Re: What broke in my outdrive?
 

Glad to hear the 300-400 hours thing. Too bad the boat has 530 hours. I hope the drive's been gone through.

I called the shop today to see what kind of coupler they were putting in it. They said it's an XR coupler.

And again... 1.36 was STOCK behind a 502 in '91.... Merc said they didn't have a HIN # associated with that drive S/N for warranty purposes and that probably meant it was sold to a boat manufacturer.

Re: What broke in my outdrive?
 

I never pulled the engines out to change a coupler, I just used a 4x4 and chained the back of the engine via the cylinder heads to the 4x4 and yanked the drive, pulled the bell housing off and took off the coupler, Alot of labor for not that much work in my opinion.
Good that you are improving the coupler with a better one, hopefully you wont have to revisit this situation in the future.
Good luck
J

Re: What broke in my outdrive?
 

I did almost this way to change out a flywheel, but the motor had to come forward a bit.....

Re: What broke in my outdrive?
 

Standard bravo? Single or twin? You should be able to get the flywheel and the coupler out without having to move the engine anywhere.
Now if you leave your engine hatch on it will make it tougher to do the job, Take the hatch off and not have that stuff in your way, you should have no problem.
J

Re: What broke in my outdrive?
 

How do you get the bellhousing to clear the coupler if the motor doesn't come forward any w/o getting wedged against the inner transom plate?

Re: What broke in my outdrive?
 

take 2 of the 3 motor mount bolts out, Loosen the big nut holding it on the stringer, Chain winch or come along strap on back of engine, rachet it up, slip out the bell housing (move it around a little bit and it will come out) you have to get the bottom part with the little 7-8MM bolts shroud off the bottom of the bell housing first.

Re: What broke in my outdrive?
 

Well they called me and said it's ready. $1530. They said they couldn't use the XR coupler, it wouldn't fit. It's too long, and there's almost no room in front of the engine on my boat. They said they couldn't get the motor in with that coupler on there, they couldn't move it forward enough to clear what it needs to clear to drop in place. d'oh. They said the new piece is still an improved design over the old one, and if the old one is as old as i think it is, i should be fine.