Hey guys, maybe someone can give a little expert advice on this one? Had a engine & bravo 1 drive swap on a 1996 mercruiser, installed a different big block mercruiser engine and using a new alignment tool did alignment so tool slipped in & out using only 2 fingers, was like butter.
Went to install a brand new bravo X drive, went 2/3rds of the way in and stopped, could not jiggle it in so removed it and rechecked alignment whuch was still perfect so tried to insgtall the drive again, this time it went in except for the last 1/2" and had to fight it in? once in I decided to remove bolts and see if it would slip out and it does but does not like going back in easily as I'm used to. Any ideas whats up? I did the install and everything works fine but in my mind I'm a little concerned why it gave me any trouble at all even after checking it twice, the tool says it's right on but the drive say's a little different. Any advice would be greatly appreciated, thanks in advance for any help.

Mine did that as well, had the drive off for about 3 weeks while getting engine coupler replaced and put on. I did the same thing you were talking about I assumed it was the o-rings on the input shaft not being compressed for a month and made it hard to install. I used plenty of grease but it was tight as can be. All is working well so far

I was wondering if the gimbal bearing possibly was not centered? in other words what if the tool went in on an angele or the angle of the where the coupler was but installing the drive it was straight to centerline on the bellhousing, I'd hate to burn up a coupler.

If your tool went in on an angle, then your not using it correct !

More importantly,, if the input shaft is putting pressure on the crank, it will ruin the rear main in short order.
Are you using the same coupler that was matched up to the drive before. Is the coupler a steel hub with the extended snout? The input shaft can interfere with the extended snout in some cases.. Taper on the shaft doesnt matcth the snout. Pushes the crank forward and destroys the motor.. So it is a good thing you are checking it. One thing you can do.. Take the input shaft off at the ujoint and slip it in the transom, see if it goes all the way in like the alignment tool.. Then you know that is not the problem.. You should be able to seat the drive on the helmet without a problem..
Another suggestion.. you aligned the motor.. now spin it over 180* and check it again. Had a warped coupler once.. drove me nuts for awhile till I found it.
Hope that helps.
Let us know what you find.

Dick

Would he have the wrong gimbal bearing in, old style which is thicker than the new ones? Just checking?

The offset difference is .050" on the old new, I believe.

appreciate the help, I think I better remove the drive and find out what the heck could be going on.