ALPHA ONE GENERATION II STERN DRIVE

74243

INDEX

Table of Contents
Page Installation Specifications .................. 1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 1 Lubricants, Sealers, and Adhesives . . . . . . . . . . 1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Transom Specifications . . . . . . . . . . . . . . . . . . . . . 1 .................... 2 Installation Procedures Transom Assembly Installation . . . . . . . . . . . . . . 2 Power Steering Control Valve and Cable Installation . . . . . . . . . . . . . . . . . . . . . . 3 Power Steering Hose Connections . . . . . . . . . . . 4 Stern Drive Unit Installation . . . . . . . . . . . . . . . . . 4 Trim Cylinder Connection . . . . . . . . . . . . . . . . . . . 4 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . 5 Drive Shaft Housing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 Upper Drive Shaft Bearing Preload . . . . . . . . . . . 6 U-joint Bearing Preload . . . . . . . . . . . . . . . . . . . . . 6 Gear Shimming Specifications . . . . . . . . . . . . . . . 6 Lubricants, Sealers, and Adhesives . . . . . . . . . . 6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 .... 8 Drive Shaft Housing Exploded Parts View U-Joint and Driven Gear Components . . . . . . . . 8 Drive Shaft Components . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . 11 Drive Shaft Housing Shimming Gear Distance, Driven Gear . . . . . . . . . . . . . . . . 11 Gear Distance, Drive Gear . . . . . . . . . . . . . . . . . 11 Standard Rotation Gear Housing . . . . . . . . . . . . . . . . . . . . . . . 12 Specifications Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 12 Shimming Specifications . . . . . . . . . . . . . . . . . . . 12 Lubricants, Sealers, and Adhesives . . . . . . . . . 12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Standard Rotation Gear Housing Exploded . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Parts View Drive Shaft Components . . . . . . . . . . . . . . . . . . . 14 Propeller Shaft Components . . . . . . . . . . . . . . . . 16

Page Standard Rotation Gear Housing Assembly ........................ Specifications Pre-Disassembly Inspection . . . . . . . . . . . . . . . . Pinion Gear Height . . . . . . . . . . . . . . . . . . . . . . . . Shift Spool End Play . . . . . . . . . . . . . . . . . . . . . . Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . Reverse Gear Backlash . . . . . . . . . . . . . . . . . . . . Counter-Rotation Gear Housing Specifications . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . Shimming Specifications . . . . . . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counter-Rotation Gear Housing Exploded ........................... Parts View Drive Shaft Components . . . . . . . . . . . . . . . . . . . Propeller Shaft Components . . . . . . . . . . . . . . . . Counter-Rotation Gear Housing Assembly ........................ Specifications Pre-Disassembly Inspection . . . . . . . . . . . . . . . . Forward and Reverse Gear Identification . . . . . Pinion Gear Height . . . . . . . . . . . . . . . . . . . . . . . . Shift Spool End Play . . . . . . . . . . . . . . . . . . . . . . Forward Gear Backlash . . . . . . . . . . . . . . . . . . . . Reverse Gear Backlash . . . . . . . . . . . . . . . . . . . . .......... Transom Assembly Specifications Torque Specifications . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants, Sealers, and Adhesives . . . . . . . . . Alpha One Transom Assembly Exploded View . . . . . . . . . . . . . . . . . . . . . . . Bell Housing Components . . . . . . . . . . . . . . . . . . Gimbal Housing Components . . . . . . . . . . . . . . . Inner Transom Plate Components . . . . . . . . . . . Gimbal Ring and Steering Lever Components . . . . . . . . . . . . . . . . . . . . . . . . . . 18 18 18 18 19 19 20 20 20 20 21 22 22 24 26 26 26 26 26 27 27 29 29 29 29 30 30 32 34 35

INDEX
2 - 0 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Installation Specifications
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.

Transom Specifications
a

e
ITEM Exhaust Pipe to Gimbal Housing Screws Propeller Nut 1 TORQUE lb. in. lb. ft. 23 55 Nm 31 75

a d b

Tighten Nut Until It Bottoms Out Against Flat Steering Cable Coupler Nut Washer, then Loosen 1/2 Turn Steering Cable Coupler Nut Steering system Pivot Bolts Transom Assembly Attaching Screws and Nuts Power Steering Hydraulic g y Hose Fi i H Fittings Stern Drive Unit to Bell Housing Attaching Nuts
1:

35 50 23 23 50

48 68 31 31 68

22170

Amount specified is MINIMUM.

a - Transom Thickness-2-2 1/4 in. (51mm-57mm) b - Transom Surfaces-Parallel to within 1/8 in. (3.2 mm) c - Area Covered by Inner Transom Plate - Flat to within 1/8 in. (3.2 mm) d - Area Covered by Gimbal Housing Assembly - Flat to within 1/16 in. (1.6 mm) e - Transom Angle-10_ to 16_ f - Keel (if Equipped) - Remove 4 ft. (1.2 m) forward of transom

Lubricants, Sealers, and Adhesives

DESCRIPTION Quicksilver 2-4-C Marine Lubricant with Teflon Quicksilver Special Lubricant 101 Perfect Seal Liquid Neoprene Quicksilver Engine Coupler Spline Grease PART NUMBER 92825407A12 92-13872A1 92-34227-1 92-25711--2 92-816391A4

Special Tools
DESCRIPTION Alignment Tool Assembly PART NUMBER 91-805475A1

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 1

Installation Procedures
Transom Assembly Installation

! CAUTION
Steering lever ground wire MUST be positioned as shown or wire may fatigue. 2 a 4

70011

5
70015

a 2

3 b 8
70006 50632

a 7 2

2 a
70005

6
50632 70012

7
1 2 3 4 5 6 7 8 Speedometer Tube Pick-up Connection Locknuts and Flat Washers Screw Steering Lever Continuity Wire Trim System Wires Shift Cable Trim Hoses (and MerCathode Wires, if so equipped) Gear Lube Hose Fitting

Torque Specification a 23 lb. ft. (31 Nm) b 70-90 lb.in. (8-10 Nm)

INDEX
2 - 2 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Power Steering Control Valve and Cable Installation

7

6 8

9 5
73901

71906

b 10 2 1

71903

71901

1 2 3 4 5 6 7 8 9 10-

Steering Cable Grease Fitting Cable Coupler Nut Cable Guide Tube Cable End Clevis Clevis Pin Cotter Pin Flats on Guide Tube MUST Be Vertical Pivot Bolt

Lubricants, Sealers, and Adhesives A - Quicksilver Special Lubricant 101 . . . . . . . . . . . . 92-13872A1

Torque Specification a 35 lb. ft. (47 Nm) b 50 lb. ft. (68 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 3

Power Steering Hose Connections

STERN DRIVE TO BELL HOUSING CONNECTION

73786

Typical Hose Routing

a - Hose Fittings - Torque Both Fittings to 23 lb. ft. (31 Nm).

Stern Drive Unit Installation

USING THE ALIGNMENT TOOL
22062

! CAUTION
Forcing the alignment tool into position may damage the Gimbal Bearing or Engine Coupler. Do not attempt to force the alignment tool! Raise or lower the engine as necessary until alignment tool moves freely.

a - Locknut and Flat Washers - Torque to 50 lb. ft. (68 Nm) b - Locknut and Continuity Circuit Washer - Torque to 50 lb. ft. (68 Nm)

Trim Cylinder Connection

c a

a a
71463

70027

a - Alignment Tool b - Gimbal Bearing c - Engine Coupler

a b c d e

Aft Anchor Pin Bushings Flat Washers (2) E-ring Clips (2) Plastic Caps (2)

INDEX
2 - 4 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Propeller Installation

a b c d g
a b c d e f g Propeller Shaft Forward Thrust Hub Propeller Continuity Washer Spline Washer Tab Washer Propeller Nut-Torque to 55 lb. ft. (75 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 5

Drive Shaft Housing Specifications

Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
DESCRIPTION Top Cover Screws U-joint Retainer Nut Oil Vent Screw 30-50 TORQUE lb. in. lb. ft. 17-23 200 Nm 23-31 271 3.45.6

Lubricants, Sealers, and Adhesives

DESCRIPTION

PART NUMBER 92-825407A12

Quicksilver 2-4-C Marine Lubricant with Teflon Quicksilver U-Joint and Gimbal Bearing Grease 3M Brand Adhesive Quicksilver Bellows Adhesive Quicksilver Needle Bearing Assembly Lubricant Quicksilver Perfect Seal Permatex Ultra Blue Silicone Sealant Quicksilver Special Lubricant 101 Quicksilver High Performance Gear Lube

92-828052A2 92-25234-1 92-86166 92-825265A1 92-34227-1 Obtain Locally 92-13872A1 92-816026A4

Upper Drive Shaft Bearing Preload

DESCRIPTION New Bearings Used Bearings* TORQUE lb. in. 6-15 3-7.5 Nm 0.71.7 0.30.8

*Bearings are considered used if spun under load once.

Special Tools U-joint Bearing Preload

DESCRIPTION New Bearings Used Bearings* TORQUE lb. in. 6-10 3-7.5 Nm 0.71.1 0.30.8 DESCRIPTION

PART NUMBER 91-38756 91-38918 91-33493 91-36577 91-37323 91-90774 91-817570 91-60526 91-60523 91-34569A1 91-66274 91-17256 91-37241

Adaptor Bearing Cup Driver Bearing Driver Cup Driver Cup Driver Rod Driver Tool Oil Seal Driver Shimming Tool (Driven Gear) Shimming Tool (Drive Gear) Slide Hammer Puller Torque Wrench (lb. in.) U-joint Bearing Retainer Wrench Universal Puller Plate

*Bearings are considered used if spun under load once.

Gear Shimming Specifications

DESCRIPTION

GEAR LOCATION inches .025 .025 millimeters 0.64 0.64

Drive Gear Driven Gear

INDEX
2 - 6 ALPHA ONE GEN. II STERN DRIVE 90-806534960

TORQUE CONVERSION CHART

Use the following table to torque the u-joint retainer to 200 lb. ft. (271 Nm).
Torque Wrench Length in Inches (cm) Torque Wrench Reading in lb. ft. (Nm) to Achieve 200 lb. ft. (271 Nm) of Torque 111 (151) 114 (155) 117 (159) 120 (163) 123 (167) 125 (170) 127 (172) 129 (175) 131 (178) 133 (180) 135 (183) 136 (184) 138 (187) 140 (190) 141 (191) 143 (194) 144 (195) 145 (197) 147 (200) 148 (201) 149 (202) 150 (203)

a
15 (38) 16 (41) 17 (43) 18 (46) 19 (48) 20 (51) 21 (53) 22 (56) 23 (58) 24 (61) 25 (64) 26 (66) 27 (69) 28 (71) 29 (74) 30 (76) 31 (79) 32 (81) 33 (84) 34 (86) 35 (89) 36 (91)

26363

a - Torque Wrench Length

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 7

Drive Shaft Housing Exploded Parts View

U-Joint and Driven Gear Components
D

13 12
A

8 11 10 11 9

23 15 16
B

14 a

24

17 18
A

19 20 19

27

21 22 23 25 b

26 3

1 7 6

29

28

70690

INDEX
2 - 8 ALPHA ONE GEN. II STERN DRIVE 90-806534960

1 - Drive Shaft Housing 2 - Screw 3 - O-ring 4 - Spring Assembly 5 - Oil Seal 6 - Wear Pad 7 - Plug 8 - Universal Joint 9 - Yoke, universal joint - gear end 10- Socket, center - universal joint 11- Cross and Bearing 12- Yoke Assembly, universal joint - coupling end 13- O-ring 14- Retainer 15- Ring 16- O-ring 17- Carrier Assembly 18- Oil Seal 19- Roller Bearing and Cups 20- Cup Spacer 21- Shim 22- Shim 23- Drive Gear Assembly 24- Roller Bearing and Cup 25- Washer 26- Nut 27- Shims 28- Ground Plate 29- Screw

Lubricants, Sealers, and Adhesives A B C D - 2-4-C Marine Lubricant with Teflon . . . . . . . . . . . . 92-825407A12 - Quicksilver High Performance Gear Lube . . . . . . . . . . . . . 92-816025A4 - Quicksilver Special Lubricant 101 . . . . . . . . . . . . 92-13872A1 - Quicksilver Engine Coupler Spline Grease . . . 92-816391A4

Torque Specification a 200 lb. ft. (271 Nm) (See Chart on p. 2B-2)

Rolling Preload b Tighten in Small Increments Until 6-10 lb. in. (.07-1.1 Nm) of Rolling Preload

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 9

Drive Shaft Components

a 5

1 4 3 2 8
B

18

11 b 12

15

10 14 16 13
A

17
74243

1 2 3 4 5 8 9 1011 12131415161718-

Cover, top Bearing and Cup Shim O-ring Screw Drive Shaft, upper Filler Wall Washer Nut Anodic Plate Screw Lockwasher Screw Seal Water Tube Stuffer Plug

Lubricants, Sealers, and Adhesives A B - Quicksilver 2-4-C Marine Lubricant with Teflon . . . 92-825407A12 - Quicksilver High Performance Gear Lube . 92-816026A4

Torque Specifications a b 20 lb. ft. (27 Nm) 35 lb. ft. (47.5 Nm)

INDEX
2 - 10 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Drive Shaft Housing Shimming

Gear Distance, Driven Gear
SHIMMING TOOL 91-60526 Overall Drive Unit Gear Ratio 1.47:1 1.62:1 1.81:1 1.94:1 2.40:1 Tool Position Z X Y Y Y

Gear Distance, Drive Gear

SHIMMING TOOL 91-60523 Overall Drive Unit Gear Ratio 1.47:1 1.62:1 1.81:1 1.94:1 2.40:1 Tool Position Z Y Y Y Y

.025 (0.64mm)

.025 (0.64mm )

23012

23012 23012

a - Feeler Gauge - .025 in. (0.635mm) a - Feeler Gauge - .025 in. (0.635mm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 11

Standard Rotation Gear Housing Specifications

Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
DESCRIPTION Water Pump Body Screws Pinion Gear Nut Gear Housing to Drive Shaft Housing Screws Gear Housing to Drive Shaft Housing Nuts Trim Tab Screw Shift Shaft Bushing Screws Drive Shaft Retainer Bear Carrier Retainer Oil Fill/Drain Screw Propeller Nut 1
1:

Lubricants, Sealers, and Adhesives

DESCRIPTION Quicksilver 2-4-C Marine Lubricant with Teflon 3M Brand Adhesive Quicksilver Bellows Adhesive Quicksilver Needle Bearing Assembly Lubricant Quicksilver Perfect Seal Permatex Ultra Blue Silicone Sealant Quicksilver Special Lubricant 101 Loctite 8831 Quicksilver High Performance Gear Lube PART NUMBER 92-825407A12 92-25234-1 92-86166 92-825265A1 92-34227-1 Obtain Locally 92-13872A1 92-823089-1 92-816026A4

TORQUE lb. in. 60 70 28 35 23 60 100 210 3050 55 lb. ft. Nm 6.8 95 38 47 31 6.8 136 285 3.45.6 75

Amount specified is MINIMUM.

Shimming Specifications
DESCRIPTION Pinion Gear Height Forward Gear Backlash Reverse Gear Backlash GEAR LOCATION inches .025 .017-.028 .034-.054 millimeters 0.64 0.43-0.71 0.86-1.37

INDEX
2 - 12 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Special Tools
DESCRIPTION Backlash Indicator Rod Bearing Carrier Retainer Wrench Bearing Preload Tool Belleville Washer Dial Indicator Dial Indicator Holding Tool Drive Shaft Nut Wrench Driver Cup Drive Shaft Bearing Wrench Needle Bearing Driver Needle Bearing Driver Oil Seal Driver Oil Seal Driver Pinion Gear Shimming Tool Pinion Nut Adapter (Includes the following item) Drive Shaft Adapter Puller Bolt Puller Jaws Slide Hammer Puller Torque Wrench (inch pound) Universal Puller Plate Water Pump Alignment Pins Universal Bearing Removal and Installation Tool (Includes the following items) Bearing Adapter Bearing Installation Tool Collar Driver Head Driver Head Driver Head Driver Head Driver Head Driver Head Rod Nut Pilot Washer Pilot Washer Pilot Washer Puller Plate Puller Head Puller Head Puller Head Puller Rod Puller Shaft Roller Bearing Removal and Installation Tool Washer PART NO. 91-53459 91-61069 91-14311A2* 12-54048 91-58222A1 91-89897 91-56775 91-31106 91-43506 91-15755 91-33491 91-31108 91-817569 91-56048 91-61067A3 91-61077 91-85716 91-46086A1 91-34569A1 91-66274 91-37241 91-821571A1

91-31229A7 91-15755 91-38628 91-30366-1 91-32336 91-36569 91-37311 91-37312 91-52393 91-37323 11-24156 91-36571 91-37324 91-37350 91-29310 91-36379 91-32325 91-38628 91-52394 91-31229 91-37292 12-34961

The 91-14311A2 Bearing Preload Tool is also used

on Mercury and Mariner V-6 gear housings. The 91-31106 Bearing Cup Driver is also used on Mercury and Mariner V-6 gear housings and Bravo Stern Drives.

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 13

Standard Rotation Gear Housing Exploded Parts View

Drive Shaft Components
31 29 30
A

18 21 19

25

a 26

20 13 f 12
D

22 27

11 24
A

17 28 10 23 34 3 38
A

32

(ID)

38 36 37 33 7
A

7 6 5 4 h
B

8 14 15 b 16
D

2
74242

INDEX
2 - 14 ALPHA ONE GEN. II STERN DRIVE 90-806534960

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738-

Gear Housing Pin Stud Oil Fill/Drain Screw O-ring Seal Dowel Pin Roller Bearing Speedometer Fitting Drive Shaft Shim Bearing and Cup Nut Gear Drive Washer Nut Face Plate Carrier Oil Seal Oil Seal O-ring Water Pump Gasket Gasket Face Seal Screw Impeller Key Coupling O-rings Sleeve Shift Shaft Retaining Ring Sleeve Bushing Assembly Oil Seal O-rings Screw

Lubricants, Sealers, and Adhesives A B C D E - Quicksilver 2-4-C Marine Lubricant with Teflon . . . 92-825407A12 - 3M Brand Adhesive . . . . . . . 92-25234-1 - Loctite 8831 . . . . . . . . . . . . . 92-823089-1 - Quicksilver High Performance Gear Lube . 92-816026A4 - Quicksilver Needle Bearing Assembly Lubricant . . . . . 92-825265A1

Torque Specifications a 60 lb. in. (6.8 Nm) b 70 lb. ft. (95 Nm) c 28 lb. ft. (38 Nm) d 35 lb. ft. (47 Nm) e 23 lb. ft. (31 Nm) f 100 lb. ft. (136 Nm) g 210 lb. ft. (285 Nm) h 30-50 lb. in. (3.4-5.6 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 15

Propeller Shaft Components

E C

32 e

35

33 34 c 31

7 9 6 10 8
C

4 5 12 14 15
D

13

17 11 23 22 21 20
A
(ID)

16
C

18 19

F
(OD)

25 g 27 30 29 28 26

24

73601

INDEX
2 - 16 ALPHA ONE GEN. II STERN DRIVE 90-806534960

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435-

Gear Housing Shift Crank Shift Spool Assembly Shim, Bearing Outer Race Bearing and Cup Forward Gear Roller Bearing Sliding Clutch Cross Pin Spring Propeller Shaft Reverse Gear Thrust Washer Thrust Hub Ball Bearing O-ring Roller Bearing Bearing Carrier Assembly Anode Screw Star Washer Oil Seal (Inside) Oil Seal (Outside) Tab Washer Retainer Thrust Hub Continuity Washer Spline Washer Tab Washer Locknut - Propeller Anodic Trim Tab (Anodic Plate - Some Models) Screw Star Washer Screw Nut

Lubricants, Sealers, and Adhesives A B C D E F - Quicksilver 2-4-C Marine Lubricant with Teflon . . . . 92-825407A12 - Loctite 8831 . . . . . . . . . . . . . 92-823089-1 - Quicksilver High Performance Gear Lube . . 92-16026A4 - Quicksilver Perfect Seal . . . . 92-34277-1 - Permatex Ultra Blue Silicone Sealant . . . . . . . . Obtain Locally - Quicksilver Special Lubricant 101 . . . . . . . . . . . . 92-13872A1

Torque Specifications a 60 lb. in. (6.8 Nm) b 70 lb. ft. (95 Nm) c 28 lb. ft. (38 Nm) d 35 lb. ft. (47 Nm) e 23 lb. ft. (31 Nm) f 100 lb. ft. (136 Nm) g 210 lb. ft. (285 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 17

Standard Rotation Gear Housing Assembly Specifications

Pre-Disassembly Inspection
Action Move propeller shaft from one side to another Rotate propeller shaft Reading Less than .003 in. (0.08 mm) .005 in. (.127 mm) or less

Shift Spool End Play

g f

b h d

c
23142

22086

a b c d e f g h

Washers (2) Spring Retainer Spool Shift Shaft Castle Nut Cotter Pin End Play Measurement: .002 in. (.05mm) to .010 in. (.25mm)

Pinion Gear Height

Check pinion height at four locations. Average pinion gear height: .025 in. (0.64 mm).

26410

INDEX
2 - 18 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Forward Gear Backlash

Apply forward pressure to the propeller shaft with puller jaws. Torque the puller bolt to 45 lb. in. (5 Nm ).

Reverse Gear Backlash

Use the pinion nut adaptor to apply backward pressure on the propeller shaft. Torque Propeller nut to 45 lb. in. (5 Nm).

70719 23355

a - Puller Jaws b - Puller Bolt

Take readings at four different locations, 90_ apart, and average them for the backlash reading. Backlash reading: .017-.028 in. (0.43-0.71 mm) d e f

a - Pinion Nut Adaptor b - Washer c - Propeller Nut

Backlash reading: .034-.054 in. (0.86-1.37 mm). d e f

b b c

a a
70717

70717

a b c d e f

Nuts (4) Threaded Rod Dial Indicator Holding Tool Dial indicator Indicator Pointer-Set at I on Backlash Indicator Rod Backlash Indicator Rod

a b c d e f

Nuts (4) Threaded Rod Dial Indicator Holding Tool Dial indicator Indicator Pointer-Set at I on Backlash Indicator Rod Backlash Indicator Rod

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 19

Counter-Rotation Gear Housing Specifications

Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
DESCRIPTION Water Pump Body Screws Pinion Gear Nut Gear Housing to Drive Shaft Housing Screws Gear Housing to Drive Shaft Housing Nuts Trim Tab Screw Shift Shaft Bushing Screws Drive Shaft Retainer Bear Carrier Retainer Oil Fill/Drain Screw Propeller Nut 1
1:

Lubricants, Sealers, and Adhesives

DESCRIPTION

PART NUMBER 92-825407A2 92-25234-1 92-86166 92-825265A1 92-34227-1 Obtain Locally 92-13872A1 92-823089-1 92-816026A1

Quicksilver 2-4-C Marine Lubricant with Teflon 3m Brand Adhesive Quicksilver Bellows Adhesive
Nm 6.8 70 28 35 23 60 100 210 95 38 47 31 6.8 136 285 3.45.6 55 75 TORQUE

lb. in. 60

lb. ft.

Quicksilver Needle Bearing Assembly Lubricant Quicksilver Perfect Seal Permatex Ultra Blue Silicone Sealant Quicksilver Special Lubricant 101 Loctite 8831 Quicksilver High Performance Gear Lube

3050

Amount specified is MINIMUM.

Shimming Specifications
DESCRIPTION

GEAR LOCATION inches .025 .017-.028 .040-.050 millimeters 0.64 0.43-0.71 1.02-1.27

Pinion Gear Height Forward Gear Backlash Reverse Gear Backlash

INDEX
2 - 20 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Special Tools
Description Backlash Indicator Rod Bearing Adaptor Installation Tool Bearing Carrier Retainer Wrench Bearing Driver Bearing Preload Tool Bearing Removal Tool Belleville Washer Dial Indicator Dial Indicator Holding Tool Drive Shaft Nut Wrench Drive Shaft Bearing Retainer Wrench Guide Plate Needle Bearing Driver Oil Seal Driver Oil Seal Driver Pinion Gear Shimming Tool Pinion Nut adapter (Includes the following item) Drive Shaft Adapter Puller Bolt Puller Jaws Puller Jaws Slide Hammer Puller Forward Gear Installation Tool Torque Wrench (inch pound) Universal Puller Plate Water Pump Alignment Pins Universal Bearing Removal and Installation Tool (Includes the following items) Driver Head Driver Head Rod Nut Pilot Washer Puller Plate Puller/Driver Head Puller Shaft Washer Tool Part No. 91-53459 91-18605A1 91-61069 91-807944 91-14311A2* 91-816245 12-54048 91-58222A1 91-89897 91-56775 91-43506 91-816243 91-15755 91-31108 91-817569 91-56048 91-61067A3 91-61077 91-85716 91-46086A1 91-816242 91-34569A1 91-815850 91-66274 91-37241 91-821571A1

91-31229A5 91-36569 91-37323 11-24156 91-36571 91-29310 91-38628 91-31229 12-34961

*The 91-14311A2 Bearing Preload Tool is also used on Mercury and Mariner V-6 gear housings. New Tool

NOTE: Water Pump Face Seal Tool is not available separately, 26-816575A2 is a kit part number which includes the tool and the face seal.

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 21

Counter-Rotation Gear Housing Exploded Parts View

Drive Shaft Components
31 18 29 21 30
A

19 25 a 26 20 13 f 12 11
A

22 27

24

17 28 23 10 3 39
A

32

(ID)

9 34 36 38 a

37 33 7
A C

7 6 5 4 h 8 14 15 b 16
D
74242

INDEX
2 - 22 ALPHA ONE GEN. II STERN DRIVE 90-806534960

1 2 3 4 5

-Gear Housing -Pin -Stud -Screw -Oil Fill/Drain Screw O-ring 6 -Seal 7 -Dowel Pin 8 -Roller Bearing 9 -Speedometer Fitting 10-Drive Shaft 11 -Shim 12-Bearing and Cup 13-Nut 14-Gear Drive 15-Washer 16-Nut 17-Face Plate 18-Carrier 19-Oil Seal 20-Oil Seal 21-O-ring 22-Water Pump 23-Gasket 24-Gasket 25-Face Seal 26-Screw 27-Impeller 28-Key 29-Coupling 30-O-rings 31-Sleeve 32-Shift Shaft 33-Retaining Ring 34-Sleeve 35-Bushing Assembly 36-Oil Seal 37-O-rings 38-Screw 39-Stuffer Plug

Lubricants, Sealers, and Adhesives A B C D E - Quicksilver 2-4-C Marine Lubricant with Teflon . . . 92-825407A12 - 3M Brand Adhesive . . . . . . . 9225234-1 - Loctite 8831 . . . . . . . . . . . . . 92-823089-1 - Quicksilver High Performance Gear Lube . 92-816026A4 - Quicksilver Needle Bearing Assembly Lubricant . . . . . 92-825265A1

Torque Specifications a 60 lb. in. (6.8 Nm) b 70 lb. ft. (95 Nm) c 28 lb. ft. (38 Nm) d 35 lb. ft. (47 Nm) e 23 lb. ft. (31 Nm) f 100 lb. ft. (136 Nm) g 210 lb. ft. (285 Nm) h 30-50 lb. in. (3.4-5.6 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 23

Propeller Shaft Components

e 2 1

5 4 c 8

9 10 11 18 13 14 15 16 17 27 25 28 25 26 27
G
(OD)

19

12 20 21 22 26 24
(ID)

23 29 30

33

31 32 33

39 36 40 38 37 35 g

34

74723

INDEX
2 - 24 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Lubricants, Sealers, and Adhesives

1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031323334353637383940Gear Housing Screw - Trim Plate or Tab Nut Screw Lockwasher Anodic Plate or Tab Shift Crank Shift Spool Assembly Shims Bearing Adapter - Reverse Gear Roller Bearing Thrust Washer Thrust Bearing Roller Bearing Reverse Gear Retainer Spring - Cross Pin Clutch Cross Pin Propeller Shaft Forward Gear Shim Spacer Thrust Bearing Roller Bearing Bearing Adapter - Forward Gear Thrust Washer Thrust Bearing Thrust Race Keepers O-ring Needle Bearing Bearing Carrier Propeller Anode and Screws Seals Tab Washer Retaining Nut Thrust Hub Continuity Washer Spline Washer Tab Washer Locknut

- Quicksilver 2-4-C Marine Lubricant with Teflon . . . . . . . . . . . . 92-825407A12 - 3M Brand Adhesive . . . . . . . 9225234-1 - Quicksilver Bellows Adhesive . . . . . . . . . . . . . . . . . . . 92-86166 - Quicksilver Needle Bearing Assembly Lubricant . . . . . 92-825265A1 - Quicksilver Perfect Seal . . . . 92-34227-1 - Permatex Ultra Blue Silicone Sealant . . . . . . . . Obtain Locally - Quicksilver Special Lubricant 101 . . . . . . . . . . . . 92-13872A1 - Loctite 8831 . . . . . . . . . . . . . 92-823089-1 - Quicksilver High Performance Gear Lube . 92-816026A4

B C D E F G H I

Torque Specifications a 60 lb. in. (6.8 Nm) b 70 lb. ft. (95 Nm) c 28 lb. ft. (38 Nm) d 35 lb. ft. (47 Nm) e 23 lb. ft. (31 Nm) f 100 lb. ft. (136 Nm) g 210 lb. ft. (285 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 25

Counter-Rotation Gear Housing Assembly Specifications

Pre-Disassembly Inspection
Action Move propeller shaft from one side to another Rotate propeller shaft Reading Less than .003 in. (0.08 mm) .005 in. (.127 mm) or less

Pinion Gear Height

Take readings in three locations, 120_ apart. Readings: .025 in. (0.64 mm).

26410

Shift Spool End Play

22086

g f

Forward and Reverse Gear Identification

IMPORTANT: The forward and reverse gears look almost identical. There are two ways to distinguish between the reverse and forward gears. The reverse gear has a shorter hub and it has a groove cut into the back of the gear just inside the thrust bearing race.

b h d

74877

50885

REVERSE
a - Shorter Hub b - Groove

FORWARD

a b c d e f g h

Washers (2) Spring Retainer Spool Shift Shaft Castle Nut Cotter Pin End Play Measurement: .002 in. (.05mm) to .010 in. (.25mm)

INDEX
2 - 26 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Forward Gear Backlash

Apply a slight preload on forward gear using tools as shown. c a b

Reverse Gear Backlash

Apply a slight preload on reverse gear using tools as shown. a b

d
50880

a b c d

Torque Wrench (91-66274) Propeller Nut [Torque to 45 lb. in. (5 Nm)] Washer (91-54048) Pinion Nut Adaptor (91-61067A3)

Check Backlash in four places. Rotate the drive shaft 90_ after each check. Backlash Reading: .017-.028 in (0.43-0.71mm). e d f

a - Torque Wrench (91-66274) b - Driver Bolt [Torque to 45 lb. in. (5Nm)] c - Bearing Adaptor Installation Tool (91-18605A1) d - Reverse Gear

70973

Check Backlash in four places. Rotate the drive shaft 90_ after each check. Backlash Reading: .050-.060 in. (1.27-1.52 mm). e d f

a a b c b c

a
70717

a
a b c d e Nuts (4) (obtain locally) Threaded Rod [3/8 in. (9.5 mm) obtain locally] Dial Indicator Holding Tool (91-89897) Dial Indicator (91-58222A1) Indicator Pointer-set indicator pointer at I on backlash indicator rod f - Backlash Indicator Rod (91-53459) 70717

a b c d e

Nuts (4) (obtain locally) Threaded Rod [3/8 in. (9.5 mm) obtain locally] Dial Indicator Holding Tool (91-89897) Dial Indicator (91-58222A1) Indicator Pointer-set indicator pointer at I on backlash indicator rod f - Backlash Indicator Rod (91-53459)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 27

THIS PAGE IS INTENTIONALLY BLANK

INDEX
2 - 28 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Transom Assembly Specifications

Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
DESCRIPTION Shift Cable Core Wire Anchor Screws Bellows Hose Clamps Gimbal Ring to Bell Housing Hinge Pins Gimbal Ring Screws Steering Screw and Nut Transom Assembly Attaching Screws, Nut 90_Fitting Nut 90_Fitting Oil Fill/Drain Screw 7090 23 TORQUE lb. in. 20 35 102 55 60 2025 1014 lb. ft. Nm 2.3 4 143 74 81 2734 1419 8-10 30

Special Tools (continued)

DESCRIPTION

PART NUMBER 91-29310 91-63616 91-38919 91-31229 12-34961 91-806928T 91-818169 91-818162

Plate (2) Puller Puller Head Puller Shaft Washer Bushing Installation Tool Sleeve Installation Tool Sleeve Removal Tool

Lubricants, Sealers, and Adhesives

DESCRIPTION

PART NUMBER 92-86166 92-825407A12

Quicksilver Bellows Adhesive Quicksilver 2-4-C Marine Lubricant with Teflon Quicksilver U-Joint and Gimbal Bearing Grease

92-828052A2 92-34227-1 92-78376-12 92-59327-1 92-823089-1 92-13872A1

Special Tools
DESCRIPTION

Perfect Seal Anti-Corrosion Grease PART NUMBER 91-31229A5 91-45497A1 91-34569A1 91-12037 91-33492 91-33491 91-33489 91-32325 91-37323 91-56775 91-805475A1 91-45497A1 91-78310 91-30366 11-24156 Locquic Primer T Loctite 8831 Quicksilver Special Lubricant 101

Bearing Removal and Installation Tool Bellows Expander Tool Slide Hammer Puller Shift Cable Removal and Installation Tool Driver Driver Driver Driver Head Driver Rod Drive Shaft Nut Wrench Alignment Tool Assembly Expander Tool Hinge Pin Tool Mandrel Nut

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 29

Alpha One Transom Assembly Exploded View

Bell Housing Components
18 17 18 13 22 24 23 6
B (O.D.) A C A

15 a

1 14

20 10 4 14 9 33
A B

b 12 7

11

16
A

14

21 a

34 36 38
E

5
C

37
F

35 c 28 29

30

31

2 25

32 27 26

73316

INDEX
2 - 30 ALPHA ONE GEN. II STERN DRIVE 90-806534960

1 - Bell Housing Assembly 2 - Gasket 3 - Connector 4 - Pipe Plug 5 - Bushing 6 - Bushing 7 - Gasket (Rubber) 8 - O-ring 9 - Washer (Synthane) 10-Stud 11- Washer 12- Nut 13- Universal Joint Bellows 14- Ground Clip 15- Clamp 16- Sleeve 17- Hose 18- Clamp 19- Exhaust Bellows 20- Seals 21- Clamp 22- Lever Assembly 23- Washer 24- Screw 25- Shift Shaft (Upper) 26- Coupling Assembly 27- Tubing 28- Clip 29- Clamp 30- Fitting Assembly 31- Connector 32- Clamp 33- Hose 34- Clamp 35- Connector 36- O-ring 37- Valve Assembly 38- O-ring

Lubricants, Sealers, and Adhesives A - Quicksilver Bellows . . . . . . . . . Adhesive . . . . . . . . . . . . . . . . . . . 92-86166 B . . . - Loctite 8831 . . . . . . . . . . . . . 92-823089-1 C . . . - Perfect Seal . . . . . . . . . . . . . . 92-34227-1 D . . . - Special Lubricant 101 . . . . . 92-13872A1 E . . . - Quicksilver High Performance . . . . . . . . . Gear Lube . . . . . . . . . . . . . 92-816026A4 F . . . - 3M Brand Adhesive . . . . . . . 92-25234-1 Torque Specifications a Tighten Securely Approximately 35 lb. in. (4 Nm) b 50 lb. ft. (68 Nm) c 8 lb. ft. (11 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 31

Gimbal Housing Components

b 43
B

44 45 42 a 41 40 5 41 3
C

46 13

18 30 d

29 40 2 1 14 4

17 16

14

15

8 9
A

11 49 c 6

10 21 27 26 19 20

7 48 12 31 32 33 47 34 39 36 37 35

38

74861

INDEX
2 - 32 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Lubricants, Sealers, and Adhesives

1 - Gimbal Housing 2 - Stud 3 - Lower Bushing 4 - Oil Seal 5 - Upper Bushing 6 - Grease Fitting 7 - Lubricap 8 - Grease Seal 9 - Bearing Assembly 10- Tolerance Ring 11- O-Ring 12- Stud 13- Seal 14- Pipe Plug 15- Water Tube 16- Bushing 17- Cover 18- Screw 19- Lower Swivel Pin 20- Cotter Pin 21- Washer 22- Bolt 23- Washer 24- Washer 25- Nut 26- Bolt 27- Clamp 28- Clamp 29- Washer 30- Nut 31- Gasket 32- Connector 33- Lockwasher 34- Nut 35- Anodic Plate 36- Seal 37- Gasket 38- Screw 39- Lockwasher 40- Hose 41- Clamp 42- 90_ Fitting 43- Nut 44- Washer 45- O-ring 46- Connector 47- Continuity Wire 48- Continuity Wire Connection 49- Hose Clamp

A B C D

- Quicksilver Bellows Adhesive . . . . . . . . . . . . . . . . . . . 92-86166 - Quicksilver Perfect Seal . . . . 92-34227-1 - Loctite 8831 . . . . . . . . . . . . . 92-823089-1 - Quicksilver U-Joint and Gimbal Bearing Grease . . 92-828052A2

Torque Specifications a 70-90 lb. in. (8-10 Nm) b 10-14 lb. ft. (14-19 Nm) c 35-42 lb. in. (3.96-4.75 Nm) d 25 lb. ft. (34 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 33

Inner Transom Plate Components

c 4 1

5 6 7 8

10 11 3 15 14 13 2 b a

74850

12 19 16 20

18 17
74865

1 2 3 4 5 6 7 8 9 1011121314-

Transom Plate Assembly Pivot Bolts Tab Washers Screw Engine Mounting Washer Spacer Washer - Fiber Lockwasher - Double Wound Locknut Washer Locknut Shift Cable Outer Casing End Guide Core Wire Anchor

151617181920-

Anchor Screws Core Wire Shift Slide Screw - Core Wire Cavity Gimbal Housing Eyelet Cable Wrapping

Torque Specifications a b c 25 lb. ft. (34 Nm) 23 lb. ft. (30 Nm) 37 lb. ft. (50 Nm)

INDEX
2 - 34 ALPHA ONE GEN. II STERN DRIVE 90-806534960

Gimbal Ring and Steering Lever Components

24 17 15 11 d 12 9 8 10 b 20 18 7 6 21 1 c 5 26 4 3 10 14 9 8 16 22 19 a 23 13 25

2
A
73318

1 2 3 4 5 6 7 8 9 101112131415161718192021-

Gimbal Ring Bushing Grease Fitting Lubricap Hinge Pin Trim Limit Switch Washer Screw Lockwasher Retainer Trim Wire Clamp Screw Steering Lever Swivel Shaft Washer Washer Nut Screw Nut Screw Washer

2223242526-

Washer Locknut Clevis Pin Cotter Pin Trim Position Sender

Lubricants, Sealers, and Adhesives A - Resiweld Sealer . . . . . . . . . . 92-65150-1

Torque Specifications a b c d 60 lb. ft. (81 Nm) 55 lb. ft. (74 Nm) 110 lb. ft. (148 Nm) 90-100 lb. in. (10-11 Nm)

INDEX
90-806534960 ALPHA ONE GEN. II STERN DRIVE 2 - 35