Drive Install Advice
 

:mad: OSO Buddies,I need advice on a problem before I torch my project.Here we go.

This weekend I installed two HP transoms and two 502 engines in my Fountain.I spent about 7 hours trying to get my port side drive installed with no success.I have all the tools and read the Merc. man. and even read all post here related to the issue.I had a hard time aligning the engine with the tool at first.I then used a little persuasion to get the tool to enter the coupler.I then hooked up my lift and adjusted the motor to where the tool will go about 7/8 of the way in with just a push and the rest of the way with a tap of the palm.The tool needs a twist but then will slip right out.For the life of me we can't get the drive to go on.It goes into the coupler one inch and stops.We moved the motor,tried taping the drive, pushed till our boots wore out,no luck.The starboard side went in the first try and the tool was a little harder to install on this side then the other,we even removed the starboard side and switched drives.The port drive went right in on the starboard side.We looked inside the transom and coupler and can't find anything.I was thinking maybe I screwed up a spline or two on the coupler when I persuaded the tool into place?I am going to pull the motor tomorrow and look an the splines up close and personal.Any one have any other idea as to what it could be??????Help!!!! :mad: :mad:

Thanks Nordic95

Re: Drive Install Advice
 

Nordic95. Hi! I sometimes have a drive that won't go in.
New gimbal or replacement gimbal.
What I have done in the past is. I will stick the alignment bar in and once its as far as it will go I hit it with a mallet or sand filled mallet. I hit the top then I hit the bottom. you can hit it from side to side. make sure you use a mallet. Remember your not trying to drive a train track to the ground but loosen the gimbal bearing. In the past I've only had to hit it a few times. If you have any problems give me a call. Hope this helps.

Best Regards Phil

Re: Drive Install Advice
 

Thanks but I tried all that.I spoke with Goodt from here on the site and he explained that to me already.Thats how I got the alignment tool to go in like it does now.I am baffled because the tool goes in so well and the drive hits a wall.I am so sore from this weekend I can't stand it.We must have tried that drive twenty five different ways,no good.

Nordic95

Re: Drive Install Advice
 

What shape are the o-ring on the Yoke assembly/coupler end?

Re: Drive Install Advice
 

part # 22. and part #21. Sometime those o-ring get slammed and out of shape. You would be surprised what those 0-rings can do.

Best Regards Phil

http://www.mercruiserparts.com/Show_...ift+Components

Re: Drive Install Advice
 

These are brand new XR drives.Everything in good or great shape.

Re: Drive Install Advice
 

o-ring are in good shape after trying to put the drive on?

Re: Drive Install Advice
 

The drive wouldn't even go as far as to hit the studs on the bell housing.I don't even think the o rings made it to the bearing.From what I could see the yoke only went into coupler about 1/2 to 3/4 of an inch.I'm thinking where the ring is cut into the coupler for grease is where the splines may be flattened out or something from hitting in the alignment tool.Its the only thing I can think of.Item #21,what is its purpose.It dose not touch anything when fully installed on starboard side?

Re: Drive Install Advice
 

Have you eye balled it? nothing in there foreign objects or to much grease?

Re: Drive Install Advice
 

Checked it all,even tried moving the inside transom plate and motor to no avail.

Re: Drive Install Advice
 

the point just before the drive gets to the studs is where the splines start to make contact, is the drive in gear and are you turning the prop shaft in the correct direction to spin the input shaft while pushing the drive in ???

Stupid question but has to be asked :eek:

Re: Drive Install Advice
 

Yes,I turned to the point that the motor started to turn over.I can feel the splines engage and then slip in about a quarter inch and thats it.I may have to fly you up here Goodt,A little working vacation in the north.


Nordic95

Re: Drive Install Advice
 

You are always welcome in our neck of the woods


give me a call alittle latter and we' ll see if we can figure this out

Joe

Re: Drive Install Advice
 

it will only take ten minutes to take the input shaft off the U joint.
do that and see if it will go all the way in. Just don't beat it in or you will have hell getting it back out.

Re: Drive Install Advice
 

I can't believe its finally in.I just got the drive to go into place.Only 9 hours to install one drive,not bad right?I ended up pulling the motor back out and just like I thought the splines of the brand new coupler were damaged.I don't know if I did it ,but it looked like a bad machine job or someone tried hitting in a larger shaft or something.The splines had a gouge on each side of each spline and on every spline.Now if the motor was not aligned properly when I tried to install drive yesterday I would think only a little section would be damaged where the yoke hit,but who knows.Then after cleaning up the damage and replacing the motor it still did not want to go in.So the motor came back out to check for and spline damage I might have missed the first round.Then motor went back in and this time I left the front mounts loose and just wiggled the motor a little bit as drive was being pushed on and it slipped right in.Has any one ever seen a coupler not machined right or damaged in the box?Thanks to every one for there input and trying to help and Goodt I owe you another beer for the advice,I'll hook up with you soon.

Thanks Nordic95 :evilb: :evilb:

Re: Drive Install Advice
 

Did you pull the drive and recheck alignment after you got the motor tightened back up?

Re: Drive Install Advice
 

No I am scared :eek: :eek: ,I have off shore mounts and no adjustment.I even pulled mounts off to see if holes were elongated and they were tight on the bolts.I though maybe the mounts settled.The shaft went right in all the way with just a push when mounts were tight.I think the damage to splines took up and extra space for shaft to slide in easily.Even with the motor out I had to tap with my hand pretty hard on the drive to set the shaft into the coupler as a test.Then with the motor in I didn't want to use any force so I just left the nuts a couple of turn loose with the chain holding and weight and it went in.Do you think I should try and recheck it?I think my buddies will shoot me if I even ask for help with that after two days on it.

Nordic95

Re: Drive Install Advice
 

Don't know. But when I replaced both of my couplers, my motor mounts were off. They are the offshore type also. I could get the alignmet dead on, then as soon as I tightened the motor mounts, the alignment shaft wouldn't go in. After alot of cussing, I discovered that Fountain bolted the Alum angles in leaning forward at top. So when I tightened the bolts, it woul dlift the rear of the motor up. Once I got the alignment back in with the motor not tight, I made shims that varied thicker at the top bolt, then thinner as went down. I didn't want to mess with changing the Alum plates. NO WAY the drives went on with the motors bolted tight. They had to have left the motors loose, slipped on the drives, then tighten the motor mounts. ***** was they did it on both motors. Must have been a Monday boat. :rolleyes: Both couplers shot completely with only 125 hrs.

Re: Drive Install Advice
 

I was censored. :eek:

Re: Drive Install Advice
 

How old are the rubber bushings on the bellhousing?

Re: Drive Install Advice
 

They are the only part on the boat that is original,1991.After sleeping on US 1 response I think I may need to raise the front of the motors and redrill the mounts to make it work a little better.After the drive went in I did have to put some weight of mine on the front of the motor to get the bolts started.I think that may be my problem.

Nordic95