Руководства по ремонту volvo penta

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  Workshop Manual Sterndrive & Transom Shield 2(2) SX-A, DPS-A…
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  Copyright © 2007 Volvo Penta of the Americas, Inc. All rights reserved. This manual may not be copied, photocopied, reproduced, or converted to any electronic or machine-readable form in whole or in part without the express written consent from Volvo Penta of the Americas, Inc.
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  Upper Gear Housing ….45 SX-A Lower Gearcase ….91 DPS-A Lower Gearcase .
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  Publ. 7746477 English 06-2008…

• Page 5: Table Of Contents

  This Workshop Manual contains technical specifications, descriptions, and instructions for the repair of the Volvo Penta products or product types described on the front cover of the manual. Check that you have the correct Workshop Manual for the product you are servicing.

• Page 6: Sterndrive

  General Information CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This is a symbol that indicates a potential personal injury hazard. Closely follow all instructions to avoid injury. In this manual, you will also find the following signal word that calls attention to a property damage message or messages;…

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  These instructions are not in any way comprehensive, since it is impossible to predict every circumstance under which service work or repairs may be carried out. Volvo Penta can only indicate the risks considered likely to occur as a result of incorrect working methods in well equipped workshops using approved methods and tools tested by Volvo Penta.

• Page 8: Engine And General

  General Information general safety guidelines covering engines, they are not in any way comprehensive. Before removing or operating the engine consult the specific manuals for that engine, especially the Safety section(s). Accidental or unintended engine starts can cause serious injury to the technician or others around the engine, sterndrive or boat.

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  The components in the electrical system, in the ignition system (gasoline engines), and in the fuel system on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion. Do not substitute automotive or other non-approved non- marine parts for these components.
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  Special service tools have been specially designed to simplify some of the disassembly and assembly operations. These tools are illustrated in this Service Manual, in many cases in actual use. All Volvo Penta special tools can be ordered from Volvo Penta Parts. Individual purchasers of Service Manuals must order Special Tools through an authorized dealer.

• Page 11: General Service Information

  In all cases, old sealants may be removed by using methylated spirits. Product References, Illustrations & Volvo Penta reserves the right to make changes at anytime, without Specifications notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change.

• Page 12: Good Service Practice

  Volvo Penta original spare parts meet these specifications. Any type of damage, resulting from the use of replacement parts that are not original Volvo Penta spare parts for the product being serviced, will not be covered under any warranty or guarantee provided by Volvo Penta.

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  If a service question does not appear to be answered in this manual, you are invited to write to the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine or sterndrive model number and serial number.
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  — The part should be primed soon after it dries, or at least within 24 hours. Where the prime coat is thin or where the surface is unpainted, prime with Volvo Penta Primer or PPG epoxy primer. Do not apply primer over hard finish coat. Primer solvents must be allowed time Publ. 7746477…

• Page 15: Painting

  See the parts catalog for the model in question for the part numbers Sields for paint for the engine, transom bracket or sterndrive. Paint may be obtained from Volvo Penta Parts. Recommendations for Antifouling All antifouling paints that prevent marine growth are poisonous Paints and may harm our marine environment.

• Page 16: Storage And Maintenance

  General Information Contact with bottom paint may cause sever corrosion of the transom and sterndrive assembly. Storage and Maintenance Off-Season Storage Preparations Change sterndrive lubricant (oil). See sections titled Chapter 2. Inspect bellows for wear or leaks. See section titled “Bellows” in “Transom Shield”…

• Page 17: Every Other Year (Every 24 Months)

  No service required, replace if worn or damaged replace if worn or damaged Trim/Tilt Pump, No service required No service required Use Volvo Penta System Check if trim/tilt performance Check if trim/tilt performance Power Trim/Tilt and is poor is poor…

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  General Information NOTES — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — -…

• Page 19: Safety Messages

  Shift System Test ……..42 Safety Messages Before working on any part of a Volvo Penta sterndrive, read the section called “Safety Messages” in the first chapter of this manual.

• Page 20: Special Tools

  3862797 Front Volvo Penta Service Tools All tools by Volvo Penta are listed in text by name and part number. Sealants, Lubricants and Adhesives Volvo Penta GL5 Synthetic gear lubricant, 75W90 Gasket sealing compound, white, (Locktite™ PST or 565, or equivalent).

• Page 21: Sterndrive Oil Capacity

  If present find cause and repair before operating drive. Also check for metal or other debris in oil. If present find cause and repair before operating drive. Sterndrive Oil Capacity All SX-A Models; Capacity = 90 oz. (2650ml) All DPS-A Models; Capacity = 83 oz. (2450ml) NOTICE! Quantities provided above are for initial fill of new, empty sterndrive.

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  Sterndrive, General Information Remove shift cover. Use 12mm socket, rachet Place a 4 quart or larger drain pan under lower gearcase skeg to catch oil. NOTICE! Clean area around plugs before removing plugs. Debris in oil can damage sterndrive. Remove oil drain plug. Discard o-ring.

• Page 23: Filling Sterndrive With Oil

  When filling drive, proper oil level is determined by filling drive with oil until oil appears at oil level hole on starboard side. Fill with Volvo Penta GL5 Synthetic Gear Lubricant, SAE 75W-90. Use pump with 3/8-16 UNC threaded fitting to fill sterndrive through oil drain hole.

• Page 24: Alternate Fill Procedure

  Sterndrive, General Information Remove pump, then quickly install oil drain plug. Make sure o-ring is installed and seated correctly on plug. Hand tighten drain plug. Check oil level with dipstick. Oil should show on flat portion of the dipstick. Add oil if required, through the dipstick hole. When oil level is correct;…

• Page 25: Propeller Removal

  Sterndrive, General Information Propeller Removal A rubber hub in the propeller is the shock absorber that minimizes impact damage to the sterndrive and engine. If the hub slips, it should be replaced. The hub should be replaced by a reputable propeller shop.

• Page 26: Dps

  Sterndrive, General Information Shift the sterndrive into forward to lock the propeller shaft. Use propeller tool 3862808 or 30 mm socket and rachet to remove rear propeller nut. Remove rear propeller. Shift the sterndrive into reverse to lock the propeller shaft. 50155 Publ.

• Page 27: Propeller Installation

  Sterndrive, General Information Use propeller tool 3862797 and rachet to remove front propeller nut. Remove front propeller. Clean the propeller shafts. Inspect for fishing line or other debris; remove if present. Inspect shaft seals, correct if leaking. Propeller Installation WARNING! Propellers turning with engine power can cause serious injury.

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  Sterndrive, General Information Coat propeller shaft and inside of prop hub with grease 828250. Future removal of the propeller will be difficult if this is not done. NOTICE! Failure to install all components could result in propeller loss and damage to sterndrive. Place thrust bushing (B) on propeller shaft with inner taper toward gearcase.

• Page 29: Dps

  Sterndrive, General Information Coat the full length of both shafts with grease 828250. Future removal of the propellers will be difficult if this is not done. Shift the sterndrive into forward to lock the propeller shaft. Install the front propeller. Install the front propeller nut, chamfered edge forward.

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  Sterndrive, General Information Torque nut to 45 ft. lb. (60 N•m). Use prop nut tool 3862797 and torque wrench. Shift the sterndrive into reverse to lock the propeller shaft. 50155 Install the rear propeller. Publ. 7746477 English 06-2008…

• Page 31: Anodes

  Sterndrive, General Information Install the rear propeller nut, chamfered edge forward. NOTICE! Be sure the chamfered edge of the propeller nut is facing forward. Failure to install the propeller nut correctly could result in a propeller coming loose and damge to the lower unit and/or propeller. Torque nut to 50 ft.

• Page 32: Testing

  Sterndrive, General Information Check the Parts Catalog for the anode part numbers. Testing Test for proper installation of the anode. Set an ohmmeter to the low ohms scale. Connect one ohmmeter lead to a good ground, and the other to the anode.

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  Sterndrive, General Information Remove Upper Cover Remove five screws securing cover. Use 12mm socket. Remove cover. Disconnect Shift Cable Remove cotter pin (P) and then washer (W) from cube (C). Remove cube and cable from bracket. Loosen jam nut (N). Thread cube off of cable.

• Page 34: Remove Sterndrive

  Sterndrive, General Information Disconnect Trim Cylinders Straighten bottom of cotter pins. Pull cotter pins up and out of housing. Pry in housing slots behind pin heads to start pins, protect painted surfaces from damage by tools. After pin head is exposed, use pliers to pull pins from housing and cylinders.

• Page 35: Sterndrive Service

  NOTICE! All references to oil or gear oil in all assembly steps are referring to the same oil used to fill the sterndrive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W90. Disassemble Mount the sterndrive in a suitable holding fixture and clamp it securely.

• Page 36: Reassemble

  Sterndrive, General Information Reassemble Mount the lower housing in a suitable holding fixture and clamp it securely. NOTICE! Fixture is not shown in the following images to provide clearer illustration of parts. Lightly oil new seals (S) and insert in grooves in lower housing. Also oil o-ring (R) on retainer.

• Page 37: Pressure And Vacuum Testing

  Sterndrive, General Information Install and hand tighten four spiral locknuts (N). NOTICE! Do not substitute other types of lock nuts for the spiral locknuts. Other nut types will not torque correctly, causing damage to the sterndrive. If spiral locknuts are lost or damaged replace with locknut part number specified in the Parts Catalog.

• Page 38: Installing The Sterndrive

  These tools should be used whenever recommended. Follow the steps and procedures described in this section—in the order listed—to perform a complete installation of a Volvo Penta engine and sterndrive assembly. 1. Prepare for installation 2.

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  Sterndrive, General Information Preparing Drive Remove and retain oil level dipstick and gasket. 50367 2. Thread lifting eye into oil level dipstick hole. 3. Use a suitable hoist to remove drive unit from work area and holding fixture. 50366 4. Make sure all attaching hardware is readily available. 6 lock nuts 6 washers, narrow 2 trim/tilt pins…
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  Sterndrive, General Information 5. If the boat transom design requires the transfer of the drive unit from a hoist onto a drive unit cart, do so now. 50368 6. Remove lifting eye bolt from upper housing. 7. Reinstall dipstick and o-ring. Tighten dipstick. 50370 8.
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  Sterndrive, General Information 9. Inspect seal ring for proper fit in its groove. Inspect and lightly lubricate u-joint bellows lip with grease 828250. 50372 10. Using handle 3850609, slide alignment tool 3851083 through gimbal bearing. Alignment tool must easily slide through gimbal bearing and into engine coupler.

• Page 42: Installing Drive Unit

  Sterndrive, General Information 12. Apply grease 828250 to the six studs. 50374 13. Reinstall the large seal 4 and small seal 5 onto the shift cable. 50380 Installing Drive Unit 1. Tilt the trim cylinders up above the upper gear splash plate. 2.

• Page 43
  Sterndrive, General Information 3. To align u-joint shaft splines, rotate propeller shaft(s) until the shaft splines engage the coupler. CAUTION!Wear gloves or use a shop cloth to protect your hands. Propeller shaft splines may be sharp. DR2023 4. Slide sterndrive onto six studs until it is completely seated against the pivot housing.

• Page 44: Install Shift Cable

  Sterndrive, General Information 8. Align trim/tilt cylinder end with upper gear housing boss. Slide trim/tilt pivot pins into upper gear housing. 9. Use the flats on pin heads to align the trim pins with the cotter pin holes in the gear housing. Install the cotter pins.

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  Sterndrive, General Information 4. Rotate eccentric piston arm 7 to extend bellcrank. 5. Move the gear shift to reverse to extend the shift cable. Thread cube halfway onto cable end. Rotate eccentric piston arm back to neutral detent position, then move gear shift to its neutral detent position.

• Page 46: Start-In-Neutral-Only Test

  Sterndrive, General Information WARNING! The cube must be securely attached to the bracket and the cable. Failure to secure cable and cube will result in the shift cable coming loose and result in loss of shift control. Start-in-Neutral-Only Test WARNING! The remote control should be designed to allow starting in NEUTRAL only.

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  Sterndrive, General Information Install Shift Cover 1. After shift system tests are performed, all adjustments are made, and after final gear oil level check: Reinstall the shift cover. Carefully thread five screws in to housing. Use 12mm socket and rachet to hand tighten, then torque to 13-17 ft.lbs (17-23N•m) Publ.
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  Sterndrive, General Information NOTES — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — -…

• Page 49: Table Of Contents Safety Messages

  Service Chart ……. 89 Safety Messages Before working on any part of a Volvo Penta sterndrive, read the section called “Safety Messages” in the first chapter of this manual.

• Page 50: Upper Gearcase — Cross Section

  Upper Gear Housing Upper Gearcase — cross section 1. Shim position 16. Vertical shaft 2. Pitot passage 17. Top nut 3. Oil passage 18. Top cover 4. Exhaust passage 19. Dipstick 5. Water passage 20. Plug, oil drain 6. U-joint 21.

• Page 51: Special Tools

  Upper Gear Housing Special Tools Tool Name Part No. View Tool Name Part No. View Assembly Tool 884932 Drift 884789 Dis-assembly 884933 Holding Fixture 3849658 Tool Retaining Ring 3850608 Drift 884168 Pliers (331045) Drift 884263 Seal Installer 885557 Drift 884266 Seal Installer 3850607 (Early versions may have the OMC part no.)

• Page 52: Sealants, Lubricants And Adhesives

  Housing Holder 128mm Spanner Wrench 3850604 Volvo Penta Tools All tools by Volvo Penta are listed in text by name and part number. Sealants, Lubricants and Adhesives Cleaning solvent Volvo Penta GL5 Synthetic gear lubricant, 75W90 Loctite primer Volvo Penta thread locking compound p/n 1161053 Volvo Penta grease p/n 828250 Publ.

• Page 53: Sterndrive Removal And Disassembly

  Upper Gear Housing Sterndrive Removal and Disassembly To service components of the upper gear housing, remove sterndrive from transom shield and separate upper housing from lower. Follow the procedures in the Sterndrive, General Information chapter of this manual. Attach spline socket 3850598 to holding fixture 3849651. Tighten set screw securely.

• Page 54: Upper Gear Housing Disassembly

  Upper Gear Housing Upper Gear Housing Disassembly Shift Mechanism Removal Remove cotter pin (C) securing rod to eccentric. Remove screw (S) and washer attaching shift bracket. Remove bracket (B) and rod. 50452 Remove four screws securing shift housing. NOTICE! Shift housing is spring loaded and may pop out when screws are loosened.

• Page 55: Pinion Bearing Carrier Removal

  Upper Gear Housing Pinion Bearing Carrier Removal Remove four screws securing pinion bearing carrier to upper housing. Remove pinion bearing carrier and u-joint using two screwdrivers. Be careful not to damage upper housing or bearing carrier mounting surfaces. Save any undamaged shims, they can be reused. Remove and discard O-ring.

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  Upper Gear Housing Save any undamaged shims (S) under cover, they can be reused. Remove and discard cover seal (G). Push holding fixture shaft up to engage upper driveshaft splines. Align flat part of fixture shaft with locking screw. Tighten locking screw to prevent upper drive shaft from turning. Remove Left-Hand threaded top nut with 30 mm socket.
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  Upper Gear Housing Use spanner wrench 3850604 to remove retainer ring that holds lower gear/bearing assembly in place. Spanner must be updated with new plate 3861651, original plate will not mate to housing. Insert tool into housing. Use two upper housing cover screws to secure spring loaded arm to top of gear housing.
• Page 58
  Upper Gear Housing Remove lower bearing and shaft assembly. Remove and save shims. They can be reused if not damaged. Turn lower bearing and shaft assembly over. Remove O-ring. Push up on shaft to disengage shaft c-clips from spacer. Remove upper driveshaft c-clips and spacer from shaft. Publ.

• Page 59: Lower Output Gear Disassembly

  Place rag in tool to protect gear. Place ring/gear/bearing assembly into tool with gear facing up. Press gear/bearing through ring, use drift Volvo Penta p/n 884789. Place sleeve 884938, large end up, in a press. Place rag in tool to protect gear.

• Page 60: Universal Joint Service

  Upper Gear Housing Universal Joint Service NOTICE! The universal joint is not servicable. No parts are offered for the u-joint. Testing has shown that when any part of the u-joint fails the other parts are also compromised. The complete u-joint must be replaced. Pinion Bearing Carrier Disassembly Secure holding fixture 3849658 in vise as shown.

• Page 61
  Upper Gear Housing Remove pinion gear retainer screw using 11mm 12 point socket. Discard screw. Remove the pinion gear retainer. NOTICE! Pinion gear screw must not be reused. Proper torque cannot be achieved with a used screw. Carefully remove pinion bearing carrier from universal joint shaft. If pinion bearing carrier is stuck, a press may be used to remove universal joint shaft from pinion bearing carrier.
• Page 62
  Upper Gear Housing Remove pretension sleeve from input gear shaft and discard. NOTICE! Pretension sleeves must not be reused. Proper rolling torque cannot be achieved with a used pretension sleeve. 34694 Clamp input gear and bearing in bearing separator, placing curved side of jaws behind bearing.

• Page 63: Upper Housing Stud Replacement

  Upper Gear Housing Place sleeve 884938 in press. Turn pinion bearing carrier over and place it on tool. Press large bearing out using tools in previous step. 884938 34690 Gearhousing Cleaning and Inspection Clean housings in solvent to remove all sealer from screw holes, gasket surfaces, and O-ring bores.

• Page 64: Shift Mechanism Overhaul

  Upper Gear Housing Shift Mechanism Overhaul Inspect cone clutch and shift shoe, replace if excessively worn. Remove shift shoe and spring. Scrap the O-ring. Pull spring pin out with side cutting pliers. Fix the pin in a vise. Tap housing with a plastic faced mallet until it comes off pin. Pull eccentric piston out of housing.

• Page 65
  Upper Gear Housing Grease the seal ring, eccentric piston and its seat in the gear shift mechanism. Install the eccentric piston. Make sure not to damage the seal ring. Tap the pin in so far that the milled cutout is level with the hole for the spring pin.

• Page 66: Pinion Bearing Carrier Assembly

  NOTICE! All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W- 9991801 Place pinion bearing carrier in press with large opening up.

• Page 67
  Upper Gear Housing Oil large and small roller bearings with gear oil. Place pinion bearing carrier on top of input gear. Place small bearing on top of input bearing shaft. Press small bearing onto shaft using drift 884263, until all end play is removed.
• Page 68
  Upper Gear Housing WARNING! Always wear eye protection when removing or installing snap rings. Install seal retaining ring in its groove in pinion bearing carrier using retaining ring pliers 3850608. Make sure retaining ring seats completely. 34712 Coat seal lips with grease 828250. 34704 Secure holding fixture 3849658 in vise.
• Page 69
  Upper Gear Housing Carefully insert universal joint shaft through seal and engage splines of input gear. Spray threads of universal joint shaft and new pinion gear retainer screw with Loctite primer “N” and allow to air dry. 34759 NOTICE! Pinion gear screw must not be reused. Use new screw supplied with u-joint or order new screw from Parts.

• Page 70: Lower Output Gear Assembly

  Upper Gear Housing Use prybar or large screwdriver through u-joint and against bolt on fixture to prevent u-joint from turning Install screw, tighten a little at a time using 11mm 12 point socket. Turn pinion bearing carrier while tightening screw to seat bearings. Frequently remove assembly from vise to check rolling torque.

• Page 71: Upper Output Gear Assembly

  Upper Gear Housing Press bearing in place until it seats, using drift 884168. 884168 34754 Upper Output Gear Assembly Press bearing in to ring; 50458 Place sleeve 3862673, large diameter end up, in a press. Lightly oil inside diameter of ring with gear oil. Place ring (R) on top of the sleeve, inner lip down.

• Page 72: Lower Output Gear Shimming

  Upper Gear Housing Place upper gear in a press. Protect gear face. Lightly oil inside diameter of bearing with gear oil. Place bearing/ring on top of gear. Orient bearing/ring as shown above. Press bearing in place until it seats, using drift 884168. NOTICE! The following procedures will set gear position for the input, lower and upper output gears.

• Page 73: Upper Output Gear Shimming

  Upper Gear Housing Upper Output Gear Shimming Place gear/bearing/ring assembly, gear down, on flat surface. Protect gear cup surface. Place shim tool 3849650, on assembly as shown. Apply light pressure to hold shim fixture properly on gear. Fixture should be level across top of gear shaft. Take feeler gauge measurement (A) at outer, lower edge of ring.

• Page 74
  Upper Gear Housing Find etching on gear, +/- number is shimming allowance (S). Number represents thousandths of an inch (0.00X”). 2 in pucture = 0.002” Add or subtract (S) from actual dimension (D). NOTICE! For pinion gear, use the following information when adding or subtracting etched allowance figure from dimension (D).

• Page 75: Upper Gear Housing Assembly

  NOTICE! All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W- Place upper shaft through lower output gear/bearing assembly. Groove must be on same side as bearing.

• Page 76: Lower Output Gear Installation

  Upper Gear Housing Move shaft down to capture c-clips in recess of spacer. Lower Output Gear Installation Mount upper gear housing on holding fixture 3849651. Secure housing to fixture with 4 nuts (N) on studs. Place required amount of shims for lower gear/bearing into upper gear housing.

• Page 77
  Upper Gear Housing Place shims on bottom bore as shown. Shims go on surface where bearing is mounted. Place lower gear/bearing assembly, bearing down, on shims. 34959 Loosen locking screw and adjust fixture shaft until there is a small amount of vertical play in drive shaft. Re-tighten fixture bolt. Lightly oil retainer ring with gear oil.
• Page 78
  Upper Gear Housing When fully seated, retainer ring will be below bottom edge of pinion bearing carrier opening. Install spanner wrench 3850604, and secure tension arm with two top cover screws. Spanner must be updated with new plate 3861651, original plate will not mate to housing. 3850604 Tighten cover screws down evenly, alternating every two turns.

• Page 79: Upper Output Gear Installation

  Upper Gear Housing Upper Output Gear Installation Place required amount of shims for upper gear/bearing/ring in upper gear housing. Place shims on upper bore as shown. Shims go on surface where bearing ring is mounted. Bearing ring sits in machined surface at top of housing. Place upper gear/bearing/ring in top of housing and over shaft.

• Page 80: Pinion Bearing Carrier Installation

  Upper Gear Housing Torque nut to 96-110 ft. lb. (130-150 N • Push up on holding fixture shaft to remove end play in shaft. Measure clearance between the top nut and upper gear. Vertical clearance should be 0.002-0.010 in. (0,05-0,25 mm). If clearance is high, install thicker nut.

• Page 81: Top Cover Shimming

  Upper Gear Housing Install pinion bearing carrier into gear housing and secure with four screws. Torque screws, in a crossing pattern, to 15-20 ft. lb. (20-28 N•m). Top Cover Shimming Measure in inches, depth of bearing seat in top cover. Save as measurement D.

• Page 82: Checking Gear Lash

  Upper Gear Housing Install 4 screws in cover. Torque screws, in a crossing pattern, first pass to 6-9 ft. lb. (8-12 N•m). final pass to 15-20 ft. lb. (20-28 N•m). Checking Gear Lash This procedure will check the relative clearance between the pinion gear and the upper and lower output gears.

• Page 83: Correcting Gear Lash

  Upper Gear Housing Zero indicator. With your finger, gently rotate gear first in one direction until tooth contact is felt, then in other direction. Do not turn gear far enough to rotate universal joint, just far enough to contact pinion gear in both directions.

• Page 84
  Upper Gear Housing Both Gears Incorrect By Same Amount Add or subtract same amount of shims at each location indicated Positions Requiring Shim Change Condition Upper gear greater than range max. Subtract Subtract Re-shim Re-shim Lower gear less than range min. Lower gear greater than range max.
• Page 85
  Upper Gear Housing Both Gears Incorrect By Different Amount Add or subtract same amount of shims at each location indicated Positions Requiring Shim Change Condition Upper gear greater than range max. Subtract Subtract Re-shim Re-shim Lower gear less than range min. Lower gear greater than range max.

• Page 86: Checking Gear Teeth Contact Pattern

  Upper Gear Housing Checking Gear Teeth Contact Pattern In order to achieve long gear life and smooth running with minimum noise, you MUST obtain proper gear tooth contact pattern. The contact pattern will give you a visual clue as to where the teeth are meshing with each other.

• Page 87: Final Assembly Of Upper Gear Housing

  Upper Gear Housing If the dye pattern shows contact as shown in this picture, shim thickness behind pinion carrier housing must be increased, (i.e. the drive gear is moved away from the driven gears.) The driven gears must be shimmed inward to maintain correct backlash. GR990876 Final Assembly of Upper Gear Hous- After gear lash and contact pattern are correct, remove the follwing…

• Page 88
  Upper Gear Housing Place upper gear/bearing/ring in top of housing and over shaft. If needed, lightly tap bearing ring to seat it in housing. Be careful not to disturb the shims when installing bearing ring. NOTICE! You may have to loosen the four nuts that secure the upper housing to the holding fixture, to center the housing and shaft.
• Page 89
  Upper Gear Housing Install pinion bearing carrier into gear housing and secure with four screws. Torque screws, in a crossing pattern, to 15-20 ft. lb. (20-28 N•m). Top Cover Installation Make sure correct shims are under cover and shims are positioned correctly.
• Page 90
  Upper Gear Housing Shift Mechanism Installation Install new O-ring on housing. Do not re-use old O-ring. Install spring and shift shoe in piston. Place shift mechanism in mounting hole. Make sure shift shoe is oriented as shown, with “UP” marking facing up.

• Page 91: Gearhousing Installation

  Upper Gear Housing Shift Linkage Assembly Install bracket (B) to housing with washer (W) and new screw (S). Screw has locking patch, if screw is removed it must be replaced. Torque screw to 15-20 ft. lb. (20-28 N•m) Make sure bracket moves freely. 50464 Install rod in hole in eccentric.

• Page 92: Specifications

  Upper Gear Housing Specifications Description U.S. Metric Bearing retainer ring 145-165 ft. lb. 196-225 N•m Nut, upper driveshaft 96-110 ft. lb. 130-150 N•m Plugs, drain and oil level 60-84 in. lb. 7-10 N•m Dipstick 48-72 in. lb. 5-8 N•m Studs, upper housing 22-25 mm height 22-25 mm height Nuts, upper to lower housings…

• Page 93: Service Chart

  Upper Gear Housing Service Chart (A) Volvo Penta Thread Locking Fluid 1161053 (B) No Gasket Sealing Compound required (C) Volvo Penta Propeller Shaft Grease 1141644 (D) Volvo Penta GL5 Synthetic Gear Lubricant 75W90 Publ. 7746477 English 06-2008…

• Page 94
  Upper Gear Housing NOTES — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — -…

• Page 95: Table Of Contents Safety Messages

  Service Chart ……122 Safety Messages Before working on any part of a Volvo Penta sterndrive, read the section called “Safety Messages” in the first chapter of this manual.

• Page 96: Lower Gearcase — Cross Section

  SX-A Lower Gearcase Lower Gearcase — cross section 1. Shim position 16. Propshaft 2. Pitot passage 17. Propshaft bearing housing 3. Oil passage 18. Seal, propshaft 4. Exhaust passage 19. Bearing, propshaft 5. Water passage 20. Plug, oil drain 6. Water intake 21.

• Page 97: Special Tools

  SX-A Lower Gearcase Special Tools Tool Name Part No. View Tool Name Part No. View 3850609 Adapter/Puller 3849652 Handle (311880) Bearing Cup 3850616 3850619 Guide Plate Installer (914695) (914700) 3.6” 3850621 92mm Bearing Cup (914703) Guide Plate 3849656 4.245” Installer…

• Page 98
  SX-A Lower Gearcase Special Tools, cont’d Tool Name Part No. View Tool Name Part No. View Pinion Bearing 3850611 3884360 Puller Bridge remover (432127) 28mm 3850612 3854864 Pinion Nut Holder Puller Jaws (432129) (914694) Pinion Shim 3850623 3855098 Pusher/Puller Fixture…

• Page 99: Sealants, Lubricants And Adhesives

  Volvo Penta Service Tools All tools by are listed in text by name and part number. Sealants, Lubricants and Adhesives Cleaning solvent Volvo Penta GL5 Synthetic gear lubricant, 75W90 Loctite primer Volvo Penta thread locking compound 1161053 Volvo Penta grease 828250…

• Page 100: Lower Gearcase Disassembly

  SX-A Lower Gearcase Lower Gearcase Disassembly Propshaft and Bearing Housing Removal Remove and retain the two screws securing propshaft bearing housing. NOTICE! Use the same type of screw that was removed if any require replacement. If a socket head screw was removed, a socket head screw must be used to replace it.

• Page 101: Vertical Shaft And Pinion Removal

  SX-A Lower Gearcase Attach threaded rod from tool 3850611 to two jaw puller 3850612. Insert puller into housing, expand jaws tightly behind bearing cup. Pull up on rod to pull out cup. Propshaft Bearing Removal Screw propeller nut on shaft to prevent thread damage.

• Page 102
  SX-A Lower Gearcase Using spanner wrench 3850601 unscrew retainer. Remove retainer and o-ring, discard o-ring. Pinion nut removal Screw pinion nut holder, 3854864 onto handle 3850609. Slide guide plate 3849656 over handle. Insert pinion nut holder in to drive gear.
• Page 103
  SX-A Lower Gearcase Vertical shaft removal Pinion gear may slip off shaft, if not, Install puller 3855923 on vertical shaft. Pull shaft and bearings up by tightening vertical screws. Hold the pinion gear while lifting shaft. Remove pinion gear. 50521 Lift out vertical shaft, bearings and upper cup.

• Page 104: Propshaft Gear Removal

  SX-A Lower Gearcase Propshaft Gear Removal Gear and Bearing Removal Remove gear and bearing. NOTICE! Do not remove bearing from propshaft gear unless you intend to replace bearing. Removal process may damage bearing. Use bearing separator to support bearing. Use drift 3861653 to press gear out of bearing.

• Page 105: Gearcase Cleaning And Inspection

  SX-A Lower Gearcase Pinion Bearing Removal To remove pinion bearing, apply grease 828250 to bearing rollers. Place all rollers in bearing case. Tool presses on rollers. Assemble pusher/puller 3850623, guide plate 3850619 (P), and remover 3884360 (R). Install remover into pinion bearing.

• Page 106
  SX-A Lower Gearcase Gearcase Magnet There is a magnet mounted in the front of the gearcase, forward of the propshaft gear. No service is needed and the magnet should not be removed during routine gearcase service. If the magnet is removed, when reinstalling, torque screw to 5-7 ft.

• Page 107: Lower Gearcase Assembly

  Final Assembly on page 119. NOTICE! All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W- Propshaft and Bearing Housing Propshaft Bearing Cup Apply gear oil to bearing cup (C).

• Page 108: Vertical Shaft Bearings

  SX-A Lower Gearcase Press cup in to housing until it seats Do not install seal at this step. Propshaft Bearing Apply gear oil to inner diameter of bearing. Slide bearing on shaft with taper facing prop end. Place bearing installer 3850617 (N) on open jaws of a press support.

• Page 109: Pinion Shimming

  SX-A Lower Gearcase Apply a light coat of gear oil to inner diamter of large bearing. Slide bearing on shaft with taper facing away from small bearing. Place bearing installer 3850617 on open jaws of a press support. Position raised lip of installer up; it must contact nose of bearing.

• Page 110
  SX-A Lower Gearcase Check all three slots with feeler gauge and record each reading. Measure between inner ring of fixture and horizontal gear surface. Average feeler gauge readings. Example: Table 1: Pinion Shims Add: Divide: Slot no. 1 = 0.011 in.

• Page 111: Propshaft Gear

  SX-A Lower Gearcase Use pusher/puller 3850623, guide plate 3850619 (P), and cup installer 3850621 (N) to install cup. Place installer on cup. Place smallest step of plate in retainer bore. Use a hammer to seat bearing cup. Propshaft Gear Bearing Installation Apply gear oil to inner diameter of bearing.

• Page 112
  SX-A Lower Gearcase Using a depth micrometer, measure the distance from top of shim fixture to end of gear shaft. Subtract 0.500 in. from this measurement. Example: 0.557 in. measurement to end of gear shaft — 0.500 in. thickness of shim fixture 0.057 in.

• Page 113: Vertical Shaft And Gear Installation

  SX-A Lower Gearcase Screw cup installer 3850616 (N) on handle 3850609. Slide alignment plate 3849656 (P) on handle. Make sure cup is straight in bore. Place installer in cup and drive cup in until seated. Vertical Shaft and Gear Installation Pinion Bearing Installation Apply grease 828250 to roller bearings.

• Page 114
  SX-A Lower Gearcase Gear Installation Install propshaft gear/bearing in gearcase. Position pinion above gear in gearcase pinion pocket. Engage pinion teeth with propshaft gear teeth. Vertical Shaft Installation Install vertical shaft in gearcase and engage pinion splines. Seat lower bearing in cup.

• Page 115: Setting Rolling Torque

  SX-A Lower Gearcase Pinion Nut Installation Apply Loctite primer to pinion threads on shaft and let air dry. Apply thread locking compound 1161053 to threads. Install a new pinion nut onto shaft. Assemble pinion nut holder 3854864 on handle 3850609.

• Page 116
  SX-A Lower Gearcase Tighten retainer to achieve a vertical shaft rolling torque of 2-4 in. lb. (0,22-0,45 N • Record rolling torque setting. Apply gear oil to o-ring for retainer. Install o-ring over retainer. Return gearcase to normal position, propshaft bore slightly above horizontal.
• Page 117
  SX-A Lower Gearcase Propshaft Bearing Housing, NOTICE! This procedure determines the amount of shims Shimming and Rolling Torque required to preload the propshaft bearings, and also ensures bearing life by setting the vertical shaft and propshaft rolling torque. Install propshaft/bearing in gear.
• Page 118
  SX-A Lower Gearcase Measure (M) gap between bearing housing (B) and gearcase (L). Record in two places, in the middle on each side. Average the measurements. NOTICE! Do not measure at gap (G) at bottom and top of housing. Round off the average amount.

• Page 119: Gear Lash

  SX-A Lower Gearcase Check for correct rolling torque, see step 5 above. Correct as needed; rolling torque is too high, add shim. rolling torque is too low, subtract shim. Gear Lash This procedure will check the relative clearance between the pinion gear and the propshaft gear.

• Page 120
  SX-A Lower Gearcase Mount dial indicator on gearcase. Position dial indicator so rod (R) holding gauge (G) is at same height as extension (E) and parallel to extension. See illustra- tion. Dial indicator pointer (P) must contact middle of flat surface of extension (E) at inner most groove for an accurate reading.
• Page 121
  SX-A Lower Gearcase If new gear lash is in range, continue to see Gear Contact Pattern on page 118. If lash is still out of range recalculate shims again. If the second shim calcualtion produces the same shim values as…

• Page 122: Gear Contact Pattern

  SX-A Lower Gearcase Gear Contact Pattern Gear lash and contact pattern must be corrected in consecutive steps. The lash MUST be correct before checking the contact pattern. NOTICE! If adjustment is made to the shims to correct the gear contact pattern, then the lash must be rechecked before final assembly.

• Page 123: Final Assembly

  SX-A Lower Gearcase Correcting If the contact pattern is running off the toe, add equal amounts of shim thickness to the propshaft and vertical shaft bearings. It the contact pattern is running off the heel, subtract equal amounts of shim thickness from the propshaft and vertical shaft bearings.

• Page 124
  SX-A Lower Gearcase Press seal in to housing until it seats. Apply gear oil to seal lip. Propshaft Bearing Housing Install o-rings on housing. Apply gear oil to o-rings. Install shims and re-install bearing housing. Install NEW screws and torque to 10 ft. lb. (13,5 N’m).

• Page 125: Lower Gearcase Installation

  SX-A Lower Gearcase Lower Gearcase Installation Proceed to Chapter 2 to; • Reassemble gearcase to the upper housing • Pressure and Vacuum test the assembled drive • Install the drive on the transom • Install the propeller Specifications Description U.S.

• Page 126: Service Chart

  SX-A Lower Gearcase Service Chart (A) Volvo Penta Thread Locking Fluid 1161053 (B) NO Gasket Sealing Compound required (C) Volvo Penta Grease 828250 (D) Volvo Penta GL5 Synthetic Gear Lubricant, 75W90 15-20 ft. Lb. (20-28 N•m) 96-110 ft. Lb. (130-150 N•m) 10 ft.

• Page 127: Table Of Contents Safety Messages

  Service Chart ……163 Safety Messages Before working on any part of a Volvo Penta sterndrive, read the section called “Safety Messages” in the first chapter of this manual.

• Page 128: Lower Gearcase — Cross Section

  DPS-A Lower Gearcase Lower Gearcase — cross section DPS-A 15 14 20 22 15 15 50606 1.Shim position16. Propshaft 2.Pitot passage17.Propshaft bearing housing 3.Oil passage18.Seals, propshaft 4.Exhaust passage19.Bearing, propshaft 5.Water passage20.Plug, oil drain 6.Water intake21.Magnet 7.Anode22.O-ring 8.Splined sleeve — Drive Saver23.Seal 9.Retainer, vertical shaft 10.Vertical shaft 11.Bearing, vertical shaft…

• Page 129: Special Tools

  DPS-A Lower Gearcase Special Tools Tool Name Part No. View Tool Name Part No. View Attachment Tool 884940 Bolt 3850623 3.6” 92mm Bearing Cup 3850621 Dismantling Tool 884803 Installer Bearing Installer 3850617 Drift 884263 Bearing Installer 3855928 Drift 884143 Bearing Installer 3849670 Drift 3855866…

• Page 130
  DPS-A Lower Gearcase Special Tools, cont’d Tool Name Part No. View Tool Name Part No. View Guide Plate 3849656 Puller 884832 4.245” 3850619 Guide Plate Puller 884789 (914700) 3850609 Handle Puller 3850623 (311880) 3850616 Installation Tool 884975 Race Installer (914695) 3.3”…
• Page 131
  DPS-A Lower Gearcase Special Tools, cont’d Tool Name Part No. View Tool Name Part No. View 2.75” 60mm 70mm Race Remover 3855862 Seal Protector 884807 44mm Remover Tip 3855859 Seal Protector 884976 Remover/ Installer Tip 3855868 Shim Fixture 3850600 Remover Tool 3849659 Shim Fixture 3849662…

• Page 132: Sealants, Lubricants And Adhesives

  Volvo Penta Service Tools All tools by are listed in text by name and part number. Sealants, Lubricants and Adhesives Cleaning solvent Volvo Penta GL5 Synthetic gear lubricant, 75W90 Loctite primer Volvo Penta thread locking compound 1161053 Volvo Penta grease 828250…

• Page 133: Sterndrive Removal And Disassembly

  DPS-A Lower Gearcase Sterndrive Removal and Disassembly To service components of the lower gear housing, separate lower housing from upper housing. Follow the procedures in the Sterndrive, General Information chapter of this manual. If only the lower housing is being serviced, do not remove the sterndrive from the transom shield.

• Page 134: Vertical Shaft And Pinion Removal

  DPS-A Lower Gearcase Remove shims (S), they can be reused if not damaged. Remove and discard o-rings (R). Remove tube gear/bearing from housing. The inner propshaft is a slide fit, not pressed. Remove innner propshaft. Save shims. 50634 Vertical Shaft and Pinion Removal Remove intermediate shaft and inspect splines.

• Page 135
  DPS-A Lower Gearcase Pinion nut removal Screw pinion nut holder 3849660 on to handle 3850609. Slide guide plate 3849656 over handle. Insert pinion nut holder in to drive gear. Turn vertical shaft to align pinion nut with holder. Slide socket 3850598 on to vertical shaft. Attach pull bar to socket.

• Page 136: Forward Gear Service

  DPS-A Lower Gearcase Lift out vertical shaft, bearings and upper race. NOTICE! Do not remove vertical shaft bearings unless you intend to replace them. Removal process may damage bearings. Gear and Bearing Removal Remove forward gear and bearing. Forward Gear Service Bearing Removal NOTICE! Do not remove bearing from forward gear unless you intend to replace bearing.

• Page 137
  DPS-A Lower Gearcase Bearing Installation Apply gear oil to inner diameter of bearing. Slide bearing on gear with taper facing away from gear. Position drift 884168 (D) upside down on inner ring of bearing with a sutible press plate, and press bearing on gear until it seats. Use a two-jaw puller and slide hammer to remove bearing race and shims.

• Page 138: Bearing Housing Service

  DPS-A Lower Gearcase NOTICE! All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; GL5 Synthetic gear lubricant, SAE 75W-90. Bearing Housing Service Bearing and seal removal NOTICE! Bearings should not be removed unless they are to be replaced.

• Page 139
  DPS-A Lower Gearcase Turn housing over again, bearing race facing down. Thread rod from 3855860 in to remover 3855862. 50947 Place housing over press or vise. Lightly tap or press on rod to remove race. Clean housing in solvent to remove all oil, sealer and other debris from holes, gasket surfaces, and bores.
• Page 140
  DPS-A Lower Gearcase Apply oil to outer surface of seals. Place seals, back to back (springs facing outward) on tool 3849661. Apply white sealing compound to outer edges of seals. 50813 Insert tool and seals in to housing Use mandrel 884263 against tool, lightly press seals in to place. NOTICE! If outer propshaft is grooved where seals contact shaft, do not press seals all the way against the end of housing.

• Page 141: Outer Propeller Shaft Service

  DPS-A Lower Gearcase Lightly oil outside edge of of bearing race, insert race in housing. Place installer 3855864 over race. Place mandrel 884263 on installer. Lightly press race in to housing. 50949 Do not install o-rings at this step. Outer Propeller Shaft Service Bearing, seal removal NOTICE! Bearings should not be removed unless they are to be replaced.

• Page 142
  DPS-A Lower Gearcase Press bearing and seals out of propshaft. Remove puller 884789 and discard bearing and seals. 43467 Position both parts of puller 884832 so flanges of puller catch inside lip of bearing race. 884832 43468 Place drift 884143 in position through propshaft. Support assembly in a press and press out race.
• Page 143
  DPS-A Lower Gearcase Bearing, seal installation Screw puller 884789 on propshaft to protect threads. Position in a press. Apply gear oil to the bearing race. 3855865 Press race into gear face using installer 3855865. 884789 43511 Place installer 3855865 on a press, bevel up. Place race in propshaft gear over installer.

• Page 144: Vertical Shaft Service

  DPS-A Lower Gearcase Apply gear oil to outside surface of needle bearing and position it in end of propshaft. Use installer 3855928 to press bearing in position. Press until tool lip seats on end of propshaft. 43676 Place double lipped seal on installer 884975 with rubber side facing stepped side of the installer.

• Page 145: Gearcase Cleaning And Inspection

  DPS-A Lower Gearcase Bearing removal Place socket 3850598 over splines to protect shaft. Using a bearing separator and press, remove bearings. NOTICE! Be ready to catch shaft when pressed out of bearings. Installation Apply gear oil to inner diameter of small bearing. Protect threads of shaft by installing a pinion nut on shaft.

• Page 146
  DPS-A Lower Gearcase Passages for Pitot If pitot (speedometer) is clogged, use compressed air to clear the passages. Apply air at opening to smaller passage on leading edge of gearcase. Water Intakes If needed, water intakes can be removed. Remove two screws from port intake. Gearcase Magnet There is a magnet mounted in the front of the gearcase, forward of the propshaft gear.

• Page 147: Lower Gearcase Assembly

  NOTICE! All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W- Pinion Shimming NOTICE! This procedure determines the amount of shims required to properly position the pinion in relation to the propshaft gears.

• Page 148
  DPS-A Lower Gearcase Measure for Shims Clamp socket 884830 (S) in a vice and place vertical shaft in socket. Place race (C) on small bearing. Slide shim fixture 3849662 (F) on shaft with three slots facing threaded end of shaft. NOTICE! The shim fixture for the DPS is similar to the SX shim fixture.
• Page 149
  DPS-A Lower Gearcase Example: Add/Subtract: 0.009 in., number from Step 3 + 0.005 in. number etched on gear 0.014 in. shims needed Use this thickness of shims for pinion gear shimming. NOTICE! No less than one shim but no more than five shims should be used to obtain needed shim thickness.

• Page 150: Forward Gear Shimming

  DPS-A Lower Gearcase Forward Gear Shimming Place gear and bearing on flat surface. Place bearing race (C) on top of bearing. Rotate race to seat bearings. Position shim fixture 3850600 (F) on top of gear and bearing, recessed side facing down. Using a depth micrometer, measure the distance from top of shim fixture to end of gear shaft.

• Page 151
  DPS-A Lower Gearcase in relation to the pinion. Record the following shimming measurement for the final gear lash check. Place shim fixture, 3849663 on a flat surface. Place forward gear bearing race (taper up) inside fixture. 50971 Place forward gear/bearing inside the fixture and position on race. Set shim spacer, 3849653 on forward gear face 50972 Insert inner propshaft/bearing in forward gear.
• Page 152
  DPS-A Lower Gearcase Place the outer propshaft over inner propshaft Position outer propshaft in shim fixture. Make sure race in gear face seats on bearing on inner propshaft. 50974 Spin both shafts to seat the gears. Load the assembly by pressing down on outer propshaft. Finger tighten the three set screws to capture outer propshaft.

• Page 153: Bearing Race And Shim Installation

  DPS-A Lower Gearcase The rear gear markings/etchings are on the outer propshaft. Forward gear mark is in the box marked R. 50957 Add or subtract shimming allowance number etched on gear from number found in Step 9.; If the etched number is +5, you would ADD 0.005 in. to actual dimension in Step 9.

• Page 154: Vertical Shaft And Gear Installation

  DPS-A Lower Gearcase Make sure race is straight in bore. Place installer in race and drive race in until seated. Vertical Shaft and Gear Installation Pinion Bearing Installation Apply grease 828250 to roller bearings. Install bearings in pinion race. Apply gear oil to pinion bearing. Install pinion bearing onto installer 3849660 (N).

• Page 155
  DPS-A Lower Gearcase Vertical Shaft Installation Install vertical shaft in gearcase and engage pinion splines. Seat lower bearing in race. Seat shaft in pinion bearing. NOTICE! Insert vertical shaft carefully so pinion bearing rollers aren’t dislodged. Apply gear oil to upper bearing race. Place race in housing, and push down until it seats on bearing.
• Page 156
  DPS-A Lower Gearcase Assemble pinion nut holder 3849660 on handle 3850609. Slide guide plate 3849656 on handle. Insert pinion nut holder in to drive gear. Turn vertical shaft to align pinion nut with holder. Slide socket 3850598 on to vertical shaft. Attach torque wrench to socket.

• Page 157: Setting Rolling Torque

  DPS-A Lower Gearcase Setting Rolling Torque NOTICE! This procedure will ensure bearing life by setting vertical shaft rolling torque. Turn gearcase so that propshaft bore is vertical and gear is down. This will ensure the propshaft gear will not interfere with the pinion rolling torque measurement.

• Page 158
  DPS-A Lower Gearcase Insert spline of inner propshaft in to spline in forward gear. 50634 NOTICE! Seal Protectors must be used whenever propshaft seals are slid over splines on the propshafts. Seal damge, then drive failure are possible if seals are damaged by the splines.
• Page 159
  DPS-A Lower Gearcase Place seal protector, 884807 into seals in propshaft bearing housing. Do not install o-rings on housing. 50961 Remove any shims that may be on the propshaft housing. Slide housing into position over outer propshaft. Remove the seal protector when seals are past propshaft splines. Install original screws removed during disassembly.
• Page 160
  DPS-A Lower Gearcase Place seal protector, 884807 into seals in propshaft bearing housing. Remove bearing housing. Install shim amount from step 10 and re-install bearing housing. Do not install o-rings at this step. Remove seal protector. 50964 Install original screws and torque to 10 ft. lb. (13,5 N’m). Then tighten screws another 70°…

• Page 161: Gear Lash

  DPS-A Lower Gearcase Gear Lash NOTICE! Verify that there is no end play on the vertical shaft and both propeller shafts before attempting to check gear lash. Lock vertical shaft in place using puller 3855923. Tighten Allen head screws to lock tool to shaft. Lightly tighten screws to keep the shaft from moving.

• Page 162: Checking Tooth Contact Pattern

  DPS-A Lower Gearcase Checking Tooth Contact Pattern Turn vertical shaft. While turning, brake the propshaft movement to simulate a propeller load. NOTICE! If you must load the propshaft with your hands, wear leather gloves. The propshaft has sharp edges and may cut or injure your hands.

• Page 163: Adjusting Tooth Contact Pattern And Gear Lash

  DPS-A Lower Gearcase Adjusting Tooth Contact Pattern and Gear Lash NOTICE! Correcting the gear contact pattern and/or gear lash will require disassmbly of the drive train. Proceed from the beginning of this chapter. Tooth Contact Pattern NOTICE! Contact pattern must be corrected before attempting to correct gear lash.

• Page 164: Final Assembly

  Final Assembly NOTICE! All references to gear oil in all assembly steps are referring to the same oil used to fill the drive; Volvo Penta GL5 Synthetic gear lubricant, SAE 75W- Place seal protector, 884976 into seals in outer propshaft. 50959 Install outer propshaft over inner shaft and in to gearcase.

• Page 165
  DPS-A Lower Gearcase Place seal protector, 884807 into seals in propshaft bearing housing. 50961 Slide housing and shims into position over outer propshaft. Remove the seal protector when seals are past prop splines. Seat the housing into the gearcase. 50964 Install NEW screws and torque to 10 ft.

• Page 166: Lower Gearcase Installation

  DPS-A Lower Gearcase Lower Gearcase Installation Proceed to Chapter 2 to; • Reassemble gearcase to the upper housing • Pressure and Vacuum test the assembled drive • Install the drive on the transom • Install the propellers Specifications Description U.S. Metric Nut, pinion gear 78-87 ft.

• Page 167: Service Chart

  DPS-A Lower Gearcase Service Chart (A) Volvo Penta Thread Locking Fluid 1161053 (B) NO Gasket Sealing Compound required (C) Volvo Penta Propeller Shaft Grease 828250 (D) Volvo Penta GL5 Synthetic Gear Lubricant, 75W90 15-20 ft. Lb. (20-28 N•m) 96-110 ft. Lb.

• Page 168
  DPS-A Lower Gearcase NOTES — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — -…
• Page 169
  Transom Shield Assembly Transom Shield Assembly Special Tools ……166 Table of Contents Trim/Tilt Cylinder Removal .

• Page 170: Special Tools

  Transom Shield Assembly Safety Messages Before working on any part of a Volvo Penta sterndrive, be sure to read the Safety Messages chapter at the beginning of this manual. Pay special attention to safety messages that appear throughout the text.

• Page 171: Trim/Tilt Cylinder Removal

  Transom Shield Assembly Special Tools Water inlet fitting Steering shaft 3849648 3849649 remover/installer remover Remove Sterndrive Remove the Sterndrive see Sterndrive Removal on page 28. If the complete transom shield assembly is being rebuilt or replaced, remove engine following procedure in the Engine and Sterndrive Installation Manual.

• Page 172: Trim/Tilt Cylinder Installation

  Transom Shield Assembly Remove trim cylinder pivot pin. Remove the trim cylinder. Remove and discard trim/tilt line O-rings and retainers only if they are leaking, otherwise, leave the O-rings and retainers in the trim cylinders. NOTICE! New O-rings and retainers come installed on new trim cylinders.

• Page 173: Gimbal Ring Removal

  Transom Shield Assembly Install and spread cotter pin ends. Place a new O-ring and retainer on trim/tilt cylinder line fittings and attach lines to cylinder. Tighten line fittings to 8 ± 0.5 Nm (70 ± 5 in. lb.). NOTICE! To fill and bleed the trim cylinders and trim motor reservoir, see Filling and Bleeding Dry System in Trim/ Tilt Hydraulic System section of this manual.

• Page 174
  Transom Shield Assembly Turn gimbal to port and remove two screws holding trim sender. Remove the trim sender from the gimbal ring. CAUTION! Do not attempt to pull the sender out of the transom shield as its leads are secured to transom shield.
• Page 175
  Transom Shield Assembly Loosen the hose clamp securing the water inlet hose to the pivot housing water nipple through the port side access hole. Disconnect water inlet hose from the nipple. Turn the gimbal ring to port as far as possible and remove the starboard pivot pin locking pin and ground terminal.

• Page 176: Pivot Housing Removal

  Transom Shield Assembly Remove cotter pin from the lower gimbal ring steering pivot pin. Remove the lower gimbal ring steering pivot pin. Using a 10 mm allen wrench, remove the two gimbal ring retaining screws from the steering shaft. NOTICE! The screws use threadlocking compound to prevent loosening.

• Page 177: Pivot Housing Disassembly

  Transom Shield Assembly Remove the port pivot pin locking screw. Remove the Trim Sender driver screw and driver arm from the pivot housing. Pivot Housing Disassembly Using the large cup and nut from special tool 3849647, press out the pivot pins. NOTICE! Do not use the bushing puller/installer to remove the pivot pins.

• Page 178
  Transom Shield Assembly Using special tool 3849648, remove the water inlet nipple from the pivot housing. Remove and discard the water nipple O-ring. Remove and discard cooling and exhaust passage seal. Inspect the nylon friction washer on pivot bosses. Peel them off and discard if they’re damaged.

• Page 179: Pivot Housing Assembly

  Transom Shield Assembly • Ground Wire — Check wire ends for frayed or loose connec- tions. Repair or replace all suspect components. Pivot Housing Assembly If a drive stud is damaged and requires replacement, install the new stud to a depth of 43 mm ± 1 (1.7 in ±.03). ±…

• Page 180: Gimbal Ring Disassembly

  Transom Shield Assembly If the old pivot boss friction washers were removed, make sure a thrust washer, coated with grease 828250, is installed in each pivot. Replace the wear pads if damaged, cracked or worn through. Gimbal Ring Disassembly Using special tool 3849647, press out the pivot pin bushings. Publ.

• Page 181: Gimbal Ring Assembly

  Transom Shield Assembly Use special tool 3849647 to press out the gimbal ring steering pivot bushing. Gimbal Ring Assembly Lightly oil outside of a new pivot bushing and place it in bore. Use installer 3889647 to seat bushing 0-1mm (0 — .03 in) into the gimbal ring.

• Page 182: Pivot Housing Installation

  Transom Shield Assembly Pivot Housing Installation Position pivot housing in gimbal ring. Align one gimbal ring pivot pin hole with hole in pivot housing. Look inside to see if thrust washer is still in position and not blocking hole. Pivot pin Apply grease 828250 to pivot pin.

• Page 183: U-Joint And Exhaust Bellows Installation

  Transom Shield Assembly Install the trim sender driver and torque screw to 10 ± 1.5 Nm (88 ± 13 in. lb) U-joint and Exhaust Bellows Installa- NOTICE! Clamp’s screw position is important. If not properly tion positioned, steering radius will be reduced because of gimbal ring contacting clamp head when turning.

• Page 184: Gimbal Ring Installation

  Transom Shield Assembly Push the exhaust bellows onto exhaust tube until it engages groove. Slide ground strap clip under hose clamp and tighten clamp securely. NOTICE! The exhaust bellows does not have a specific position. Mounting the worm screw on top allows access through an opening in the pivot housing.

• Page 185
  Transom Shield Assembly Apply grease 828250 to the steering pivot pin. Align gimbal ring with gimbal housing steering pivot hole and install the steering pivot pin. Install a new cotter pin and spread ends. Reinstall the pitot sensor port connector. Publ.

• Page 186: Gimbal Housing Disassembly

  Transom Shield Assembly Gimbal Housing Disassembly Remove trim/tilt cylinders (see Trim/Tilt Cylinder Removal on page 167), and gimbal ring (see Gimbal Ring Removal on page 169). Shift Cable Hose Removal If not already removed, cut tie straps that attach the speedometer hose to the shift cable tube.

• Page 187: Water Hose Removal

  Transom Shield Assembly Water Hose Removal Once the water inlet nipple is removed, pull the water hose through the port toward the rear of the transom shield. Anode Replacement NOTICE! The sacrificial anode need not be removed unless it is 2/3 deteriorated and needs to be replaced.

• Page 188
  Transom Shield Assembly Use a small straight tip screwdriver and pry weatherpak gasket back from connector. NOTICE! The material is very soft. be careful not to tear or damage the gasket. If the gasket is torn or damaged, the terminal must be replaced. Use a small pair of needle nose pliers, grab the small knob on the face of the terminal support block and pull the support out of the connector.

• Page 189: Hydraulic Lines Removal

  Transom Shield Assembly Hydraulic Lines Removal NOTICE! The trim system is a hydraulic system and is extremely sensitive to dirt and debris. Only remove the hydraulic lines and/or trim pump if you have a problem with the trim system. Remove two screws that secure the hydraulic line retainer to the trim pump.

• Page 190: Steering Bearing, Gimbal Bearing And Seal Removal

  Transom Shield Assembly Steering Bearing, Gimbal Bearing and Seal Removal Using a 5/8 socket wrench, remove the steering shaft bolt. Remove the steering shaft to tiller arm retainer nut. Install special tool 3591637 with the longer leg facing outward toward the rear of the transom shield. Screw the flange nut onto the special tool bolt and remove the steering shaft from the tiller arm.

• Page 191: Gimbal Housing Cleaning And Inspection

  Some screw holes have special Heli-Coil inserts that provide a thread- locking feature. CAUTION! Do not clean Heli-Coil holes with a thread tap. This will damage the Heli-Coil inserts and force their replacement. Use only Locking Heli-Coils available from Volvo Penta Parts. See your parts catalog. Publ. 7746477 English 06-2008…

• Page 192: Gimbal Housing Assembly

  Transom Shield Assembly Gimbal Housing Assembly Steering Bearing, Gimbal Bearing and Seal Installation Assemble special tool 3849646 onto drive handle 9991801. Face chamfered end of a new steering shaft bearing up and install on the special tool. Drive the bearing into the shield until the tool bottoms.

• Page 193: Trim Pump Installation

  Transom Shield Assembly Install new O-ring (A) onto steering shaft. Place new thrust washer (B) over the steering shaft bushing in the transom shield. Install the steering shaft into the steering shaft bushing and align the tiller arm with the square post on the steering shaft. Place the tiller arm nut on top of the tiller arm.

• Page 194
  Transom Shield Assembly Install pump into transom shield and install six bolts. Tighten the bolts to 10 ± 1.5 Nm (88 ± 13 in. lb.). Make certain the grommet is completely seated in the opening. Insert the wires in the correct openings of the connector. Slide the terminals in until the locking tab engages the stop on the terminals.

• Page 195: Trim Sender Installation

  Transom Shield Assembly Trim Sender Installation Apply grease 828250 to trim/tilt sender lead grommet. Feed wires through opening in transom shield and out through transom plate. Push grommet into hole until it seats. NOTICE! Do not route trim/tilt sender leads under extension tube or hydraulic lines.

• Page 196: Water Tube Installation

  Transom Shield Assembly Water Tube Installation Install water hose though transom shield opening. Push the water tube into the water hose until the water hose stop against the water tube mounting flange. Push the water hose and water tube assembly into the transom shield.

• Page 197: Trim Sender Adjustment

  Transom Shield Assembly Tighten hose clamp through the access window of the pivot housing. Check the water hose travel for kinking, pinching or binding in all pivot housing positions. Slide the other end of the exhaust bellows over the exhaust opening of the pivot housing.

• Page 198: Transom Shield Removal

  Transom Shield Assembly With pivot housing pushed in towards gimbal housing, check adjustment of sending unit between pins “1” and “3” of sending unit connector. Rotate sending unit to obtain a 11 ± 1 ohm reading on the meter, then tighten mounting screws to 21 ± 3 in. lb. (1.75 ± 0.25 Nm).

• Page 199: Shift Cable Sleeve Replacement

  Transom Shield Assembly Shift Cable Sleeve Replacement Unscrew shift cable sleeve and connector assembly. Discard connector O-ring. Apply gasket sealing compound to a new O-ring. Slide it onto connector and position it against hex, then coat connector threads with sealer. Install sleeve and connector assembly and use a crowfoot adapter to tighten connector to 44 ±…

• Page 200: Transom And Exhaust Seal Replacement

  Transom Shield Assembly Transom and Exhaust Seal Replace- ment Remove and discard exhaust O-ring seal and large rubber transom seal. Apply 3M Scotch Grip Rubber Adhesive 1300 in exhaust groove and install new O-ring seal. Apply 3M Scotch Grip Rubber Adhesive 1300 to entire transom seal groove around gimbal housing.

• Page 201
  Transom Shield Assembly Lightly coat the eight gimbal housing studs with gasket sealing compound. 4. Install outer transom shield into transom. Guide studs through drilled holes in transom. CAUTION! Ensure the wires are not caught under the transom seal. Failure to follow this instruction will result damage to wires and seal.
• Page 202
  Transom Shield Assembly Tighten the eight lock nuts in a cross pattern, starting with the two center nuts. Tighten them to of 20–25 ft. lb. (27–34 Nm). Attach transom plate ground strap to steering arm and secure with screw and washer. Tighten screw securely. Publ.

• Page 203: Torque Specifications

  Transom Shield Assembly Torque Specifications Description U.S. Metric Anode 18 ± 3 ft. lb. 24 ± 4 Nm Shift Cable Sleeve 44 ± 4 ft. lb. 60 ± 5 Nm Trim Pump Fill Cap 23 ± 4 in. lb. 2.7 ± 0.5 Nm Trim Line to Cylinder/Pump 70 ±…

• Page 204: Sealants, Lubricants, And Adhesives

  3M Scotch Grip Transom Seal Rubber Adhesive Exhaust Seal 1300 Lubricants Where Used Volvo Penta Grease Alignment Tube, Inner Transom Plate 828250 Bushing, Upper Steering Post Washer, Pivot Housing Grommet, Trim Sender Lead Grommet, Trim Pump Power Lead O-ring, Upper Steering shaft…

• Page 205: Service Chart

  Transom Shield Assembly Service Chart (A) Volvo Penta P/N 828250 grease (B) Loctite® 271 Thread Locking compound (C) Perfect Seal gasket sealing compound (D) 3M Scotch Grip rubber adhesive 1300 50978 Publ. 7746477 English 06-2008…

• Page 206
  Transom Shield Assembly NOTES — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — -…

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