive. Never use compressed air to blow anything
clean.
• Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under
running water before removing them.
The following seals are most probably made from
fluorocarbon rubber:
Seal rings for the crankshaft, camshaft, drive shafts.
O-rings, regardless of where they are installed. O-
rings for cylinder liner sealing are almost always
made of fluorocarbon rubber.

Please note that seals which have not been ex-

posed to high temperature can be handled nor-
mally.

8
 Special tools

884 143 884 161 884 359 884 611 884 721

884 723 884 726 884 752 884 753 884 754

884 777 884 830 884 833 884 959 885 178

884 143 1) Standard extension 884 753 1) Plate for installing the gear wheel on the
propeller shaft

884 161 1) Slide hammer for removing the propeller 884 754 1) Mandrel for installing bearings, output
shaft shaft, upper gear

884 359 1) Mandrel for installing bearing races in 884 777 1) Mandrel for installing bearing race,
the upper gear lower gear.
884 830 1) Splined socket 130S

884 611 1) Adapter for above slide hammer 884161 884 833 1) Mandrel for removing the vertical shaft

884 721 1) Puller for bearing races, lower gear 884 959 1) Mandrel for disassembing the bearings
on the input shaft
884 723 1) Counterhold for disassembling the bear-
ing race, propeller shaft 885 178 1) Circlip pliers

884 726 1) Expander for disassembling the bearing

race, propeller bearing housing
884 752 1) Mandrel for disassembling the gear
wheel from the propeller shaft, installing
seal rings in the propeller bearing hous-
ing.

1)
This tool is used with one or more of Volvo Penta’s older prod-
ucts.

9
Special tools

885 370 885 377 885 474 885 475 885 479

885 480 885 481 885 523 885 560 885 568

885 571 885 572 885 849 885 850 885 851

885 370 1) Mandrel for disassembling the bearing 885 560 1) Splined socket 150S
on the input shaft 885 568 1) Plate for puller halves
885 377 Press tool for splitting the gear wheel
1)
885 571 1) Fixture for magnetic stand
unit
885 572 1) Fixture for measuring gear flank clear-
885 474 1) Fixture for upper gear housing ance, lower gear.
885 475 1) Clamp for fixing the input shaft upper 885 849 Counterhold for removing the nut on the
gear upper vertical shaft 130S
885 479 1) Counterhold for removing the nut on the 885 850 Counterhold for removing the nut on the
upper vertical shaft 130S upper vertical shaft 130S
885 480 1) Fixture for shim calculation, input shaft. 885 851 Puller for needle roller bearing, lower
885 481 1) Plate for removing bearing races in the gear
upper gear
885 523 1) Measurement fixture, cam shift mecha-
nism

1)
This tool is used with one or more of Volvo Penta’s older prod-
ucts.

10
 Special tools

885 852 885 853 885 854 885 870 385 0617

999 1801 999 2584 999 5028 888 20004 888 20005

888 20007 888 20009 888 20010 888 20012 888 20013

888 20014

885 852 Puller for bearing and needle roller bear- 888 20004 Puller for lower vertical shaft.
ing race, lower vertical shaft 888 20005 Splined socket
885 853 Counterhold for removing bearing on 888 20007 Fixture for removing upper nut on lower
propeller shaft, 150S vertical shaft
885 854 Mandrel for installing bearing race, lower 888 20009 Mandrel for installing seal ring in gear
gear (with plastic ring). mechanism
885 870 Alignment tool for shift mechanism 888 20010 Fixture for lower gear housing
385 0617 1) Counterhold for removing bearing on 888 20012 Measurement fixture, vertical shaft 130S
input shaft, propeller shaft (only 130S)
and for installing bearing and needle 888 20013 Measurement fixture, vertical shaft 150S
roller bearing on lower vertical shaft. 888 20014 Press tool for changing rubber bushing,
999 1801 Standard extension
1) upper gear housing
999 2584 1) Counterhold for disassembling the gear
wheel, propeller shaft
999 5028 1) Mandrel for removing output shaft, upper
gear

1)
This tool is used with one or more of Volvo Penta’s older prod-
ucts.

11
Special tools

Other special equipment

885 511 885 516 885 531 998 5472 998 9876

999 9701 999 8081 999 9696 999 2520 380 7716

888 20006

885 511 1) Roller for sealant

885 516 1) Gasket scraper
885 531 Pressure testing kit
885 636 1) Roller (spare part for 885 511)
998 5472 1) Depth micrometer
998 9876 1) Dial gage
999 9701 1) Micrometer 0-25 mm
999 8081 1) Torque wrench, for checking turning
resistance
999 9696 1) Magnetic stand
999 2520 1) Stand for fixture

380 7716 1) Marker dye for checking gear engage-

ment pattern 2)
888 20006 Dial gage with long tip

1)
This tool is used with one or more of Volvo Penta’s older prod-
ucts.
2)
The powder is mixed with a drop of oil to form a “dry” mixture.

12
 Design and function

REVERSE position for

left-hand rotating propeller

FORWARDS position for

left-hand rotating propeller

13
Design and function

Upper gear housing

14
 Design and function

Lower gear housing

15
Repair instructions

Repair instructions

Upper and lower gear housing,

disassembly
1
Install fixture 888 20010 on drive.
Install fixture in stand 999 2520.

2
Clean the outside of the upper and lower gear hous-
ings.
Remove the drain plug and drain the oil.
Scrap the O-ring.

16
 Repair instructions

3
Then remove all the screws, 10 pcs below the divi-
sion line of the drive.

4
Split the drive.
Save the shims (1) and note the thickness of the shims.
Lift away the splined socket (2). Scrap the gasket.

5
Remove the adapter plate and remove the rubber
seal.
Check the rubber seal for cracks and wear.

WARNING! The rubber seal should be changed

every seven years, or earlier if defects are
found.

Scrap the O-rings.

17
Repair instructions

Upper gear, renovation

Disassembly
IMPORTANT! Mark the components when dis-
assembled, to avoid mixing them up.
Note the thickness and position of all the shims
in the gear housing when you are working.
There is a template for this at the end of the
manual.

1
Install fixture 885 474 on the gear housing, if this has
not been done previously.
Install fixture in stand 999 2520.

2
Remove the rear cover. Scrap the gasket. Save the
shims.
Put the gear selector in neutral and remove the gear
mechanism.

3
Remove the upper part of the gear housing. Tap the
input shaft with a plastic-faced mallet to break the ad-
hesive joint between the housing halves.

18
 Repair instructions

4
Remove the plug and slide the selector fork shaft out.

5
Lift the input shaft out.
Scrap the seal ring.
Save the shims and note the thickness of the shims.
Remove the outer bearing races.

6
Install splined socket 888 20005 in the vice. Put the
input shaft in the splined socket.
Remove the screws and washer and shims. Note the
thickness of the shims.
Clean all traces of locking fluid off the threads.

19
Repair instructions

7
Put the input shaft in a press, with the splines facing
down.

Press off, in one and the same operation:

– tapered roller bearing
– sintered washer
– needle roller bearing
– spacer sleeve
– needle roller bearing
– spacer ring
– shims
– rear gear wheel unit
– rear friction plate unit
– clutch unit
– front friction plate unit
– front gear wheel unit
Use mandrel 884 959.
Save the shims and note the thickness of the shims.

8
Remove the key from the shaft.

20
 Repair instructions

9
Lift off the shims, spacer ring and needle roller bear-
ing.
Save the shims and note the thickness of the shims.

10
Press off:
– needle roller bearing race
– spacer
– needle roller bearing with needle roller bearing race
– sintered washer
– tapered roller bearing
Use mandrel 884 959 and counterhold 385 0617.

21
Repair instructions

11
Remove the front and rear gear wheels from their
flanges as follows:
Press the sintered washer down with press tool
885 377 as in the illustration.
Remove the circlip with circlip tong 885 178.

12
Lift away:
– sintered washer
– the two disc springs
– washer

Remove the circlip.

Lift away:
– spacer ring
– shim
Save the shims and note the thickness of the shims.

13
Tap the gear off the flange with a plastic faced ham-
mer.
Save the shims and note the thickness of the shims.

22
 Repair instructions

14
1
Remove the three springs (1) and the two holders (2)
and (3) from the clutch unit. Be careful to save the 2
balls, three in each holder.

NOTE! Put the hub (4) with clutch plate (5) in a cloth 4
etc. before separating them, to prevent pins and
springs from flying away.
5
Carefully separate the hub and clutch plate.
Save the pins and springs.

15
Lock the slotted nut with counterhold 885 849 (130S-
A/B) and 22296432. Do not screw the screws in all
the way, the counterhold must be able to move axially.
Undo the nut by turning the shaft clockwise with
splined socket 884 830 (130S) or 885 560 (150S).

16
Remove counterhold and ring nut.
Press out the shaft, using mandrel 999 5028.

23
Repair instructions

17
Remove the lower bearing, shims and spacer sleeve.
Save the shims and note the thickness of the shims.

18
Press out the upper bearing race with plate 885 481
and standard shaft 999 1801.
Save the shims and note the thickness of the shims.

19
Turn the gear housing over and press the lower bear-
ing race out. Use tool 885 481 and standard shaft
999 801.

24
 Repair instructions

20
If the upper bearing needs to be changed, remove
the bearing with a knife puller.

25
Repair instructions

Inspection
1
Check all bearings and gear wheels.

2
If the sailboat drive is fully renovated, it is recom-
mended that the front and rear friction plate pack-
ages and the four thrust washers should be changed.

3
Check the clearance between the gear selector fork
and shaft, as in the illustration.
Permissible clearance 0.05 mm.
Change the gear selector fork if this clearance is ex-
ceeded.

26
 Repair instructions

4
Measure the wear on the sliding surfaces of the gear
selector fork.
Max permissible wear 0.2 mm.

5
Check that there is no cracking between the lugs on
the selector fork shaft.

6
Check the wear on the gear shift mechanism cam,
please refer to “Gear mechanism, renovation”.

27
Repair instructions

Gear mechanism, renovation

Special tool: 885 523

Removal
1
Undo the clamping screw and remove the selector
arm.
Clean any paint residue off the shaft and then sepa-
rate the shaft/cam from the housing.

2
Carefully prise out the seal ring with a screwdriver.

Inspection
3
Check the wear on the cam, using measurement fix-
ture 885 523.
Thread the fixture onto the cam. Tighten the socket
cap screw slightly, to eliminate any clearance be-
tween the fixture and the cam.

28
 Repair instructions

4
Measure as in the illustration.
Max permissible difference between the two mea-
surements 0.6 mm.
Change the cam if the difference exceeds the per-
missible value.

Assembly
5
Put the gear change mechanism on two plates (sepa-
rated slightly so that the tension pin is free) and press
the seal in with mandrel 888 20009. Align the seal as
in the illustration.
Align the mandrel as in the illustration, and press until
the mandrel bottoms against the plates.

6
Grease the bore and the seal ring liberally with
grease, VP part no. 828 250.
Install the cam and the selector arm.
Angle the selector arm as in one of the two alterna-
tives in the illustration (depending on what the boat
installation looks like) and make sure that the clear-
ance between the arm and the housing is at least 0.5
mm.
IMPORTANT! Torque the clamping screw to:
22 ± 1 Nm

29
Repair instructions

Upper gear, assembly

Output shaft
1
Place shims for the upper bearing race in the gear
housing as follows:
- if the original drive kit and bearings are to be used,
use the original quantity of shims.
- if the drive kit and/or bearing has been changed,
use 0.60 mm as a rough guide.
Press the bearing race in with mandrel 884 359.

2
Turn the gear housing over and press the lower bear-
ing race in with mandrel 884 359.

30
 Repair instructions

3
Press the bearing onto the output shaft with mandrel
884 754. Remember to protect the gear tooth tips.

4
Put spacer sleeve (1) on the output shaft.
Put the original shim thickness on the shaft. If this
value is not known, use 0.90 mm as rough guide.
Put the output shaft in the gear housing and press
the lower bearing on with mandrel 884 754. Press the
gear until it bottoms against the shim.

IMPORTANT! Check that the bearings do not

lock against each other, by turning the gear
housing over during the press operation. Aban-
don the operation in this case, press the out-
put shaft out and increase the shim thickness
slightly.

5
Check the turning round torque with torque wrench
1 rpm/sec 999 8081 and splined socket 884 830 (130S) or 885
560 (150S).
Correct value:
New bearings Slack free–0.5 Nm
Run-in bearings Slack free–0.5 Nm
If there is slack, press the output shaft out and re-
duce the shim thickness. If the turning round torque
is too high, the shim thickness should naturally be
increased.

31
Repair instructions

6
When the correct value has been obtained, screw the
hook nut on.

NOTE! Align the nut as in the illustration.

Fix the nut with counterhold 885 479 (130S-A/B) or

885 849. Tighten the nut by turning the shaft anti-
clockwise with splined socket 884 830 (130S) or 885
560 (150S).
Tightening torque 50 Nm.

Shim calculation
7
Put the following components on measurement fix-
ture 885 480 in this order:
– tapered roller bearing
– sintered washer
– needle roller bearing
– spacer sleeve
– needle roller bearing
– spacer ring
– shims (the original thickness, if this is not
known, use 0.50 mm as a rough guide)
– front flange
– hub
– shims (the original thickness, if this is not
known, use 0.50 mm as a rough guide)
– spacer ring
– needle roller bearing
– spacer sleeve
– needle roller bearing
– rear flange
– sintered washer
– tapered roller bearing
– washer
– screw
Tighten the screw lightly, about 10 Nm.

32
 Repair instructions

8
Measure the clearance between the hub and both
flanges with a feeler gage.
The clearance should be equal on each side and
should be 0.50–0.55 mm.
Correct the shim thickness if necessary, to give the
correct clearance.

9
Slide the flanges apart and measure distance (A).
This distance indicates the distance that the front and
rear gear wheels will be placed from each other.
Example: A = 109.80 mm

10
The gear wheels are made to be located 107.60
(2x53.8) mm away from each other.
This distance (B) should be corrected by the devia-
tion in the gear wheels. The deviation in mm is en-
graved on the gear wheel, for example “0,15”. The
values are always positive.
Read the distance on the gear wheel and correct di-
mension B.
Example: B = 107.60 + 0.20 + 0.21 = 108.01

33
Repair instructions

11
If we now delete distance (B) (which we want to have
between the gear wheels) from distance (A) (which
is the actual distance between the flanges) and halve
this amount, we get the shim thickness that needs to
be put between each flange and gear wheel.
Example: Shim thickness = (A - B) x 0.5 =
(109.80 - 108.01) x 0.5 = 0.895
Round the value off to 10/100 mm, which
in this example gives us a shim thickness
of 0.90 mm.
When shim calculation is completed, remove all com-
ponents from the measurement fixture.

Input shaft, assembly

12
Put the calculated thickness of shims on each flange.
Install each gear wheel on its flange. Tap them to-
gether with a plastic faced mallet. Be careful to en-
sure that the flanges bottom properly.

13
Put the original shim thickness and spacer ring on
the flange. Install the new circlip. Make sure that the
circlip seat securely.
Check that there is no slack between the circlip and
the spacer ring. Increase the shim thickness in this
case.

34
 Repair instructions

14
3 Put the washer (1), the two cup springs (2) and the
2 sintered washer (3) on the appropriate flange. Align
the components as in the illustration.
Compress the disc springs using press tool 885 377
and install the new circlip. Make sure that the circlip
seats properly in its groove before the cup springs
are unloaded.

15
Install the springs (1), pin (2) and (3) in the hub as in
the illustration.

16
Put the hub in the clutch plate. Align the components
as in the illustration.
Press the pin in at the same time as the hub is
pressed down into the clutch plate. Make sure that
the pin engages in the groove for neutral gear.

35
Repair instructions

17
IMPORTANT! Note the appearance of holder (A) as
shown in fig (A). Place holder (A) on the workbench.
Install:
- the balls
- the assembled hub
IMPORTANT! Make sure that the inner part of the
hub is aligned so that the ball seats face as shown in
figure (B).
-the balls
-holder (C)
IMPORTANT! Note the appearance of holder (C) as
shown in fig (C).
Install the springs, facing as in the illustration.

18
Press:
– bearing
– sintered washer (aligned as in the illustration)
– needle roller bearing
– spacer
– needle roller race
on the input shaft. Use mandrel 885 370. Make sure
that the components seat securely.

19
Put the input shaft in splined socket
888 20005.Thread on:
– needle roller bearing
– spacer ring
– shim (thickness as item 8)
– front gear wheel unit
on the input shaft.

36
 Repair instructions

20
Install the two keys.
Install the front friction plate package. Put the steel
plate at the bottom, and then alternate with coated
friction plates. There is a total of three of each for the
130S, or four of each for the 150S.

21
Thread the clutch hub onto the shaft. Align the steel
clutch plate tags so that they enter the cutouts in the
hub.

IMPORTANT! Make sure that the groove in the

inner part of the hub is aligned as in the illustra-
tion.

22

Thread on:
– shim (thickness as item 8)
– spacer ring
on the input shaft.

37
Repair instructions

23
Press on:
– needle roller bearing
– spacer
– needle roller race
on the input shaft. Use mandrel 885 370.

24
Thread the needle roller bearing on.
Install the rear friction plate package. Put a coated
friction plate at the bottom, and alternate with steel
discs. There is a total of three of each for the 130S, or
four of each for the 150S.

25
Install the rear gear wheel unit. Rock the gear wheel
to centre the coated friction plates.
Thread the coated washer on, facing as in the illus-
tration.

38
 Repair instructions

26
Press the bearing on. Use mandrel 885 370.

27
Measure distance (A) between the bearing race and
the shaft with a depth micrometer.
Fill the distance up with shims as follows:
Round off to the nearest 10/100 mm. Then deduct
0.10 mm.
Example: A = 1.76 (rounded off to 1.80)
Shim thickness = 1.80 – 0.10 = 1.70

28
Put in the calculated thickness of shims.
Apply thread locking fluid, VP part number 114 1053
to the screw.
Install the washer and screw. Torque 50 Nm.

39
Repair instructions

Input shaft, turning torque

29
Put the input shaft together with the rear bearing race
(1), the front bearing race (2) and the original shim
thickness (3) in the gear housing.
If the original shim thickness is not available, use
0.50 mm as a rule of thumb.
Fix the shaft with clamps 885 475. Align the rear
clamp flush with the gasket plane and tighten the
screws lightly, app. 10 Nm.

30
Install the rear cover together with the gasket and the
original shim thickness.
If the original shim thickness is not available, use
0.50 mm as a rule of thumb.
Tighten the screw, about 14 Nm at the same time as
the shaft is turned. This is to check that the turning
torque is not so high that it “locks” the shaft.

31
Measure the turning torque with splined socket
1 rpm/sec
888 20005 and torque wrench 999 8081.
The correct turning torque should be:
1.0-1.4 Nm (new bearings)
1.0-1.4 Nm (run-in bearings)
If the turning torque is too low, increase the shim
thickness inside the rear cover.
If, on the other hand, the value is too high, reduce the
shim thickness.

40
 Repair instructions

Flank clearance
32
When the correct turning torque has been obtained,
check the gear flank clearance.
Install fixture 885 571 on the gear housing. Put mag-
netic stand 999 9696 and dial gage 8888 20006 on
the fixture.

33
Put the dial gage measurement tip on the output gear
wheel as in the illustration.

34
Slide the clutch plate backwards and read off the
gear lash on the rear gear wheel by carefully rocking
the input gear wheel.
Note the value.

41
Repair instructions

35
Slide the clutch plate forwards and read off the gear
lash on the front gear wheel by carefully rocking the
input gear wheel.
Note the value.

36
Compare the two values. The flank clearance should
be as equal as possible on each gear wheel.

Adjust (center) the input shaft if necessary, by chang-

ing the shim thickness on the outer bearing races.

NOTE! Remember to remove the same amount

on one side as you add on the other side, to avoid
changing the turning torque.

Correct clearance after centering should be

0.12–0.27 mm on each gear wheel.

Always check the gear engagement pattern before

doing any adjustment to the clearance.

42
 Repair instructions

Marking pattern
37
When the input shaft has been centered (equal clear-
ance on each gear wheel) across the output gear
wheel, check the gear engagement pattern.
Brush a thin layer of marker dye 380 7716 to 5-6
teeth on the rear gear wheel.
Slide the clutch plate backwards.
Put splined socket 888 20005 on the input shaft and
turn it clockwise 3-4 turns at the same time as the
output shaft is braked with splined socket 884 830
(130S) or 885 560 (150S).

It is easiest to check the gear engagement pattern on

the concave outer side of the gear wheel.
The marking pattern on the lower gear wheel should
be located centrally on the lower gear, in both the
lengthways direction and in height.

38
Brush a thin layer of marker dye 380 7716 to 5-6
teeth on the front gear wheel.
Slide the clutch plate forwards.
Repeat the procedure and check the location of the
gear engagement pattern on the convex side of the
output gear.
The marking pattern on the lower gear wheel should
be located centrally on the lower gear, in both the
lengthways direction and in height.

43
Repair instructions

39
If you need to adjust the gear flank clearance in
cases where the marking pattern is correct:
In most cases, the location of the front and rear gears
is retained and the output gear is moved up or down.
If the output gear wheel is moved 0.10 mm, the gear
flank clearance is changed about 0.05 mm.

NOTE! Remember to compensate the shim thickness

between bearings so as to retain the turning torque.

Put the current shim thickness, gear flank clearance

and marking pattern locations in a copy of the “Shim
table, upper gear housing” at the end of the book.
This considerably facilitates work if you should need
to fine adjust the shim thicknesses.

44
 Repair instructions

If you need to adjust the marking pattern without

changing the gear flank clearance:
The outgoing gear wheel, rear and front gear wheel
are all moved.
For example, if the output gear wheel is moved 0.05
mm, the front and rear gear wheels should be moved
twice the distance, i.e. 0.10 mm to retain the gear
flank clearance.

If the marking pattern is as shown here, move the

output gear wheel up, and the rear and front gear
wheels outwards.

If the marking pattern is as shown here, move the

output gear wheel down, and the rear and front gear
wheels inwards.

NOTE! Remember to compensate the shim thickness

between the output shaft bearings so as to retain the
turning torque.

NOTE! Remember to compensate the shim thickness

between the flange and lock rings.

Put the current shim thickness, gear flank clearance

and marking pattern locations in a copy of the “Shim
table, upper gear housing” at the end of the book.
This considerably facilitates work if you should need
to fine adjust the shim thicknesses.

45
Repair instructions

Upper gear housing, final assembly

1
Oil the selector fork bearing bush. Put the gear in
place and slide the shaft in.
Apply thread locking fluid, VP part number 116 1053
to the plug.

If the shaft design is as shown in (A), tighten the plug

to 5 Nm.
If the shaft design is as shown in (B), tighten the plug
to 35 Nm.

2
Check that the clearance between the plug and the
shaft is min. 0,5 mm and the selector fork can move
easily.
If the shaft design is as shown in (A) above, check
that the clearance between the plug and the shaft
is at least 0.5 mm and that the selector fork moves
freely.

3
IMPORTANT! Clean all contact surfaces on both
gear housing halves with denatured alcohol and
a gasket scraper 885 516.
Old sealant residue must be completely re-
moved, to promote successful re-sealing.

46
 Repair instructions

4
Apply a thin layer of sealant (red), part number
840 879, to the top gear housing half as in the illus-
tration. Use roller 885 511.

5
Place the input shaft together with the bearing races,
calculated shim thickness on the input side and the
seal ring in the gear housing. Align the seal as in the
illustration.

6
Install the upper gear housing half.

NOTE! Make sure that the clutch plate is in neutral.

NOTE! Make sure that the selector fork engages on

the clutch plate.

NOTE! Align the front of the housing.

Tighten the bolts diagonally to 22 Nm.

47
Repair instructions

Install the rear cover together with the tested shim

thickness and a new gasket.
Torque the screws to 14 Nm.

8
IMPORTANT! Clean all contact surfaces on the
gear housing and gear mechanism with dena-
tured alcohol and a gasket scraper 885 516.
Old sealant residue must be completely re-
moved, to promote successful re-sealing.

9
Apply a thin layer of sealant (red), part number
840 879 on the gear shift mechanism as in the illus-
tration. Use roller 885 511.

48
 Repair instructions

Shift mechanism, adjustment

Special tool: 885 870

1
Check that the clutch plate is in neutral.
Install the shift mechanism as in the illustration.
Roughly adjust the position by centering in the screw
holes. Tighten the nuts to about 10 Nm (it should be
possible to fine adjust the position of the gear mecha-
nism by lightly tapping it with a plastic-faced mallet).

IMPORTANT! The position of the shift mecha-

nism must be fine adjusted as in the points
below, to reduce wear on the selector fork and
clutch plate!

2
885 870 Install measurement fixture 885 870. The fixture can
be installed along or across the reversing gear, de-
pending on how the gear shift arm is installed.

49
Repair instructions

3
Put the shift mechanism in the neutral position.
Find the shift arm “neutral position” by turning the
mechanism carefully in each direction (without en-
gaging a gear). Mark up the end positions as in the
illustration.

NOTE! If you put masking tape on the measurement

fixture, the markings are easier to see.

Find the end positions of the shift arm with the gear
engaged by engaging a gear and by carefully turn-
ing the mechanism in each direction, until contact is
made with the clutch plate. Mark up this position and
repeat the procedure with the opposite gear position.

5
Measure the distances between A and B as in the il-
lustration.
The permissible values of the A and B dimensions
are not more than 24 mm. In addition, the difference
between the two dimension must not exceed 3 mm.
Example:
A = 23.1 mm
B = 22.3 mm
A - B = 23.1 - 22.3 = 0.8 mm

50
 Repair instructions

6
If the values are outside the specified maximum di-
mensions, adjust the shift mechanism by carefully
tapping it in the direction where the smallest value
was measured.
Repeat the measurements and adjustments until
you end up between the specified dimensions. If the
specified dimensions are not achieved, the reversing
gear must be changed.

7
When the correct dimension has been found, remove
the fixture and install the bracket for the control cable.
Torque all nuts to 20 Nm.

8
Install the dipstick with a new O-ring.

51
Repair instructions

Lower gear, renovation

Disassembly
1
Install fixture 888 20010 on the gear housing, if this
has not been done previously.
Install fixture in stand 999 2520.

2
NOTE! Remove the oil drain plug.
Remove the zinc anode.

3
Remove the screws for the propeller seal housing.
Remove the propeller shaft and gear housing with a
slide hammer 884 161 and adapter 884 611.
Scrap the O-rings.

52
 Repair instructions

4
Fix the upper nut for the vertical shaft with fixture
888 20007.
Undo the nut by turning the vertical shaft clockwise,
with splined socket. 884 830 (130S) or 885 560
(150S).

5
Fix the pinion nut. Use a clean rag to protect the gear
case.
Undo the nut by turning the vertical shaft anti-clock-
wise with the splined socket. 884 830 (130S) or 885
560 (150S).

6
Pull up the vertical shaft puller 888 20004 and man-
drel 884 833 as in the illustration.
Catch the pinion gear.

53
Repair instructions

7
Pull the bearing race up with puller 885 850 and
884 721.
Save the shims and note the thickness of the shims.

8
Remove the needle roller bearing.
Use 22563001 and 22518599.

9
Pull out the bearing race for the front propeller
shaft bearing with puller 884 760 (130S) or 885 850
(150S).
Save the shims and note the thickness of the shims.

54
 Repair instructions

10
Tap the seal rings out of the propeller bearing hous-
ing, using a screwdriver.

11
Press the bearing race out with expander 884 726
and standard shaft 884 143. Use ring 884 723 as a
counterhold.
Save the shims and note the thickness of the shims.

12
Press the bearings off with puller halves 885 852 and
plate 885 568.
Save the washer (1).

55
Repair instructions

13
Press the needle roller bearings off with puller halves
885 852 and plate 885 568.

14
Press the inner bearing off the propeller shaft.

15
Press the gear wheel and outer bearing off. Use 884
753 (130S) or 999 2584 (150S) as a counterhold.
Use something like mandrel 884 752 as a spacer to
avoid damaging the threads on the shaft.

WARNING! Great pressure required (tapered

joint). Wear goggles.

56
 Repair instructions

Assembly

NOTE! Brush a thin layer of glycerin on the tapered

surface of the gear wheel and the propeller shaft
(only 150S).

Press the propeller shaft down onto the gear wheel.

Use plate 884 753 as a counterhold.
Press until the step bottoms solidly against the gear
wheel.

2
Press the front bearing on. Use ring 385 0617 (130S)
or 885 853 (150S) as a counterhold.
Use something like mandrel 884 752 as a spacer to
avoid damaging the threads on the shaft.

57
Repair instructions

Gear wheels 130S, shimming

3
Gear wheel dimension (Getched) is engraved on the
gear wheel.

Read off the gear wheel deviation (Getched,) and com-

pare this dimension with the table on the next page.
The deviation is noted in plain language.
Example: 0.1 = 0.10 mm

Read off the gear housing dimension deviation

(Xstamped) and note this dimension in the table on the
next page.
Only decimals of 1/100 mm are marked.
Example: X12 = 0.12 mm

58
 Repair instructions

Put the propeller shaft on the bearing race as in the

illustration.
Press the shaft hard against the bearing race and
measure the distance between the bearing race and
the gear wheel. Do a number of measurements and
prepare an average.
Example:
Gmeasured = 100.27 + 100.25 + 100.23 = 100.25 mm
3

Put the calculated and measured dimensions into the

table and calculate the shim thickness (Gshim).
Round off to the nearest 5/100 mm.

59
Repair instructions

Gear wheels 150S, shimming

4
Gear wheel dimension (Getched) is engraved on the
gear wheel.

Read off the gear wheel deviation (Getched,) and com-

pare this dimension with the table on the next page.
The deviation is noted in plain language.
Example:
0.08 = 0.08 mm

Read off the gear housing dimension deviation

(Xstamped) and note this dimension in the table on the
next page.
Only decimals of 1/100 mm are marked.
Example: X04 = 0.04 mm

60
 Repair instructions

Put the propeller shaft on the bearing race as in the

illustration.
Press the shaft hard against the bearing race and
measure the distance between the bearing race and
the gear wheel. Do a number of measurements and
prepare an average.
Example:
Gmeasured = 111.27 + 111.31 + 111.29 = 111.29 mm
3

Put the calculated and measured dimensions into the

table and calculate the shim thickness (Gshim).
Round off to the nearest 5/100 mm.
NOTE! If Xstamped value is close to 100, e.g. X96,
housing nominal = 50.00 mm applies.

61
Repair instructions

5
Put the calculated thickness of shims (Gshim) into the
housing. Fix them with some grease.
Install the bearing race with tool 885 854 and a plas-
tic-faced mallet. Turn the lower part of the tool to suit
the bearing race in question.

6
Press the bearing onto the vertical shaft with ring 385
0617. Align the bearings as in the illustration.

NOTE! Be careful not to damage the threads for the

pinion nut.

Align the needle roller bearing with the text side out-
wards (towards the tool).
Knock the bearing up until it bottoms.
Use 22563001 and 22518599.

62
 Repair instructions

Pinion gear 130S, shimming

8
Pinion gear nominal height = 49.70
Lower gear housing nominal dimension = 357

The pinion gear deviation is engraved on the pinion

gear. The deviation is noted in plain language.
Example: 0,04 = 0.04 mm
Read off the pinion gear deviation (Petched,) and insert
this into the calculation table “Shim calculation, lower
gear housing 130S-A, 130SR-A”. The table, intended
to be copied, is at the end of the book.

Put splined socket 884 830 in a vise. Place the verti-

cal shaft in the splined socket and thread on mea-
surement fixture 888 20012.
Install the pinion gear and the old pinion nut. Torque
the nut to 110 Nm.

63
Repair instructions

Use a feeler gauge to measure the distance between

the tool and the pinion gear. Measure the three cut-
outs in the measurement fixture and take the aver-
age:
Example:
1.78 + 1.77 + 1.79 = 1.78 mm
3
Add the fixed length of the measurement fixture,
which is 307,00 mm, and we obtain a dimension
called:
Pmeasured = 1.78 + 307.00 = 308.78 mm

Put this dimension into the table below.

Read off the gear housing deviation Zstamped, only

decimals of 1/100 mm are marked. Put this dimen-
sion into the table below.
Example: Z93 = 0.93 mm

Put the calculated and measured dimensions into the

table and calculate the shim thickness Pshim.
Round off to the nearest 5/100 mm.

64
 Repair instructions

Pinion gear 150S, shimming

9
Pinion gear nominal height = 56.00
Lower gear housing nominal dimension = 357

The pinion gear deviation is engraved on the pinion

gear. The deviation is noted in plain language.
Example: 0,09 = 0.09 mm
Read off the pinion gear deviation (Petched,) and insert
this into the calculation table “Shim calculation, lower
gear housing 150S-A, 150SR-A”. The table, intended
to be copied, is at the end of the book.

Put splined socket 885 560 in a vise. Place the verti-

cal shaft in the splined sleeve and thread measure-
ment fixture 88 20013 on.
Install the pinion gear and the old pinion nut. Torque
the bolts to 240 Nm.

65
Repair instructions

Use a feeler gauge to measure the distance between

the tool and the pinion gear. Measure the three cut-
outs in the measurement fixture and take the aver-
age:
Example:
1.44 + 1.48 + 1.46 = 1.46 mm
3
Add the fixed length of the measurement fixture,
which is 301.00 mm, and we obtain a dimension
called:
Pmeasured = 1.46 + 301.00 = 302.46 mm

Put this dimension into the table below.

Read off the gear housing deviation Zstamped, only

decimals of 1/100 mm are marked. Put this dimen-
sion into the table below.
Example: Z93 = 0.93 mm

Put the calculated and measured dimensions into the

table and calculate the shim thickness Pshim.
Round off to the nearest 5/100 mm.

66
 Repair instructions

10
Install the calculated shim thickness in the gear hous-
ing and install the bearing race with tool 885 854 and
a plastic-faced mallet. Turn the lower part of the tool
to suit the bearing race in question.

11
Press the needle roller bearing onto the vertical shaft
with ring 385 0617.

12
Put the vertical shaft in the gear housing.
Install the pinion gear and screw the old nut on
(aligned as in the illustration) by hand.

67
Repair instructions

13
Fix the pinion nut. Use a clean rag to protect the gear
case.
Tighten the nut by turning the vertical shaft with
splined socket 884 830 (130S) or 885 560 (150S).
Tightening torque 110 Nm (130S) or 240 Nm (150S)
respectively.

14
Put the original shim thickness in the propeller bear-
ing housing.
(Or adjust the shim thickness with the difference be-
tween the calculated and the original shim thickness
for the front bearing race).
Press the bearing race in with tool 885 854. Turn the
lower part of the tool to suit the bearing race in ques-
tion.

15
Press the rear bearing onto the propeller shaft. Use
plate 884 753 and ring 385 0617 (130S) or 885 853
(150S) as a counterhold.

68
 Repair instructions

16
Oil the bearings lightly.
Put the propeller shaft in the gear housing.
Install the propeller bearing housing without O-rings.
Torque the screws to 28 Nm.

17
Check the turning round torque with adapter nut 884
1 rpm/sec
611 and torque wrench 999 8081.
Correct turning torque is 0.3 Nm – 1.6 Nm
If the turning torque is too low, increase the thick-
ness of shims under the bearing track in the propeller
bearing housing, and if the turning torque is too high,
reduce the thickness of shims.

18
When the correct turning torque has been obtained,
the gear flank clearance and the marking pattern on
the gear wheels should be checked.
Remove the propeller bearing housing and propeller
shaft.
Brush a thin layer of marker dye 380 7716 on 5-6
teeth on the pinion gear.

69
Repair instructions

19
Put the propeller shaft back in the gear housing.
Assemble the propeller bearing housing with fixture
885 571 as in the illustration. Torque the screws to
28 Nm.

20
Drive the upper bearing race down with a plastic-
faced mallet and mandrel 884 777.

21
The shafts must be braked at the same time as the
propeller shaft is turned, to permit the gear marking
pattern to be checked.
Install adapter nut 884 611 on the propeller shaft.
Put splined socket 884 830 (130S) or 885 560 (150S)
on the vertical shaft and turn it 3-4 turns clockwise at
the same time as the propeller shaft is braked.

NOTE! Continue with the following points, to check

the gear flank clearance, before disassembling to
check the appearance of the marking pattern.

70
 Repair instructions

22
Install fixture 885 572, magnetic stand 999 9696 and
dial gage 888 20006 as in the illustration.
Put the measurement tip on the inner marking of the
fixture.

23
Fix the vertical shaft in a suitable manner.
Rock the propeller shaft forwards and backwards
(avoid pressing in the radial direction) and read off
the gear flank clearance.
Correct value: 0.10 - 0.20 mm
Note the measured value in the “Shim table, lower
gear”.

24
Remove all measurement tools and special tools.
Remove the propeller bearing housing and lift the
propeller shaft out.

71
Repair instructions

25
Check the position of the marking pattern.
The marking pattern on the gear wheel should be
displaced slightly towards the “large end” and slightly
towards the tooth tips.
During operation, the propeller forces will press the
gear wheel forwards, which displaces the marking
pattern and makes it centrally located in both height
and lengthways direction.

26
If you need to adjust the gear flank clearance in
cases where the marking pattern is correct:
In most cases, the pinion position is retained (Pshim)
and the gear wheel is moved (Fshim ).
If the gear wheel is moved 0.05 mm, the gear flank
clearance is moved about 0.05 mm.

NOTE! Remember to compensate the shim thick-

ness under the bearing race in the propeller bearing
housing (Pre-loadshim ) so that the turning torque is
retained. Total of:

Fshim + Pre-loadshim is maintained unchanged.

Put the current shim thickness, gear flank clearance,

turning torque and marking pattern locations in a
copy of the “Shim table, lower gear housing” at the
end of the book. This considerably facilitates work if
you should need to fine adjust the shim thicknesses.

72
 Repair instructions

If you need to adjust the marking pattern without

changing the gear flank clearance:
Move both the pinion and the gear wheel.
For example, if the gear wheels are moved 0.05 mm,
the pinion should be moved twice the distance, i.e.
0.10 mm to retain the gear flank clearance.

If the gear engagement pattern is as follows, move

the gear wheel in (Fshim ) and the pinion outwards
(Pshim).

If the gear engagement pattern is as follows, move

the gear wheel out (Fshim) and the pinion inwards
(Pshim).

NOTE! Remember to compensate the shim thick-

ness under the bearing race in the propeller bearing
housing (Pre-loadshim ) so that the turning torque is
retained. Total of:

Fshim + Pre-loadshim is maintained unchanged

Put the current shim thickness, gear flank clearance,

turning torque and marking pattern locations in a
copy of the “Shim table, lower gear housing” at the
end of the book. This considerably facilitates work if
you should need to fine adjust the shim thicknesses.

When correct turning torque, gear flank clearance

and marking pattern have been obtained, remove the
propeller bearing housing and propeller shaft.

73
Repair instructions

Final assembly
25
Remove the old pinion nut and scrap it.
Apply thread locking fluid, VP part number 116 1053
to the new pinion nut and screw it on by hand.

NOTE! Align the nut as in the illustration.

Fix the pinion nut. Use a clean rag to protect the gear
case. Tighten the nut by turning the vertical shaft with
splined socket 884 830 (130S) or 885 560 (150S).
Torque 110 Nm (130S) or 240 Nm (150S).

26
Thread the washer on.
Apply thread locking fluid, VP part number 116 1053
to the nut and screw it on by hand.

NOTE! Align the nut as in the illustration.

27
Fix the nut with fixture 888 20007.
Tighten the nut by turning the vertical shaft anti-
clockwise with the splined socket. 884 830 (130S) or
885 560 (150S).
Torque 50 Nm.

74
 Repair instructions

28
Put the propeller shaft in the gear housing.

29
Press the bearing race out of the propeller bearing
housing with expander 884 726 and standard shaft
884 143. Use ring 884 723 as a counterhold. Save
the shims.

30
Install the outer seal ring with standard shaft 999
1801 and mandrel 884 752 in the propeller bearing
housing.

NOTE! Install the seal ring dry and aligned so that

the spring comes outwards.

Press until it meets the heel on the propeller bear-

ing housing and retain the press force for a couple of
seconds to allow the seal ring to “settle”.

75
Repair instructions

31
Install the inner seal ring with standard shaft 999
1801 and mandrel 884 752 in the propeller bearing
housing.

NOTE! Install the seal ring dry and aligned so that

the spring comes inwards.

Press until it meets the heel on the propeller bear-

ing housing and retain the press force for a couple of
seconds to allow the seal ring to “settle”.

32
Place the tested shim thickness in the propeller bear-
ing housing.
Press the bearing race in with tool 885 854. Turn the
lower part of the tool to suit the bearing race in ques-
tion.

33
Install new O-rings on the propeller bearing housing.
Grease the seal rings and the O-rings liberally with
grease, VP part no. 828250.
Put the propeller bearing housing in place. Be care-
ful to ensure that the splines do not scratch the seal
rings.
Tighten the screws. Torque 28 Nm.

76
 Repair instructions

34
Install a new O-ring on the oil drain plug. Torque the
plug to 10 Nm.

35
Scrape the mating surface clean and install the zinc
anode. Tighten the bolts to 9 Nm

77
Repair instructions

Upper and lower gear housing,

assembly
1
Align the rubber sleeve on the upper gear as in the
illustration.

WARNING! The rubber sleeve must be in-

stalled dry. No kind of grease, silicone sealant
or other sealant may be used.

2
Put the four O-rings on the adapter plate. Fix them
with some grease.
Install the adapter plate on the upper gear.

NOTE! Align the plate so it suits the type of drive in

question. Depending on whether the drive should
be located in front of or behind the engine, align the
plate (and the lower gear) as in the illustration.

Apply grease, VP part number 828 250 to the screws.

Torque 22 ± 1 Nm.

78
 Repair instructions

3
Check that there is no end float in the vertical shaft. If
necessary, tap the upper bearing housing down with
mandrel 884 777.

4
Measure the depth (C) in the lower gear housing with
depth micrometer 998 5472.
Example: C = 13.97 mm

5
Measure the thickness (G) of a new gasket with mi-
crometer 999 9701.
Example: G = 0.37 mm

79
Repair instructions

6
Measure the height (X) of the adapter plate flange,
depth micrometer 998 5472.
Example: X = 12.36 mm

7
To calculate the clearance between the bearing race
and the upper gear housing, you must add the gasket
thickness (G) to dimension (C) and then deduct di-
mension (X).
Example:
Clearance = C + G - X = 13.97 + 0.37 - 12.36 =
1.98 mm
To obtain the recommended gear pre-load 0.00-0.05
mm shims must be put between the bearing race and
the upper gear housing.
The example above leads to a shim thickness of 2.00
mm, which gives a bearing preload of 0.02 mm.

8
Put the calculated thickness of shims (1) in the lower
gear housing.
Put a new gasket (2) on the lower gear housing. Align
the gasket as in the illustration.
Install the splined socket (3) on the vertical shaft.
Carefully lift the upper gear housing/adapter plate
into place.
Apply grease, VP part no. 828 250 to the screws.

80
 Repair instructions

9
Tighten the screws as in the tightening torque sched-
ule, to 22 ± 1 Nm.

81
Repair instructions

Pressure testing
Special tools: 885 531

Before the drive is filled with oil, it must be pressure

tested to check that the drive has been made oil-tight
after repair.
If a used drive is tested, the oil must be drained first.
Note the appearance of the oil. Gray oil indicates
leakage (water entry).

1
Remove the drain plug.
Install the nipple and pump from the pressure test kit
885 531.

2
Pump the pressure up to 21–35 kPa.
Turn the propeller shaft, gear shift mechanism and
input shaft, and check the sealing. If any pressure
drop is noticed, use soapy water or immerse the drive
completely in water to find the leakage. Carry out the
necessary repairs and repeat the test.

If no pressure drop can be noticed, raise the pres-

sure to 90–95 kPa. Use soapy water again or im-
merse the drive completely in water to find the leak-
age, if a pressure drop can be noticed. Permissible
pressure drop max 7 kPa in 3 minutes.

82
 Repair instructions

Rubber bushing, change

Special tools: 888 20014

1
130S-A/B, 150S-A/B:
Remove the rubber bush with press tool 888 20014.

2
130S-A/B, 150S-A/B:
Brush glycerin in the cutout for the bushing in the
gear housing.
Align the new bushing as in the illustration. Press it in
with the new press tool 888 20014.

3
130S-C, 150S-C:
Åtdragningsmoment: 40 Nm

83
Repair instructions

Painting
IMPORTANT! Read and carefully follow the in-
structions and warnings on the packaging.

1
Remove all marine fouling.

2
Remove all loose paint and corrosion residue by grit
blasting or sandpaper.
If grit blasting is used, the grit should be aluminum
oxide with a particle size of between 0.2 and 0.7 mm.
Blow clean after grit blasting.
If sandpaper is used, it must be coated with alumi-
num oxide. Sand painted surfaces and the damaged/
corroded raw aluminum surfaces to be touched up.
Then clean with water or a good cleaning fluid.

IMPORTANT! Do not use steel wool. Small

pieces of steel will become embedded in the
aluminum and will cause severe corrosion dam-
age.

IMPORTANT! Do not use emery cloth. Small

pieces of iron oxide which are used in the em-
ery cloth will become embedded in the alumi-
num and will cause severe corrosion damage.

3
When the primer coating is thin or the surface is un-
painted, it must first be coated with primer, VP part
number 1141562-7. The solvent in the primer must
be given time to evaporate and the primer must hard-
en before the top coat is applied. Allow 8 to 12 hours
drying time.

4
Apply the top coat. The spare parts catalogue and
the “Penta accessories” catalogue specify the part
numbers for surface treatment products.

5
Also apply anti-fouling.

IMPORTANT! The sacrificial anodes on the

drive and the propeller must not be painted.

IMPORTANT! Find out about current legislation

for use of growth inhibiting paints / anti-fouling
paints.

84
 Repair instructions

Shimming, quick reference guide

Shim calculation, lower gear housing 130S-A, 130SR-A

85
Repair instructions

Shim calculation, lower gear housing 150S-A, 150SR-A

86
 Repair instructions

Shim calculation, lower gear housing

Original shim thickness

Turning Back Contact
torque lash pattern

Shim thickness

87
88
Shim table, upper gear housing
Repair instructions

Original shim thickness

Back Back Contact
lash - R lash - F pattern

Shim thickness
 Troubleshooting
In case of a fault, first check if all items in the installation m
­ anual have been performed and that the operating
instructions are being followed.
The table below will help you with fault tracing.

1 Oil leakage
Cause: Pores in castings.
Action: Change defective components.

Cause: Leaking oil seals.

Action: Change the defective oil seals.

Cause: Leakage at mating surface.

Action: Check that screws have been tightened to the correct torque. Clean the surfaces and apply new
sealant.

Cause: Leakage at dipstick.

Action: Change the dipstick or the O-ring on the dipstick.

Cause: Oil level too high.

Action: Drain/suck out surplus oil.

2 High oil temperature

Cause: Oil level too high.
Action: Drain/suck out surplus oil.

Cause: Slipping clutch.

Action: See item 3.

3 Slipping clutch
Cause: Gear shift arm wrongly adjusted/installed.
Action: Adjust the gear shift mechanism.

Cause: Worn friction plates.

Action: Disassemble the sailboat drive, change the friction plates.

Cause: Wrong oil type.

Action: Drain the oil and re-fill with the correct type of oil.

Cause: Water in oil.

Action: Check and change the propeller shaft seals in the first instance. Then check the O-rings and seal be-
tween the upper and lower gear housings.

89
Troubleshooting

4 Noise, under load

Cause: Wrongly shimmed gear wheels and roller bearings.
Action: Check shimming and assembly of the sailboat drive.

Cause: Defective gear wheels.

Action: Change the relevant gear set (gear wheels are not sold separately).

5 The sailboat drive cannot be shifted

Cause: Gear shift arm wrongly installed.
Action: Adjust the gear shift arm.

Cause: Flexible coupling defective.

Action: Change the flexible coupling.

Cause: Gear shift arm loose.

Action: Check the gear shift arm and the tightening torque of the clamp screw.

Cause: Defective components as below.

Action: Check the cam on the gear shift mechanism, change if necessary.
Change the springs in the clutch package.
Change the friction disks.
Change the selector fork.
Adjust the gear shift mechanism.

6 Hard shifting
Cause: Idle speed too high.
Action: Adjust idle speed to the correct level.

7 Output shaft rotates in neutral position

Reason: Distorted clutch plates because of overheating.
Action: Change clutch plates and other damaged components.

Cause: Defective needle bearing on input shaft.

Remedy: Remove the sailboat drive and input shaft, change the appropriate bearing and other damaged
components.

90
 Technical data

General data
Type designation ���������������������������������������������������������������������� 130S-A, 130SR-A, 130S-B, 130SR-B,
150S-A, 150SR-A, 150S-B, 150SR-B

Total gear ratio

130S-A, 130SR-A �������������������������������������������������������������������� 2.19:1 2.47:1
130S-B, 130SR-B �������������������������������������������������������������������� 2.19:1
150S-A, 150SR-A, 150S-B, 150SR-B ������������������������������������� 2.19:1

Weight
130S-A, 130SR-A, 130S-B, 130SR-B ������������������������������������� 26.5 kg
150S-A, 150SR-A, 150S-B, 150SR-B ������������������������������������� 27 kg

Flank clearance
Lower gear,
Pinion gear– Gear wheels ������������������������������������������������� 0.10–0.20 mm

Upper gear
input front gear - output gear wheel ���������������������������������� 0.12–0.27 mm
input rear gear - output gear wheel ����������������������������������� 0.12–0.27 mm

Pre-load (turning round torque)

Input shaft
new bearings ��������������������������������������������������������������������� 1.0–1.4 Nm
used bearings �������������������������������������������������������������������� 1.0–1.4 Nm
Output shaft (upper gear)
new bearings ��������������������������������������������������������������������� Slack free–0.5 Nm
used bearings �������������������������������������������������������������������� Slack free–0.5 Nm
Propeller shaft
new bearings ��������������������������������������������������������������������� 0.3–1.6 Nm
used bearings �������������������������������������������������������������������� 0.3–1.6 Nm

Lubrication system
Oil volume, app.
130S-A, 130SR-A, 130S-B, 130SR-B gear ratio 2.19:1 ���� 2.91 liter
130S-A, 130SR-A gear ratio 2.47:1 ����������������������������������� 3.01 liter
150S-A, 150SR-A, 150S-B, 150SR-B ������������������������������� 3.01 liter

91
Technical data

Torque
General tightening torque values
Nm
M6 standard screw 8.8....................................................... 10
M8 standard screw 8.8....................................................... 25
M10 standard screw 8.8..................................................... 50
M12 standard screw 8.8..................................................... 85
M14 standard screw 8.8..................................................... 140

Special tightening torques

Upper gear housing, split plane ......................................... 22
Gear shift mechanism......................................................... 20
Clamp screw, gear shift arm............................................... 22 ± 1
Rear cover.......................................................................... 14
Screw, input shaft............................................................... 50
Nut, output shaft................................................................. 50
Upper gear housing - adapter plate.................................... 22 ± 1
Upper gear housing - lower gear housing.......................... 22 ± 1
Nut, vertical shaft................................................................ 50
Pinion nut
130S, 130SR................................................................... 110
150S, 150SR................................................................... 240
Propeller bearing housing.................................................. 28
Oil drain plug...................................................................... 10

92
 Notes

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................
...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

93
 References to Service Bulletins

Group No. Date Refers to

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................
...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................
...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

...........................................................................................................................................................................................

94
 Report form

Do you have any complaints or other comments about this manual? Please make
a copy of this page, write your comments down and post it to us. The address is at
the bottom of the page. We would prefer you to write in English or Swedish.

From:...............................................................................  

........................................................................................

........................................................................................

........................................................................................

Refers to publication:................................................................................................................................................

Publication no.:....................................................................... Issued:......................................................................

Suggestion/reasons:.................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

.................................................................................................................................................................................

Date:..............................................................

Name:............................................................

AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
7742984 English 05-2015