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Workshop Manual AC

1. lt VPA 7743008 07 2003 On later models the gear markings are on the outer propeller shaft The front gear marking will be found in the box with F indi cating the front gear etching Place gear and bearing on a flat surface Place the bearing race on top of the bearing Rotate the race to seat the bearing Position Shim Fixture Volvo Penta P N 3850600 2 on top of the gear and bearing assembly recessed side facing down Using a depth micrometer measure the distance from the top of the shim fixture to the end of the gear shaft in three spots Average the three recorded measurements by adding them together then dividing by three Subtract 0 500 in from the average measure ment 199 DP S Lower Gearcase Outer Propeller Shaft Shimming 200 Example Table 3 Add Divide No 1 0 546 in 1 639 in 3 0 5463 in No 2 0 547 in Round off to 0 546 in No 3 0 546 in Total 1 639 in Subtract 0 546 in measurement to end of gear shaft 0 500 in thickness of shim fixture 0 046 in actual dimension 4 Add or subtract the shimming allowance number etched on the gear from the actual dimension in Step 2 If the etched number is 5 you would ADD 0 005 in from the actual dimension in Step 2 If the etched number is 5 you would SUBTRACT 0 005 in to the actual dimension in Step 2 If the etched number is zero 0 you add or subtract nothing from the actual
2. 42616 Driveshaft and Gear Removal 1 Using Spanner Wrench Volvo Penta P N 3850601 or Joint Ven 38506 ture P N 3850601 unscrew retainer and O ring Discard O ring a EA C lt gt 42617 2 Screw Pinion Nut Holder Volvo Penta P N 3854864 or Joint Ven ture P N 3854864 onto Handle Volvo Penta P N 3850609 Slide Alignment Plate Volvo Penta a P N 3850613 onto handle 3854864 Wir y KH 3850613 33821A 152 VPA 7743008 07 2003 SX Lower Gearcase l Pa ae 3850598 M Dd Be 42618 VPA 7743008 07 2003 42619 33818 33842 Insert pinion nut holder pilot into drive gear Turn the driveshaft to align pinion nut with holder Slide Spline Socket Volvo Penta P N 3850598 onto driveshaft To remove pinion nut turn driveshaft counter clockwise Remove and retain pinion nut and pinion The nut will be used later for shimming Lift out driveshaft assembly then remove propeller shaft gear assembly 153 SX Lower Gearcase oe ae La 21435 ad 3850625 UL 20793 3850610 20795 154 33848 7 8 The 19 pinion roller bearings may fall out of the retainer remove and retain the roller bearings Use a three jaw puller such as Owatonna Tool P N 1176 to remove the bearing cup and shims Note The shims will be damaged during removal and must be replaced on
3. 34678 34677 884263 34676 3850607 A a N 34761 VPA 7743008 07 2003 5 Oil the large and small roller bearings with GL5 Synthetic gear lubricant SAE 75W 90 Place the pinion bearing carrier on top of the input gear Place the small bearing on top of the input bearing shaft 6 Press the small bearing onto the shaft using Drift Volvo Penta P N 884263 until all end play is removed Note This is the starting point for determining rolling torque of the pinion bearing carrier Use caution Do not press the bearing on too far If the pretension sleeve is distorted by pressing the bearing on too far proper rolling torque can not be achieved The carrier will have to be disassembled and pretension sleeve replaced 7 Coat the outside surface of a new seal with Volvo Penta Gasket Sealing Compound Place the protruding lip of the seal into the recess of Seal Installer Volvo Penta P N 3850607 109 Upper Gear Housing 8 Press the seal into the pinion bearing carrier until it seats 34713 9 Wear eye protection Install seal C clip into its groove in the pin ion bearing carrier using Retaining Ring Pliers Volvo Penta P N 3850608 Make sure the retaining ring seats completely 34712 10 Coat the seal lips with Volvo Penta Grease P N 828250 11 Place the Universal Joint yoke support used during disassembly through both yokes and place it in a vise 110 VPA 7743008 07 2003 Uppe
4. 4 Check the position of the nipple drain hole If it s not facing down loosen the nipple clamp and rotate nipple until the drain hole is facing down Tighten clamp securely DR1867 2 N IN A 34471 U joint and Exhaust Bellows Installa tion 1 Coat the outside surface of the gimbal bearing bore with Volvo Penta Gasket Sealing Compound Sealer is not required on the outside of the exhaust opening Note Clamp s screw position is important If not properly posi tioned steering radius will be reduced because of gimbal ring contacting clamp head when turning VPA 7743008 07 2003 43 Transom Shield Assembly SX M 2 Place clamp on the small end of the U joint bellows There is an internal rib that must engage a corresponding groove around the opening s surface Push the bellows on and engage the groove then rotate the clamp until the screw fitting is in the one or two o clock position Slide ground strap clip under hose clamp Tighten the clamp securely 3 The large end of the exhaust bellows has an internal rib similar to the U joint bellows Place clamp on this end Bellows must be positioned with exhaust relief cutout facing down Push the bel lows onto the exhaust tube until it engages the groove Turn the clamp screw to the three o clock position Slide ground strap clip under hose clamp and tighten the clamp securely 4 Install gimbal ring trim tilt cylinders and pivot housing fol
5. 195 Lower Driveshaft Bearing 000eeee eee eens 195 Pinion Bearing 00e eee e eee e eee eee eee 195 Forward Bearing Race 0seee cece eee eee 196 Propeller Shaft Housing Service 196 Outer Propeller Shaft Service 198 Forward Gear Service 0000 cece eee 201 Driveshaft Service 00 cece eee eee 202 Magnet Service 00 cece cece eee eee 203 Upper Housing Stud Replacement 204 Pinion Shimming 0000c cece eee eee 204 Forward Gear Shimming 0020ee eee eens 205 Outer Propeller Shaft Shimming 55 207 Oil Screen Service Upper Housing 211 Exhaust Cover Service 0 200 cece eee e eens 211 Lower Gearcase Assembly 20 00055 212 Gearease Bearing and Race Installation 212 Forward Bearing Race 0 0 ee eee cere eens 212 Pinion Bearing 2 0 eee eee ee eee eee eae ee 212 Lower Driveshaft Bearing 000eee eee eens 213 Driveshaft and Pinion Installation 5 214 Setting Initial Rolling Torque 00200e eee 215 Propeller Shaft Housing and Propeller Shaft Installation 216 Setting Final Rolling Torque 0020eeeeeee 219 Checking Tooth Contact Pattern 221 Adjusting Tooth Contact Pattern and Gear Lash 222 Final Assembly 2 ie iccaiis tceee eee eas es 223 Lower Gearcase Installation
6. 42671 3 Install anode and secure with two screws Tighten the screws to 60 84 in Ib 6 8 9 5 N m 170 VPA 7743008 07 2003 SX Lower Gearcase 4 Install intermediate driveshaft with the groove facing upward onto driveshaft 5 Install and position water grommet and supply tube into upper gear housing Check oil filter for proper installation aan r i 5 Note Care must be used on reassembly of gearease If i machined surface is damaged leakage may occur or 39433 39389 6 Attach lower gearcase to upper gear housing Engage intermedi DS ate driveshaft splines and water supply tube 42610 VPA 7743008 07 2003 171 SX Lower Gearcase 7 Apply Volvo Penta Gasket Sealing Compound to the lower gear case mounting screws Install four short screws two on either side of gearcase and two longer screws aft Tighten 3 8 16 screws to 22 24 ft Ib 30 33 N m and 7 16 14 screws to 32 40 ft Ib 43 54 N m 8 Install trim tab and align with marks made during removal Tighten mounting screw to 14 16 ft Ib 19 22 N m 34103B Pressure and Vacuum Testing Stern Before filling drive with gearcase oil it must be pressure and vacuum drive tested to verify proper sealing during assembly Remove the oil level plug at the back of the gear housing Install and tighten oil level gauge at top
7. If the etched number is 5 you would ADD 0 005 in to the feeler gauge measurement taken in Step 1 If the etched number is zero 0 you ADD or SUBTRACT noth ing to from the feeler gauge measurement taken in Step 1 Example Add Subtract Feeler Gauge Measurement Shimming Allowance Etched On Gear Amount Of Shims Required Note All mating thrust and bearing faces must be clean Shims to be used during assembly must be clean and undam aged No less than one shim but no more than four shims should be used 113 Upper Gear Housing Upper Output Gear Shimming 1 Place the upper gear and bearing assembly gear side down on a suitable work surface Place Shim Tool Volvo Penta P N 3850701 on the assembly as shown Take a feeler gauge mea surement at the lower edge of the adaptor ring Record this mea surement 2 Add or subtract the shimming allowance on the gear from the measurement taken in Step 1 This is the amount of shims required to properly position the upper output gear in the upper gear housing Note Because of the location of shims in relation to the gear use the following information when adding or subtracting the etched allowance figure from the measurement in Step 1 If the etched number is 5 you would ADD 0 005 in to the feeler gauge measurement taken in Step 1 If the etched number is 5 you would SUBTRACT 0 005 in from the feeler gauge measurement in Step 1 If t
8. O ring Seal Groove Check for sharp edges that would pre vent O ring sealing water passage e Mounting Studs Look for damaged threads and looseness Ground Wire Check wire ends for frayed or loose connec tions Repair or replace all suspect components VPA 7743008 07 2003 23 Transom Shield Assembly SX M Pivot Housing Assembly 1 Apply 3M Adhesive sealant to the groove around the water pas Y sage and install a new O ring seal 4 34523 2 If the old pivot boss friction washers were removed make sure a thrust washer coated with Volvo Penta Grease P N 828250 is installed in each pivot Install two new friction washers and coat them with Volvo Penta Grease P N 828250 12961 Pivot Housing Installation 1 Position the pivot housing in the gimbal ring Guide the water tube nipple through the housing and position the bellows behind their respective openings 2 Align one gimbal ring pivot pin hole with the hole in the pivot hous ing Look inside to see if the thrust washer is still in position and not blocking the hole Screw in the pivot pin until it seats but do not tighten it at this time less 3 Align and install the other pivot pin Tilt the housing up and down to see if it moves freely Use a 1 2 in hex socket and tighten the pivot screws to 105 120 ft Ib 142 163 N m Note Hold pivot housing to keep housing from over rotating and damaging bellows and water hose wh
9. Remove all trace of grease and wash with hot water and deter gent Roughen all painted surfaces with medium 3M Scotchbritetm pad Rinse thoroughly with water Treat any bare aluminum with chromate conversion coating Clean the entire area with an acid cleaner that does not contain fluoride such as DuPonte 5717 Scrub the surface with 3M Scotchbriterm pad until it is completely wetted with no beads of water Note Fluoride in a cleaner causes a smut dark discoloration on silicon alloy aluminum castings and paint will not stick to smut If this happens sand the surface and start over using a different acid cleaner Note Do not use steel wool Small pieces of steel wool become 7 8 embedded in the aluminum and will cause severe corro sion Rinse thoroughly with water The area must appear wetted or the surface is not clean and paint will not adhere While the surface is still wet from rinsing treat all bare aluminum with DuPonte 226S chromate conversion solution Brush the chro mate solution as required for 2 to 5 minutes to prevent it from dry ing on the surface Rinse the surface thoroughly with water and allow to air dry Follow the label instructions exactly If the chromate is allowed to dry anywhere on the bare alumi num surface chromic acid salts will form which will prevent paint adhesion and promote corrosion Sand the surface to bare metal It is best to let the part a
10. 1 Remove two screws and remove exhaust cover Remove and dis card seal 2 Apply Loctite Gasket Adhesive yellow to the exhaust cover groove and install a new seal 3 Apply Loctite Primer to the two screws and let air dry Apply Loctite 242 to the screw threads Install the cover and secure with two screws Tighten the screws to 14 17 ft Ib 19 5 22 5 N m VPA 7743008 07 2003 DP S Lower Gearcase Lower Gearcase Assembly Gearease Bearing and Race Installa tion Forward Bearing Race 1 Select the correct number of shims to equal your recorded mea surement Place shims into recess of bearing race bore Note No less than one shim but no more than three shims should be used If possible sandwich the thinnest shims in between the thickest shims 43532 2 Apply alight coat of GL 5 Synthetic gear lubricant SAE 75W 90 to 3855863 the bearing race Place bearing race on top of shims in lower gear 3850623 3855864 case Slide Guide Plate Volvo Penta P N 3855863 onto Rod Volvo Penta P N 3850623 Screw nut from Rod Nut and Washer r4 Volvo Penta P N 3855860 and Race Installer Volvo Penta P N 3855864 onto rod Tighten the nut against the installer 3855860 43542 3 Use a wooden 2x4 or 2x6 to cushion forward gearcase edge Wear Safety Glasses Drive bearing cup in until seated pa 43544 Pinion Bearing 1 Lightly oil the outside case of the pinion bearing with GL 5 Syn thetic gear
11. DRC7454 VPA 7743008 07 2003 Transom Shield Assembly SX MHP Transom Shield Assembly SX MHP Table of Contents Safety Warnings VPA 7743008 07 2003 Special Tools eede ss seit seen ee VA we a 56 Sealants Lubricants and Adhesives 055 56 Trim Tilt Cylinder Installation 000200 ee eeee 58 Pivot Housing Removal 000eee eee eee eens 59 Pivot Housing Assembly 000 eeee scene eens 62 Pivot Housing Installation 0 00 eee eee 62 Gimbal Ring Removal 20000 e cece eee eee 64 Gimbal Ring Disassembly 0 000e eee eeee 67 Gimbal Ring Assembly 0000 2 cece eee eee 67 Gimbal Ring Installation 0 00 00s eee eee 68 Trim Sender Adjustment 0 000 cece eee eee 71 Gimbal Housing Disassembly 202200000 72 Anode Replacement 20 200es eee ee eee eneeeee 72 Trim Sender Removal 00002e cece eee eens 73 Water Tube Removal 2 00000 0e ee eee eee eee 73 Hydraulic Lines and Manifold Removal 74 Steering Bearing Gimbal Bearing and Seal Removal 75 Gimbal Housing Cleaning and Inspection 75 Gimbal Housing Assembly 05 76 Steering Bearing Gimbal Bearing and Seal Installation 76 Hydraulic Lines and Manifold Installation 77 Trim Sender Installation 000200 eee eee 79 Anode and Sensor Housing Installation
12. Face the large diameter end of Remover Installer Volvo Penta P N 3854358 toward the gimbal ring Insert the tool into either tilt bearing and drive it out Remove the other tilt bearing in a similar manner Insert small end of Remover Installer Volvo Penta P N 3854355 into bearing and drive out bearing Remove the support from the gimbal ring only if it needs to be replaced Remove the two large and two small screws securing the support to the gimbal ring Position the support on top of the gimbal ring Spray two large screws and two small screws with Loctite Primer and allow to air dry Apply Volvo Penta Thread locking compount P N 1161053 to all screws Install and tighten screws to 38 59 ft Ib 51 81 N m Install and tighten screws to 13 28 ft Ib 18 38 N m Lightly oil the outside of a new lower pivot bearing and place it in the bore Use Remover Installer Volvo Penta P N 3854358 to seat the bearing into the bottom of the gimbal ring Install two new trim tilt nylon pivot pin bushings into the gimbal ring 65 Transom Shield Assembly SX MHP 4 Apply Volvo Penta Grease P N 828250to the inside of both trim tilt nylon bushings grease gt 4992A 5 Lightly oil the outside of two new tilt bearings Insert a bearing into the gimbal ring from the outside Insert the blunt end of Remover Installer Volvo Penta P N 3854358 into bearing Using a soft face 3854358 hammer seat bearing flush to 0 010
13. SX Lower Gearcase 3 Screw in driveshaft retainer using Spanner Wrench Volvo Penta P N 3850601 and seat upper driveshaft bearing cup 4 Apply Loctite Primer to the threads on the drive shaft and let air dry Apply Volvo Penta Thread locking compount P N 1161053 or adhesive to the threads Install a new pinion nut onto driveshaft Screw Pinion Nut Holder Volvo Penta P N 3854864 or Joint Ven ture P N 3854864 onto Handle Volvo Penta P N 3850609 Slide Alignment Disc Volvo Penta P N 385061 3 5 onto handle then insert into propeller shaft gear J 3854864 3850609 SH 3850613 33821A 5 Install Spline Socket Volvo Penta P N 3850598 onto driveshaft SS and tighten pinion nut to 150 160 ft Ib 203 217 N m Lb 7 33829 Setting Initial Rolling Torque Note This procedure will ensure bearing life by setting the driveshaft rolling torque Turn gearcase so that propshaft bore is vertical This will ensure the propshaft gear will not interfere with the pinion rolling torque measurement Record the following shimming measurement for the final rolling torque setting 1 Turn driveshaft several times to ensure bearing is seated before each torque reading 2 Tighten driveshaft retainer to achieve a driveshaft rolling torque of 2 4 in lb 0 22 0 45 N m Record rolling torque setting 42666 VPA 7743008 07 2003
14. Special Tools Owatonna Service Tools Order From Remove Sterndrive Trim Tilt Cylinder Removal 18 Tool Name Volvo P N Panel Location Drive Handle 3850609 3 A Driver 3854356 7 E Insert Tool 3854349 2 B Installer 3854359 1 E Installer 3854360 9 E Installer K Remover 3854355 9 E Installer Remover 3845358 3 E Installer Retaining Ring 3850608 5 B Pliers Rod 3854351 8 C Socket Removal 3854350 0 B Tool Tiller Arm Puller 3845361 7 K Same panel position as obsoleted Installer P N 912279 OTC No 1176 Slide Hammer OTC Division of SPX Corporation 655 Eisenhower Drive Owatonna Minnesota 55060 USA Toll free order line 1 800 533 5338 Or 1 800 533 0492 http www otctools com Remove the Sterndrive see Sterndrive Removal on page 227 If the complete transom shield assembly is being rebuilt or replaced remove engine following procedure in the Engine and Sterndrive Installation Manual 1 Remove screw and ground wire from the front of the cylinder VPA 7743008 07 2003 Transom Shield Assembly SX M 2 Carefully remove pivot pin cap 3 Wear safety glasses Cover fittings with a shop cloth and discon nect trim tilt lines 48624 4 Remove and discard trim tilt line O rings 20707 5 Wear safety glasses Remove pivot pin E clip and flat washer Pull pivot pin out of cylinder gimbal ring and cylinder on opposite side Remove bushing from gimbal ring and replace if necessary Remov
15. X 0 2488 kilo pascals kPa feet2 X 0 0929 metres2 m2 bars X 100 kilo pascals kPa yards2 X 0 8361 metres2 m2 pounds sq ft X 47 88 pascals Pa acres X 0 4047 hectares 104 m2 ha POWER miles2 X 2 590 kilometres2 km2 horsepower X 0 746 kilowatts kW VOLUME ft lbf min X 0 0226 watts W inches3 X 16387 millimetress mms TEMPERATURE inches3 X 16 387 centimetress cm3 Celsius 0 556 X F 32 inchess X 0 01639 liters I Fahrenheit 1 8 X C 32 quarts X 0 94635 liters I TORQUE gallons X 3 7854 liters I pound inches X 0 11299 newton metres N m feets X 28 317 liters I pound feet X 1 3558 newton metres N m feets X 0 02832 metress m3 VELOCITY fluid oz X 29 57 milliliters ml miles hour X 1 6093 kilo metres hour km h yards3 X 0 7646 metress m3 feet sec X 0 3048 metres sec m s MASS kilo metres hr X 0 27778 metres sec m s ounces av X 28 35 grams g miles hour X 0 4470 metres sec m s pounds av X 0 4536 kilograms kg tons 2000 Ib X 907 18 kilograms kg tons 2000 Ib X 0 90718 metric tons t FORCE ounces f av X 0 278 newtons N pounds f X 4 448 newtons N av kilograms f X 9 807 newtons N ACCELERATION feet secz X 0 3048 metres sec2 m S2 inches secz X 0 0254 metres sec2 m S2 ENERGY OR WORK foot pounds X 1 3558 joules j calories X 4 187 joules j Btu X 1055 joules j watt hours X 3500 joules j kilo
16. 3 Place two seals back to back seal lips facing away from each other onto Seal and Race Installer Volvo Penta P N 3855925 or Joint Venture P N 3855925 Coat the outside surface of the seals with Volvo Penta Gasket Sealing Compound Press the seals into the housing until the tool seats 4 Remove the tool and apply a light coat of Volvo Penta Grease P N 828250 to the seal lips 43464 Outer Propeller Shaft Service Removal Note Bearings should not be removed unless they are to be replaced Removal will damage the bearings 1 Screw Puller Volvo Penta P N 884789 on to the end of the outer propeller shaft to protect the threads Place the assembly in a press a a 884789 D al a D A 43510 VPA 7743008 07 2003 191 DP S Lower Gearcase 43466 43467 884143 7 884832 43468 884143 43469 192 Slide Dismantling Tool Volvo Penta P N 884803 and Drift Volvo Penta P N 884143 down into the outer propeller shaft Press the bearing and seals out of the outer propeller shaft Dis card the bearing and seals Position both parts of Puller Volvo Penta P N 884832 so the flanges of the puller catch the inside lip of the outer propeller shaft bearing race Place Drift Volvo Penta P N 884143 into position through the outer propeller shaft Support the assembly in a press and remove the race VPA 7743008 07 200
17. 39433 39389 6 Attach lower gearcase to upper gear housing Engage intermedi NS ate driveshaft splines and water supply tube 42610 7 Apply Volvo Penta Gasket Sealing Compound to the lower gear case mounting screws and studs Install four nuts two on either side of gearcase and two longer screws aft Tighten 3 8 16 nuts and screw to 22 24 ft Ib 30 33 N m and 7 16 14 screw to 32 40 ft Ib 43 54 N m 43640 Pressure and Vacuum Testing Before filling drive with gearcase oil it must be pressure and vacuum tested to verify proper sealing during assembly Remove the oil level plug at the back of the gear housing Install and tighten oil level dipstick at top of drive and the drain plug at the end of the gearcase VPA 7743008 07 2003 219 DP S Lower Gearcase Pressure Testing 47120 Vacuum Testing BD 47119 Sterndrive Filling 220 1 Attach a pressure tester such as a Stevens S 34 to the oil level hole and pressurize drive to 3 5 PSI 20 7 34 5 kPa Rotate pro peller shaft and Universal Joint shaft to check sealing If pressure loss is indicated use a soapy water solution or submerge drive in water to find source Make necessary repairs then repeat test If pressure loss is not indicated increase pressure to 16 18 PSI 110 124 kPa Again use a soapy
18. 5 6 Turn the gimbal to port and remove the two screws holding the trim sender Do not attempt to pull out the sender as its leads are secured to the transom bracket Disengage the U joint boot from the lip of the pivot housing and push it inside Unscrew the nut securing the water hose nipple and push the nip ple through the housing as far as possible Turn gimbal ring to the starboard Remove screw and both ground straps VPA 7743008 07 2003 Transom Shield Assembly SX MHP 7 Use a 1 2 in hex drive wrench or socket and remove both pivot pins 48633A Pivot Housing Disassembly 1 Remove and discard the cooling passage O ring e DE S 34521 2 Inspect the nylon friction washer on the pivot bosses Peel them off and discard them if they re damaged Remove and inspect the thrust washer underneath 12961 Cleaning and Inspection Clean housing in solvent and dry thoroughly Remove sealer and or adhesive from the cooling passage opening U joint bellows opening and pivot bosses Note Clean screw holes with solvent only A thread tap would damage the Heli Coil inserts and force their replacement O ring Seal Groove Check for sharp edges that would pre vent O ring sealing water passage e Mounting Studs Look for damaged threads and looseness Ground Wire Check wire ends for frayed or loose connections Repair or replace all suspect components VPA 7743008 07 2003 59 Tra
19. Adhesives 3M Adhesive Gasket top cover VPA 7743008 07 2003 143 Upper Gear Housing Service Chart A Volvo Penta Grease P N 828250 F B Volvo Penta Gasket Sealing Compound P 96 110 ft Lb N 1161099 130 149 Nem C Volvo Penta White Sealing Compound for Drives P N 1141570 D Synthetic Gear Lubricant GL 5 P N 1141634 E Volvo Penta Thread Locking Fluid P N 1161053 F 3M Adhesive G Volvo Penta Propeller Shaft Grease P N 1141644 Vertical Drive Oil Capacity 71 oz 2100 cc 48 72 ft Lb 5 4 8 1 Nem K 145 165 ft Lb 197 224 Nem 108 123 in Lb 12 15 Nem 60 84 in Lb i lt _ 6 8 9 5 Nem 48 72 in Lb 5 4 8 1 Nem 9 D 60 84 in Lb 10 12 ft Lb P 6 8 9 5 Nem 14 16 Nem Zeon tL oW eas A DR5023 144 VPA 7743008 07 2003 SX Lower Gearcase SX Lower Gearcase Table of Contents Safety Warnings VPA 7743008 07 2003 Special Tools 3405 srre niona pran eye ene ents 152 Lower Gearcase Removal 00200eeeeeeeeeee 153 Lower Gearcase Disassembly 154 Propshaft Bearing Housing Service 154 Seal and Bearing Removal 0 200eeeeeeeee 155 Seal and Bearing Installation 155 Propshaft Bearing Removal 0 00eeeeeeeee 156 Propshaft Bearing Installation 157 Intermedia
20. Example Add Subtract 0 009 in figure from Step 3 ia 0 005 in figure etched on gear 0 014 in shims required 6 Record dimension example 0 014 in for the pinion gearshim Note No less than one shim but no more than five shims should be used to obtain the average recorded shim thickness VPA 7743008 07 2003 157 SX Lower Gearcase Upper Gear Housing Oil Screen Remove the oil screen from the upper gear housing Clean and replace as necessary Install the oil screen into the oil passage in the upper gear housing Make sure the screen is secure Lower Gearcase Assembly 1 The selected pinion shims are installed into the gearcase under the lower small bearing cup 42658 2 Apply a light coat of GL5 Synthetic gear lubricant SAE 75W 90 to the small bearing cup Install bearing cup on top of shims with cup taper facing up Use Pusher Puller Volvo Penta P N 3850623 Guide Plate Volvo Penta P N 3850613 and Bearing Cup Installer Volvo Penta 3850621 to install bearing cup 42659 3 Place Cup Installer on cup then seat Guide Plate onto gearcase Wear Safety Glasses Use a hammer to seat bearing cup 42660 158 VPA 7743008 07 2003 SX Lower Gearcase Propshaft Gear Bearing Installation 3850617 VPA 7743008 07 2003 Note This procedure determines the amount of shims required to properly po
21. Workshop Manual ac Sterndrive Transom Shield 2 2 Sterndrive SX M SX MTD DP SM DP SMTD DP SMTD1 Transom Shield SX M SX MLT SX MACLT SX MHP SX MDA SX MDB General Information 0 0e008 3 Transom Shield Assembly SX M 17 Transom Shield Assembly SX MHP 53 Upper Gear Housing 89 SX Lower Gearcase 000000 gt 145 DP S Lower Gearcase 179 Sterndrive Removal and Installation 227 Trim Tilt Hydraulic System 241 PrOpellerS 4 1 2 c20noe sawed ead fede 259 VPA 7743008 07 2003 1 VPA 7743008 07 2003 General Information General Information Safety Warnings VPA 7743008 07 2003 Introduction Sterndrive Lubrication SX Models Adding Lubricant to Sterndrive 0 20005 Sterndrive Oil Capacity 0 cece eee eee Draining and Filling Sterndrive 2 00 0000e Sterndrive Lubrication DP S Models Adding Lubricant to Sterndrive 2005 Sterndrive Oil Capacity 0 cece eee eee eee Draining and Filling Sterndrive 0 00 0000es Power Trim Tilt Fluid Level 02000 00sec ee eeeee Off Season Storage Preparations All Models Panting aa eaaa cette eee aa teehee eee eae Preparation for Boating After Storage 10 Gimbal Bearing and Universal Joints Lubrication 10 Recommendations For Antifouli
22. e Mounting Studs must be tight and have no thread damage Seal Grooves Check for corrosion burrs and damaged edges Anode Check amount of deterioration Clean parts in solvent and dry thoroughly Some screw holes have special Heli Coil inserts that provide a thread locking feature Do not clean Heli Coil holes with a thread tap This will damage the Heli Coil inserts and force their replacement Locking Heli Coils are available only from Volvo Penta Parts See your parts catalog Face the open end of a new gimbal housing seal toward Installer Volvo Penta P N 3850038 and place it on the projecting nose of the tool Lightly coat the metal case with Volvo Penta Gasket Seal ing Compound Screw the installer onto Drive Handle Volvo Penta P N 3850609 Drive the seal into the housing until it seats Coat the seal lip with Volvo Penta Grease P N 828250 To ensure adequate lubrication of the gimbal bearing it must be correctly positioned prior to installation Rotate the outer band until its slot aligns with the lubrication hole Scribe a reference mark at this point on the bearing case VPA 7743008 07 2003 Transom Shield Assembly SX M 45228a 3852571 3854360 3854359 34505 Hydraulic Lines and Manifold Installa tion asker seali Ompoun 4963 VPA 7743008 07 2003 Screw the seal installation side of Installer P N 3850038 onto Drive Handle P N 3850609 Oil the exterior of the
23. 3 Press the seal in place with Drift Volvo Penta P N 884259 large diameter down until the tool seats on the housing 34992 4 Coat the seal lips with Volvo Penta Grease P N 828250 132 VPA 7743008 07 2003 Upper Gear Housing 5 34997 6 7 34996 8 34999 lt lt Ee pa Cay gt VPA 7743008 07 2003 Install the eccentric piston through the seal and bushing Orient the piston with the offset screw towards the side of the housing with the notch Align hole in the eccentric piston pin with the hole in the eccentric piston Insert the piston pin into the piston until the two holes align Install the tension pin Drive the pin in until it s flush with the top of the piston Install the shift shoe spring into the hole in the eccentric piston Install the shift shoe on top of the spring Orient the shift shoe as shown Note Make sure the shift shoe is installed correctly as shown The shift mechanism will not operate properly if the shift shoe is installed in any other position 133 Upper Gear Housing Shift Actuator Housing Installation 35012 47125 134 Coat a new O ring with GL5 Synthetic gear lubricant and install it in the O ring groove on the shift housing Install the shift actuator housing into the upper gear housing and secure with four screws Tighten the screws to 60 84 in Ib 6 8 9 5 Nm Sup
24. 3850598 43552A 7 Place Spline Socket Volvo Penta P N 3850598 onto the drive S shaft Tighten driveshaft retainer using Spanner Volvo Penta P N 3850601 to achieve a driveshaft rolling torque of 2 4 in Ib m 0 22 0 45 N m Record rolling torque setting 3850598 43577 Propeller Shaft Housing and Propeller Shaft Installation 1 Select the correct number of shims to equal your recorded mea surement Place shims onto the inner propeller shaft and slide them into position Note Use the least number of shims possible and sandwich the thinnest shims in between the thickest shims 43554 VPA 7743008 07 2003 209 DP S Lower Gearcase 2 Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the outer gear bearing and slide it down into position inside the gearcase 43553 3 Thread the Propeller Shaft Adaptor Volvo Penta P N 3855919 onto the inner propeller shaft M 3855919 43575 4 Slide Tube Volvo Penta P N 3855922 over the inner propeller shaft and rest it on the outer gear bearing Apply Volvo Penta Grease P N 828250 to the end of the tube Thread Nut Volvo Penta P N 3855920 onto the adaptor Tighten the nut to install the bearing until the bearing seats 5 Apply gear marking compound such as GM Gear Marking Com pound P N 1052351 to several teeth of outer propeller shaft 43616 210 VPA 7743008 07 2003 DP S Lower
25. 4 Install the RIBBED BLACK wire in the A terminal the WHITE wire in the B terminal and SMOOTH BLACK wire in the C termi nal on the Amphena connector Use Socket Installer Volvo Penta P N 3854349 to push the wire sockets into the rubber plug until they seat Note The use of alcohol will make socket installation into the rubber plug easier Anode and Sensor Housing Installa 1 Install the anode and sensor lead into the gimbal housing following tion Steps 1 and 2 above 2 Connect the anode and sensor leads to the electronic control unit mounted on the inside transom Water Tube Installation 1 If the grommet was discarded face the tapered end of a new one toward the hooked end of the tube and slide it up against the ae flange 15996 2 From inside the boat insert the hooked end of the tube through the gimbal housing Hold the tube vertically then install the two mounting screws and tighten them to 120 144 in Ib 14 16 N m 48698 Water Hose Installation 1 Remove and discard the nipple O ring Clean all grease from the nipple making sure the drain hole is clear If the nipple needs to be replaced remove the clamp and pull it out of the hose Install a new nipple and secure with a clamp Tighten the clamp securely 2 Coat anew O ring with Volvo Penta Grease P N 828250 Slide it onto the nipple and position it in the groove closest to the square at the end of the fitting Cle
26. Upper gear greater than range max No Change Required 126 VPA 7743008 07 2003 Upper Gear Housing Both Gears Incorrect By Different Amount DR5061 Add or subtract same amount of shims at each location indicated Table 4 Positions Requiring Shim Change Condition A B c D E Upper gear greater than range max Subtract Subtract Re shim Re shim Lower gear less than range min Lower gear greater than range max Add Add Re shim Re shim Upper gear less than range min Lower gear less than range min Subtract Add Re shim Re shim Upper gear less than range min Lower gear greater than range max Add Subtract Re shim Re shim Upper gear greater than range max No Change Required VPA 7743008 07 2003 127 Upper Gear Housing Checking the Gear Teeth Contact Pat tern GR990878 GR990872 GR990874 __ o S Zz CA GR990875 128 In order to achieve long gear life and smooth running with mini mum 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 The proper pattern on the upper gear unit will be checked on the driven gears upper and lower on their respective convex sides Paint three teeth B on both the upper and lower driven ge
27. _ _ _ _ _ _ VPA 7743008 07 2003 A Volvo Penta Grease P N 828250 Volvo Penta Gasket Sealing Compound GL 5 Synthetic gear lube SAE 75W 90 Loctite 242 or 609 3M Gasket Adhesive yellow B 14 17 ft Lb C 19 5 22 5 Nem Coo D E iS F Perfect Seal Sterndrive Oil Capacity 81 oz 2400 ml 32 40 ft Lb 22 24 ft Lb 30 33 Nem esl T 22 24 ft Lb 30 33 Nem 10 15 ft Lb 14 20 Nem DR6400 225 226 VPA 7743008 07 2003 Sterndrive Removal and Installation Sterndrive Removal and Installation Table of Contents Sealants Lubricants and Adhesives 233 Sterndrive Removal 00 00eeeeeneaueee 233 Sterndrive Installation 00 000e ea eeee 236 Check and Adjust Trim Sending Unit 241 Shift and Throttle Cable Installation 241 Shift Cable Installation 00022200 cence 242 Throttle Cable Installation 00000 cues 245 Sealants Lubricants and Adhesives Motor Oil Volvo Penta White Sealing Compound for Drives P N 1141570 Volvo Penta Grease P N 828250 Molybdenum Trioxide Moly Grease Wheel Bearing Grease Safety Warnings Before beginning work in this section read Safety chapter at end of this manual Proper installation is important for the safe reliable operation of all mechanical products The procedures we recommend and des
28. drain Screws lower to upper gearcase Screw propshaft bearing housing retainer Seal water tube VPA 7743008 07 2003 SX Lower Gearcase Service Chart A Volvo Penta Grease P N 828250 P B Volvo Penta Gasket Sealing y Compound P N 1161099 0O C Volvo Penta Propeller Shaft Grease P N 1141644 CD D GL5 Synthetic gear lube P N w 1141634 E Volvo Penta Thread Locking Fluid 0 P N 1161053 om Sterndrive Oil Capacity 71 oz 2100 cc 150 160 ft Ib 203 217 Nem 14 16 ft Lb _ 19 22 Nem 60 84 in Lb g 6 8 9 5 Nem 32 40 ft Lb 43 54 Nem 42 60 in Lb 4 8 6 8 Nem 22 24 ft Lb 30 33 Nem eo 60 84 in Lb j 6 8 9 5 Nem B pe g on 271 305 Nem VPA 7743008 07 2003 177 178 VPA 7743008 07 2003 DP S Lower Gearcase DP S Lower Gearcase Table of Contents Safety Warnings VPA 7743008 07 2003 Gearcase Retaining Plate 0 20e seen eeeee 186 Special Tools 2505 d ccudwcwiverdteadeetebas 187 Propeller Shaft Runout 0 000e eee eee 189 Lower Gearcase Removal 20 005 189 Lower Gearease Disassembly 191 Propeller Shaft Housing Propeller Shaft Removal 191 Inner Propeller Shaft Removal 0020e0000s 192 Water Tube Guide and Anode Removal 193 Driveshaft and Pinion Removal 2 0000005 194 Gearease Bearing and Race Removal
29. removing the lower gearcase 5 Use the trim tilt system to raise sterndrive to the full tilt up position 143034 Be prepared to support the lower gearease When the last fastener retaining the lower gearcase to the upper gear housing is removed the lower gearcase will be free to drop down 6 Remove four nuts two on either side and two screws Pull off lower gearcase assembly 43640 VPA 7743008 07 2003 183 DP S Lower Gearcase 7 Mount the lower gearcase in a suitable holding fixture Retain the gearcase with the plate and longer screws described on Page 5 2 43427 Lower Gearease Disassembly Propeller Shaft Housing Propeller Shaft Removal 1 Remove retaining ring using Spanner Tool Volvo Penta P N 3855877 Remove and discard both O rings 2 Remove the bearing housing retainer 43430 3 Thread Puller Volvo Penta P N 884789 onto the end of the outer propeller shaft Tighten the 5 8 11 bolt to remove the outer propel ler shaft and propeller shaft housing from the lower gearcase Remove the puller then remove the outer propeller shaft from the propeller shaft housing Remove and discard all O rings on the housing 43431 184 VPA 7743008 07 2003 DP S Lower Gearcase Inner Propeller Shaft Removal 1 Remove intermediate driveshaft and inspect splines If damaged replace driveshaft 2 Assemble Pusher Tip Volvo Penta P N 3855921 and Tub
30. 055 224 Pressure and Vacuum Testing 20e0eeeeeeee 226 Sterndrive Filling 00ecs eee eee eee eee 227 Anode Testing and Replacement 5 229 Specifications iia ie inne verre ee ore oe oe we 230 Sealants Lubricants and Adhesives 231 Service Chart lt lt cacawonsimweenGieata tee rake 32 Before working on any part of the lower gearcase read the section called Safety at the end of this manual Several of the following procedures require the use of an arbor or hydraulic press Always wear safety glasses when using this device to perform these procedures 179 DP S Lower Gearcase Gearcase Retaining Plate 180 A gearcase retaining plate can be made from 1 4 in steel or 3 8 in aluminum following the dimensions given to work with most large lower gearcase holding fixtures Dimension distance between bolt certerlines should be taken from your holding fixture Dimension is dimension 1 1 4 in Longer screws 4 1 2 in are also required Use the existing nuts and washers from the fixture VPA 7743008 07 2003 DP S Lower Gearcase Special Tools Table 1 Tool Name Volvo P N Panel Tool Name Volvo PIN Panel Location Location Attachment Tool 884940 Rod Nut and Washer 3855860 M Bearing and Sleeve 3855866 M Seal and Bearing 3855925 L Installer Installer Bearing Cup Installer 3850621 G Seal and Bearing 3855924 L Remover Bearing Installer 3850617 G Shim Fixture 3850600 H Bearin
31. 108 132 in Ib 12 15 N m 12 After drive has been run recheck oil level Add make up oil through the dipstick opening to bring oil up to the proper level within range on the dipstick Anode erosion or disintegration in salt or brackish water indicates they re performing their function Anodes should be inspected and or replaced at intervals or corrosion of the drive will increase Note If any anode has been reduced to two thirds its original size one third eroded it must be replaced 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 Be sure anode surface is clean to make good contact Ohmmeter should indicate a very low reading Zero If not remove the anode and clean the mounting screws the anode and the area where the anode is installed Install and retest the anode Note Do not paint or otherwise coat the anodes This will pre vent them from functioning properly If anode appears to be corroded on its surface but is not deteriorating it should be replaced VPA 7743008 07 2003 DP S Lower Gearcase Specifications Table 5 Description U S Metric Nut Pinion gear 72 87 ft Ib 98 118 Nem Lower to upper gearcase 22 24 ft Ib 30 33 Nem 3 8 16 Screw Anode 60 84 in Ib 6 8 9 5 Nem Drain 10 15 ft Ib 14 20 Nem Exhaust cover 14 17 ft Ib 19 5 22 5 Nem Lower to upper g
32. 163 SX Lower Gearcase Initial Propshaft Bearing Housing Shimming 3850626 21486 20810 32670 164 Note This procedure determines the amount of shims required to preload the propshaft bearings and also ensures bear ing life by setting the driveshaft propshaft rolling torque Apply GL5 Synthetic Gear Lubricant SAE75W 90 to the threads of the propshaft bearing housing Use Volvo Penta Grease P N 828250 to hold Shim Ring 160 in Volvo Penta P N 3850626 and place Shim Ring on housing Do not install O ring at this time Screw in propshaft bearing housing Attach torque wrench to Housing Remover installer Volvo Penta P N 3850707 at a 90 angle and tighten housing to 80 ft Ib 108 5 N m Note Record the following shimming measurement for the final gear lash check Determine depth of propshaft bearing housing Measure from gearcase hub edge to top of each bearing housing rib Stay away from the bolt holes Record and average the measurements Example Table 3 Add Divide Rib no 1 0 403 in 1 208 in 3 0 4026 in Rib no 2 0 407 in Rib no 3 0 398 in Total 1 208 in Round off division figure example 0 403 in and add 0 160 in Shim Ring Volvo Penta P N 3850626 to rounded off number example 0 403 in 0 160 in 0 563 in This result will be used later to determine the amount of shims required for the propshaft bearing h
33. 4 Remove O ring from manifold 49699 5 Remove two screws securing motor to manifold VPA 7743008 07 2003 247 Trim Tilt Hydraulic System 6 Discard O ring on motor and four O rings on screws 7 Remove and inspect filters Clean or replace as necessary 8 Install filters using a socket or suitable tool Drive the filters into place The end of the pick up tube should not touch the filter 9 Pull out pump drive coupling and inspect for wear or damage 248 VPA 7743008 07 2003 Trim Tilt Hydraulic System 10 Install the pump coupler and align the slot with the two pump motor mounting holes gah EUS 49645 Separation of Pump and Manifold Note Mating surfaces between pump and manifold are critical for sealing and cannot be scratched or gouged Use extreme care during disassembly and reassembly proce dures The pump is serviced as an assembly Do not attempt to disassemble the pump or try to put a reassem bled pump back into service Reassembled pumps have a very short service life Remove two pump mounting screws The two remaining screws are not to be removed Installation of Pump Rest pump on manifold Install screws Tighten screws to 35 in Ib 4 0 N m VPA 7743008 07 2003 249 Trim Tilt Hydraulic System Installation of Motor and Reservoir 49649 49657 250 1 Co
34. 7 16 25 0098 1 85 0728 sa 1610 20 7 0 2756 11 5 4528 3 0118 iz 0730 49 4 1 1614 a 2770 J 11 51 4531 29 64 ast 0135 80 1 9 0748 4 2 1654 7 1 2795 11 91 4687 15 32 35 0138 D 0760 48 baa 1660 19 i 2811 K 12 0 4724 P 0415 79 1 95 0767 4 25 1673 7 14 2812 9 32 12 30 4843 31 64 39 0156 1 64 1 98 0781 5 64 4 3 1693 7 2 2835 12 5 4921 4 0157 ise 0785 47 Sia 1695 18 7 25 2854 12 7 5000 1 2 at 0160 78 2 0 0787 4 37 1719 11 64 7 3 2874 13 0 5118 45 0177 2 05 0807 bes 1730 17 wd 2900 L 13 10 5156 33 64 ve 0180 77 ne 0810 46 4 4 1732 7 4 2913 13 49 5312 17 32 5 0197 s 0820 45 se 1770 16 ae 2950 M 13 5 5315 et 0200 76 2 1 0827 4 5 1771 7 5 2953 13 89 5469 35 64 ase 0210 75 2 15 0846 vas 1800 15 7 54 2968 19 64 14 0 5512 55 0217 ei 0860 44 4 6 1811 7 6 2992 14 29 5624 9 16 ni 0225 74 2 2 0866 or 1820 14 it 3020 N 14 5 5709 6 0236 2 25 0855 4 7 1850 13 7 7 3031 14 68 5781 37 64 by 0240 73 p 0890 43 4 75 1870 7 75 3051 15 0 5906 a 0250 72 2 3 0905 4 76 1875 3 16 7 8 3071 15 08 5937 19 32 65 0256 2 35 0925 4 8 1890 12 7 9 3110 15 48 6094 39 64 te 0260 71 ee 0935 42 iad 1910 11 7 94 3125 5 16 15 5 6102 ie 0280 70 2 38 0937 3 32 4 9 1929 8 0 3150 15 88 6250 5 8 7 0276 2 4 0945 ie 1935 10 E 3160 O 16 0 6299 PA 0292 69 T 0960 41 ai 1960 9 8 1 3189 16 27 6406 41 64 75 0295 2 45 0964 5 0 1968 8 2 3228 16 5 6496 oe 0310 68
35. 84 108 in lb 9 5 12 2 N m Route the lines together down the side of the housing Install the clamp and screw tighten the screw securely VPA 7743008 07 2003 Transom Shield Assembly SX MHP 7 Ifthe grease extension tube was removed install it as follows a Remove the grease fitting from the tube Apply Volvo Penta Gasket Sealing Compound to the last 1 4 in of the grease fit ting end of the tube Insert the tube through the outer wall of the housing b Spray the tapered end of the tube and housing hole with Loc tite Primer or equivalent and allow to air dry c Sparingly apply Volvo Penta Thread locking compount P N 1161053 to the tapered end of the tube and drive the tube into the housing until it seats Wipe away any excess adhesive that may enter the bearing cavity or the end of the tube Install the grease fitting 34508 Trim Sender Installation 1 Apply Volvo Penta Grease P N 828250 to the trim tilt sender lead grommet Feed the wires through the opening in the rear of the gimbal housing and out through the transom plate 2 Push the grommet into the hole until it seats Note Do not route trim tilt sender leads under extension tube or hydraulic lines Leads must be free to move when drive unit steers otherwise sender or wire will be damaged 48685 3 Attach the retaining clip to the grommet inside the transom plate VPA 7743008 07 2003 77 Transom Shield Assembly SX MHP
36. Allen head screws to lock tool to the driveshaft Lightly tighten screws to keep the driveshaft from mov ing 212 VPA 7743008 07 2003 DP S Lower Gearcase 2 Place Lash Tool Volvo Penta P N 3855873 onto the inner propel ler shaft Stay away from the propeller splines Set up a dial indi cator to read the forward gear lash by setting the indicator tip on outer lash tool line Rotate the inner propeller shaft back and forth to check the amount of lash for the forward gear Lash should be 0 006 0 012 in 0 15 0 30 mm Record your measurements 3855873 a Es N A oog L EC Z A 43621 3 Reposition the Lash Tool Volvo Penta P N 3855873 onto the outer propeller shaft Stay away from the propeller splines Set up a dial indicator to read the rear gear lash by setting the indicator tip on inner lash tool line Rotate the outer propeller shaft back and j forth to check the amount of lash for the rear gear Lash should be 0 006 0 014 in 0 15 0 35 mm Record your measurements 3855873 43622 VPA 7743008 07 2003 213 DP S Lower Gearcase Checking Tooth Contact Pattern 43624 DRC6396 214 DRC7524 Wrap a rag around each propeller shaft Hold on to the shafts while turning the vertical drive shaft This will load the gears and give a good tooth contact pattern on the rear gear Remove the outer propeller shaft and propeller shaft
37. Fluid Sterndrive Drain and refill every 100 hours or once a year Check level occasionally during boating season Use Volvo Penta Syn thetic Gear Lubricant SAE 75W 90 Universal Joint Shaft Splines Lubricate seasonally Use Moly Lube or equivalent VPA 7743008 07 2003 Transom Shield Assembly SX M Transom Shield Assembly SX M Table of Contents Safety Warnings VPA 7743008 07 2003 Special Toolsie c00 sii wns eaw Cee a ia he wa oes 18 Trim Tilt Cylinder Removal 0 00 eee ee ee eens 18 Trim Tilt Cylinder Installation 00020e ee eeee 20 Pivot Housing Removal 00 0eeee eee ences 21 Pivot Housing Disassembly 000 e eee eeeee 23 Pivot Housing Assembly 20 0eeee scene eens 24 Pivot Housing Installation 0 00 eee eee 24 Gimbal Ring Removal 20000e cece eee eee 26 Gimbal Ring Disassembly 20000eeeeeeee 28 Gimbal Ring Assembly 0000e cece eee eee 29 Gimbal Ring Installation 0 000 e eee eee eee 30 Trim Sender Adjustment 0 000 c cece eee eee 33 Gimbal Housing Disassembly 34 Water Hose and Bellows Removal 0 05 34 Anode Replacement 0 0eeeeeee eee eeneeees 34 Trim Sender Removal 000 eee e eee eee eee 35 Water Tube Removal 200s see ee cece eens 35 Hydraulic Lines and Manifold Removal 36
38. N 884938 large diameter end up in u a press Lightly oil the inside diameter of the adaptor ring with GL5 2 Synthetic gear lubricant Place it on top of the sleeve flange side up e 884938 34753 112 VPA 7743008 07 2003 Upper Gear Housing 3850606 34752 Lower Output Gear Shimming 3850701 VPA 7743008 07 2003 34893 Place the upper bearing gear side down on top of the adaptor ring Press the bearing into the adaptor ring until it seats using Remover Installer Volvo Penta P N 3850606 and a suitable piece of flat stock Note The following procedures will set gear position for the input lower and upper output gears Record all measure ments for future reference Place the lower gear and bearing assembly gear side down on a suitable work surface Place Shim Tool Volvo Penta P N 3850701 on the assembly as shown Take a feeler gauge mea surement at the outer edge of the bearing Record this measure ment Add or subtract the shimming allowance on the gear from the measurement taken in Step 1 This is the amount of shims required to properly position the lower output gear in the upper gear housing Note Because of the location of shims in relation to the gear use the following information when adding or subtracting the etched allowance figure from the measurement in Step 1 e If the etched number is 5 you would SUBTRACT 0 005 in from the feeler gauge measurement taken in Step 1
39. Propeller Shaft Runout Remove Propellers 884940 K DRC7429 Lower Gearcase Removal 182 1 DR5387A Move the shift lever to REVERSE 1 Remove the rear propeller retaining nut and propeller using a 30 mm socket Move the shift lever to FORWARD 4 Remove the front propeller retaining nut and propeller using Front Propeller Remover Installer Volvo Penta P N 3855876 Note Do not attempt to hold the propellers by hand while removing propeller nuts serious injury may result Attach a dial indicator to Special Tool Volvo Penta P N 884940 and attache to the outer propshaft with the tip resting on the inner propshaft as close to the edge of the outer propshaft as possible Rotate the shaft one turn and read off the throw on the dial indica tor The Reading should not exceed 0 0027 in 0 07 mm To measure the play in the propeller shaft move the inner prop shaft toward and away from the dial indicator Check the shaft in several different positions The play between shafts should not exceed 0 0012 in 0 03 mm With the sterndrive in the full tilt down position place a 4 quart oil drain pan under the gearcase VPA 7743008 07 2003 DP S Lower Gearcase 2 Remove the oil level dipstick so the oil reservoir can vent while draining 43677 3 Remove oil fill drain screw using an 8 mm Allen wrench 4 Discard the O ring Let the sterndrive drain completely before
40. Remove the five screws and washers holding the steering support bracket and pull the bracket off 62 VPA 7743008 07 2003 Transom Shield Assembly SX MHP 5 If it s tight use a drift punch and mallet to tap on alternating sides of the bracket until its free 48667 6 Remove cotter pin and steering arm pin Remove ground strap from steering arm 19351 7 Remove two screws securing the gimbal housing cover to the transom 48699 8 Remove four screws and the gimbal housing cover Remove and discard the two foam seals from the inside of the cover VPA 7743008 07 2003 63 Transom Shield Assembly SX MHP 9 Remove and discard the sealing ring 10 Unscrew the steering arm bolt part way out of the gimbal support Push down on the gimbal ring assembly to remove it from the gim bal housing If it does not come out easily lightly tap on the assembly with a rawhide mallet Finish removing the screw and remove the gimbal ring assembly from the gimbal housing 11 Remove the steering arm from inside the boat 12 Remove thrust washer from the gimbal housing 17 48690 64 VPA 7743008 07 2003 Transom Shield Assembly SX MHP Gimbal Ring Disassembly 19646 17685 X 48682 Gimbal Ring Assembly 17684 VPA 7743008 07 2003 Remove and discard the O ring around the upper steering post
41. Rib no 2 0 407 in Rib no 3 0 398 in Total 1 208 in Subtract this figure from first recorded measurement example 0 563 in 0 445 in 0 1 18 in The result will be the amount of shims required for the propshaft bearing housing A 0 118 in shim is required for the propshaft bearing housing in this example 2 Apply GL5 Synthetic Gear Lubricant SAE 75W 90 to O ring and threads of propshaft bearing housing Apply Volvo Penta Grease P N 828250 to the selected shim ring to help hold it in place then attach shim to bearing housing Install assembly into gearcase 21483 3 Install torque wrench at a 90 angle to Housing Remover Installer Volvo Penta P N 3850707 Tighten bearing housing to 200 225 ft lb 271 305 N m Recheck final total rolling torque to make sure it hasn t changed 3850707 Note If final rolling torque is too high more than 23 in Ib 2 6 N m for 1 43 1 1 51 1 1 60 1 1 79 1 and 1 89 1 gear ratio vertical drives and 18 in Ib 2 03 N m for 1 66 1 1 97 1 and 2 18 1 gear ratio sterndrives remove the prop shaft bearing housing shim ring and install the next size larger shim ring Recheck final rolling torque 20815 Note If final rolling torque is too low less than 14 in Ib 1 58 N m for 1 43 1 51 1 60 1 79 1 and 1 89 1 gear ratio sterndrives and 11 in Ib 1 24 Nm for 1 66 1 85 and 1 97 1 gear ratio vertical drives remove the propshaft bearing
42. Universal Joint Kit Volvo Penta P N 3850628 in tool and tighten tool until retaining ring groove of one cap com pletely clears the inside of the coupler 4 Wear eye protection Discard old retaining rings and replace them with new ones Attach to cap with pliers or hammer 5 Remove Universal Joint from tool and rotate it 180 Press in opposite cap until the retaining ring of the first cap seats against the yoke Face the open end of the ring toward the driveshaft and attach it to the cap If necessary use a punch and hammer to seat the ring in the groove VPA 7743008 07 2003 99 Upper Gear Housing 6 Repeat steps 1 thru 5 above for all remaining bearing caps 7 Check the Universal Joint for freedom of movement Drive the end caps outward against the clips as necessary to ensure freedom of movement Pinion Bearing Carrier Disassembly 1 Make a Universal Joint Support by cutting a 1 in 25 4 mm diam eter pipe 2 875 in 73 0250 mm long Slide the support through both yokes 34760 2 Rest the pinion bearing carrier on top of a vise and clamp the yoke securely 3 Remove the pinion gear retainer screw using a FTX 500 Torx bit Discard the screw Remove the pinion gear retainer 100 VPA 7743008 07 2003 Upper Gear Housing 4 Carefully remove the pinion bearing carrier from the Universal Joint shaft If the pinion bearing carrier is stuck a press may be used to the remove the Universal Joint sha
43. aged Discard O ring 21483 Seal and Bearing Removal 1 Use a punch and hammer to remove propshaft seal from housing Seal will be damaged during removal and must be replaced 2 Attach threaded rod from Volvo Penta Drive Handle P N 3850611 to Two Jaw Puller Volvo Penta P N 3850612 Slide Guide Plate Volvo Penta P N 3850613 stepped side facing up onto threaded rod Insert Puller into housing expand jaws tightly behind bearing cup and pull out cup 33853 Seal and Bearing Installation 1 Clean and inspect propshaft bearing housing VPA 7743008 07 2003 149 SX Lower Gearcase 3850613 P AN ml i S 21488 Propshaft Bearing Removal 20527 150 Assemble the Pusher Puller Volvo Penta P N 3850623 Guide Plate Volvo Penta P N 3850613 and Seal Installer Volvo Penta P N 3850627 as shown Face lip of seal toward tool and slide seal onto installer Apply Volvo Penta Gasket Sealing Compound to metal casing of seal Press seal into bearing housing until it seats Apply Volvo Penta Grease P N 828250 to the seal lip Apply a light coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the bearing cup Using Pusher Puller Volvo Penta P N 3850623 Guide Plate Volvo Penta P N 3050613 and Bearing Cup Installer Volvo Penta P N 3850621 press bearing cup into housing until it seats Pull out and inspect p
44. and mi C EE adjustment to prevent loading the control box and adversely a affecting shift adjustments 2 Note position of small seal and large seal of the shift cable Remove and retain jam nut small seal and large seal from the shift cable 236 VPA 7743008 07 2003 Sterndrive Removal and Installation 47553 47554 47555 VPA 7743008 07 2003 Apply a light coat of Volvo Penta Grease P N 828250 to the end of the remote control shift cable casing Slide shift cable through transom sleeve and connector assembly until it appears on the outside of the transom For ease of installation of shift cable turn sterndrive to port Rein stall the retained large seal and small seal onto the shift cable in the same position as noted in step 2 Loosen cable anchor clamp and slide to starboard Slide shift cable through pivot housing and sterndrive Slide anchor clamp in engaging the shift cable anchor groove Tighten anchor clamp screw securely 237 Sterndrive Removal and Installation 7 Rotate eccentric piston arm to extend bellcrank 47131 8 Remove cotter pin flat washer and cube 9 Thread cube halfway onto remote control cable end 47130 10 Rotate shift lever back to neutral detent position then move remote control handle to its neutral detent position Turn cube IN or OUT until it aligns with center of bellcr
45. bearing case Place the bearing with the reference mark facing the extension tube opening onto the installer Drive the bearing into the housing until it seats Lubricate the bearing with Wheel Bearing Grease through the grease fitting on the starboard side of the housing To install the upper steering bearing slide Installer Volvo Penta P N 3854360 onto Rod Volvo Penta P N 3854351 then place a new bearing Volvo Penta P N 3852571 on the installer Lightly oil the outside of the bearing The installer Volvo Penta P N 3854359 will act as a stop to seat the bearing When positioned inside the steering arm cavity the recessed side of the tool must face the bearing as shown Face recessed side of Installer Volvo Penta P N 3854359 down and insert it into the steering arm cavity from inside the boat Screw puller rod into the installer until it s flush with the top of the installer Hold the rod and tighten the nut until the bearing seats Coat a new O ring with Volvo Penta Gasket Sealing Compound P N 1161099 and place it on the manifold Lubricate two new O rings with hydraulic fluid and place them on the hydraulic line tips 39 Transom Shield Assembly SX M 40 34503 34506 Hold the manifold as shown and attach the lines Make sure the tagged line goes in its proper location Route both lines parallel and at the angle shown Line routing is important otherwise mani fold will be difficult or impossible to ins
46. changes at anytime without notice in Specifications 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 All information illustrations and specifications contained in this manual are based on the latest product information available at the time of printing The right is reserved to make changes at anytime without notice All photographs and illustrations used in this manual may not depict actual models or equipment but are intended as representative views for reference only The continuing accuracy of this manual cannot be guaranteed Sterndrive Lubrication SX Models Adding Lubricant to Sterndrive Occasionally check oil level in sterndrive Screw dipstick fully into hole Remove and read oil level in reference to mark on dipstick If oil level is low add oil through dipstick opening 34086 Add only enough lubricant to bring the oil level to the proper level somewhere in the range on the dipstick Sterndrive Oil Capacity 33836 Change Lubricant Every 100 Hours or Once Each season Use Volvo Penta Synthetic Gearcase Lubricant or Mobilube 1 SHC Fully Synthetic SAE 75W 90 gear lubricant All SX Models 710z 2100 cc Draining and Filling Sterndrive When a complete change of lubricant is required in the sterndrive proceed a
47. dimension in Step 2 Example Add Subtract 0 046 in actual dimension in Step 2 0 000 in etched number 0 on gear 0 046 in total 5 Subtract the total figure in Step 3 from a nominal dimension of 0 055 in This new total is the number of shims required to position the forward gear Example Subtract 0 055 in nominal dimension 0 046 in total from Step 3 0 009 in total shims required 6 Record dimension example 0 009 in for the forward gear shims required Note No less than one shim but no more than three shims should be used to obtain the required shim thickness Note This procedure determines the amount of shims required to properly position the outer propeller shaft in relation to the pinion Record the following shimming measurement for the final gear lash check VPA 7743008 07 2003 DP S Lower Gearcase 1 Place Bearing Installer Volvo Penta P N 3855361 in a press with the recessed side of the tool facing up Center the forward gear on top of the tool 43561 2 Lightly lubricate the splined end of the inner drive shaft with GL 5 Synthetic gear lubricant SAE 75W 90 Position the shaft in the for ward gear Thread a rear propeller nut onto the threaded end of the shaft to protect the threads Press the shaft into place until it seats 43562 3 Position Shim Fixture Volvo Penta P N 3855872 on a flat surface Place the forward gear bearing race tapered side up insi
48. does not protrude through the nut when it s seated then the square nipple collar is not located properly behind the housing Loosen the nut and rotate the nipple to reposition it Make sure the drain hole in the nipple faces down Tighten the nut to 96 120 in Ib 11 14 N m 6 Apply Volvo Penta Gasket Sealing Compound around the com plete inner V shaped lip of the pivot housing to seal the U joint bellows against water entry 7 Pull the U joint bellows through the opening and seat the lip in the groove 34584 8 Bellows must seal the entire circular opening any flat spot on the lip indicates the bellows has not engaged the V groove 34583 VPA 7743008 07 2003 61 Transom Shield Assembly SX MHP 9 Attach the ground wires with screw to the threaded hole on the port side of gimbal ring 10 Install and adjust the trim sending unit following instructions found under Trim Sender Adjustment in this section 48616 Gimbal Ring Removal 1 Remove trim tilt cylinders and pivot housing following instructions elsewhere in this section 2 Turn the gimbal to port and remove the two screws holding the trim sender Do not attempt to pull out the sender as its leads are secured to the transom bracket 19475 3 Remove four Allen head screws and two anodes from the steering support bracket Move the anode and sensor housing out of the way 4 Note the position of the two ground straps
49. drive through a complete trim in tilt down cycle Record run ning and stall PSI and compare to specifications If system fails to meet specifications perform Test No 4 This test will isolate the pump manifold trim in tilt down components from the trim cylinders It will help determine whether defective components are in the pump manifold or in the trim tilt cylinders 1 Attach the tester as described in Test No 3 2 Rundrive to the full down position Momentarily activate trim switch in the UP direction to relieve pressure on gauge VPA 7743008 07 2003 Trim Tilt Hydraulic System Completely close the tester shut off valve Run pump in the trim in tilt down direction and record the stall PSI Release the trim switch and check the leak down rate and final PSI Compare the results to specifications Test Results If the pressure gauge shows a stall PSI less than specifications or a leak down rate greater than specifications the problem lies within the pump manifold If the stall PSI and leak down figures are within specifications the problem is with either or both trim tilt cylinders Servicing Motor and Pump Removing Motor and Draining Reser A Warning valk The hydraulic lines may contain fluid under pressure All of the pressure can not be relieved before the system is opened Safety Glasses must be worn All line fittings must be covered with shop towels before they are opened DO NOT remove any lines comp
50. housing shim ring and install the next size smaller shim ring Recheck final rolling torque 168 VPA 7743008 07 2003 SX Lower Gearcase Propshaft Bearing Housing Retainer Installation 1 Apply Loctite Primer to set screw let dry then apply Volvo Penta Thread locking compount P N 1161053 Tighten set screw no more than 42 60 in Ib 4 8 6 8 N m Note Bearing housing lip will be distorted or broken if set screw is tightened more than recommended 20553 2 Apply Volvo Penta Gasket Sealing Compound to the bearing housing retainer screw Position the thickest edge of the retainer toward the handle side of the Retainer Installation Tool Volvo Penta P N 3850603 Compress the spring loaded tip as you install 3850603 the retainer into the tool Position retainer and screw inside the chamber Uy S 42668 3 Use a 1 4 in drive 3 8 in socket and extension to tighten retainer screw to 20 25 ft Ib 27 34N m Remove the installation tool by pushing it towards the rear exhaust chamber 33837 VPA 7743008 07 2003 169 SX Lower Gearcase Lower Gearcase Installation 1 Install water tube retainer Apply Volvo Penta Gasket Sealing Compound to the outside of the water tube seal and install in the cavity 2 Apply GL5 Synthetic Gear Lubricant to a new driveshaft retainer O ring and new oil passage O ring Install oil passage O ring into groove and driveshaft retainer O ring onto retainer
51. if present VPA 7743008 07 2003 Propellers Installation 70 80 ft Lb 95 108 Nem 6604 VPA 7743008 07 2003 6598 A 10 11 CAUTION Failure to install all components could result in loss of propeller and damage to drive unit next time the boat is operated Ignition switch must be OFF Make sure the remote control is in NEUTRAL Coat the full length of the propeller shaft 7 and the inside of the propeller hub with Volvo Penta propeller shaft grease P N 1141644 removal of the propeller will be difficult if this is not done Place the thrust bushing 6 on the propeller shaft with the inner taper toward the gearcase to match the taper on the propeller shaft Install the propeller 1 onto the propeller shaft aligning splines and push the propeller onto the thrust bushing until the splines are exposed Install thrust washer 2 on propeller shaft splines Shift the remote control into REVERSE gear to lock the propeller shaft Install and tighten the propeller nut 5 to 70 80 ft Ib 95 108 Nem Index the keeper on the propeller nut until it is aligned with the cot ter pin hole Install the cotter pin and bend the ends to secure use a new cotter pin if necessary Shift the remote control into NEUTRAL Note Propeller should turn freely Propeller spacer nut keeper and cotter pin must be installed as shown Failure to install all components could result in loss of the propell
52. in 0 25 mm below inner surface of gimbal ring Repeat procedure for installation of the other bearing 6 If bushing around upper steering post is damaged it can be removed by splitting it down one side with a sharp tool Note When replacing steering post bushing check upper bear ing inside gimbal housing to see if it also needs replace ment 19717A 7 f upper steering post bushing was removed lubricate inside diam eter of a new bushing with Volvo Penta Grease P N 828250 and place bushing on top of steering post Install steering arm and cen ter bolt Tighten center bolt until bushing seats then remove center bolt and steering arm Gimbal Ring Installation 1 Coat anew O ring with Volvo Penta Grease P N 828250 and place it around the base of the upper steering post 2 Coat the thrust washer with Volvo Penta Grease P N 828250 and set it over the upper pivot bearing inside the top of the gimbal housing 48683 3 From inside of boat position steering arm over the thrust washer 48679 66 VPA 7743008 07 2003 Transom Shield Assembly SX MHP 4 Guide gimbal ring steering post up engaging steering arm Seat the steering post into the steering arm by pushing up The steering post is a slip fit with the steering arm Apply Volvo Penta Gasket Sealing Compound to the center screw Install center screw finger tight 5 Tighten the center screw
53. ing ring Reset the rolling torque to the torque established earlier Adjust the retaining ring to align with the oil drain hole Note Failure to reset the rolling torque to the figure established in an earlier procedure will change gear lash and tooth contact pattern 43574 7 Apply alight coat of GL 5 Synthetic gear lubricant SAE 75W 90 to NX the drain screw O ring Place the O ring onto the drain screw 43634 8 Install the drain screw and tighten to 10 15 ft Ib 14 20 N m 43635 Lower Gearcase Installation 1 Apply GL 5 Synthetic gear lubricant SAE 75W 90 to a new drive shaft retainer O ring and new oil passage O ring Install the O rings into their respective grooves 42671 VPA 7743008 07 2003 217 DP S Lower Gearcase 2 Install water tube retainer Apply Volvo Penta Gasket Sealing Compound to the outside of the water tube seal and install in cavity 42670 3 Install anode and secure with two screws Tighten the screws to 60 84 in Ib 6 8 9 5 N m 4 Install intermediate driveshaft with the groove facing upward onto driveshaft 43674 218 VPA 7743008 07 2003 DP S Lower Gearcase 5 Install and position water grommet and supply tube into upper ge 5 gear housing Check oil filter for proper installation 5 Note Care must be used on reassembly of gearcase If machined surface is damaged leakage may occur oy
54. install higher pitch propeller Remember if the engine operates below the recommended full throttle RPM range the engine is laboring and power and efficiency are being lost If the engine operates above the recommended full throttle RPM range engine speed is excessive and additional power and efficiency are not being gained In either case serious engine damage may result Note Changing propellers on some SX models covered in this manual may require readjusting the trim tab on stern drives so equipped A rubber hub in the propeller is the shock absorber that minimizes damage to the sterndrive and engine If the rubber hub should begin to slip it should be replaced This can be safely done by any reputable propeller repair shop Only genuine Volvo Penta Parts should be used to rebuild the propeller A Warning To avoid accidental starting of engine be sure remote control is in NEUTRAL position and ignition key is removed Protect your hands from sharp edges of propel ler blades by wearing gloves when removing or installing the propeller 1 Ignition switch must be OFF Make sure the remote control is in NEUTRAL Remove the cotter pin 3 and keeper 4 Shift the remote control into FORWARD to lock the propeller shaft Remove the propeller nut 5 using a 1 1 16 wrench 2a KR wD Remove the thrust washer 2 propeller 1 and thrust bushing 6 7 Wipe the propeller shaft 7 clean Inspect for fishing line remove
55. installation Rotate the outer band until its slot aligns with the lubrication hole Scribe a reference mark at this point on the bearing case 4959 74 VPA 7743008 07 2003 Transom Shield Assembly SX MHP 3852571 3854360 3854359 3854351 34505 Hydraulic Lines and Manifold Installa tion Sasket seali ompound 4963 VPA 7743008 07 2003 Screw the seal installation side of Installer Volvo Penta P N 3850038 onto Drive Handle Volvo Penta P N 3850609 Oil the exterior of the bearing case Place the bearing with the refer ence mark facing the extension tube opening onto the installer Drive the bearing into the housing until it seats Lubricate the bear ing with grease or equivalent through the grease fitting on the star board side of the housing To install the upper steering bearing slide Installer Volvo Penta P N 3854360 onto Rod Volvo Penta P N 3854351 then place a new bearing on the installer Lightly oil the outside of the bearing Installer Volvo Penta P N 3854359 will act as a stop to seat the bearing When positioned inside the steering arm cavity the recessed side of the tool must face the bearing as shown Face recessed side of Installer Volvo Penta P N 3854359 down and insert it into the steering arm cavity from inside the boat Screw puller rod into the installer until it s flush with the top of the installer Hold the rod and tighten the nut until the bearing seats
56. lubricant SAE 75W 90 gear lubricant and place it on 3855860 Remover and Installer Volvo Penta P N 3855868 with the num bers facing the installer Position the bearing and installer inside the gearcase Thread the rod from Rod Nut and Washer Volvo B Penta P N 3855860 into the installer 3855868 UC 43545 VPA 7743008 07 2003 205 DP S Lower Gearcase 2 Place Spacer Volvo Penta P N 3855867 onto the rod Lightly oil Na the rod with gear oil y fA 3 Place Guide Plate Volvo Penta P N 3850619 and washer and nut from Rod Nut and Washer Volvo Penta P N 3855860 onto the rod Tighten the nut to pull the bearing into place until the tool seats 1 Select the correct number of shims to equal your recorded mea surement Place shims into recess of bearing race bore Note No less than one shim but no more than five shims should be used If possible sandwich the thinnest shims in between the thickest shims 2 Apply a light coat of Volvo Penta GL 5 Synthetic gear lubricant SAE 75W 90 to the bearing race Place bearing race on top of shims in lower gearcase 206 VPA 7743008 07 2003 DP S Lower Gearcase 3 Use Rod Volvo Penta P N 3850623 G
57. match the engine boat combination its intended application and the anticipated load of the boat Note Selection of the wrong propeller will reduce engine ser vice life affect boat performance and may cause serious engine damage It is important to remember that propeller pitch and diameter determine engine RPM at full throttle To determine the propeller best suited for 259 Propellers Propeller Removal and Installa tion SX Models Removal 260 each application use a tachometer of known accuracy to check engine RPM The propeller which allows the engine to obtain the maximum percentage of available horsepower and run near the top limit of its full throttle operating range with the lightest load the boat will carry is suited for your application In most cases selecting a propeller in this manner will prevent the maximum RPM dropping below the low limit of the operating range when the boat has a maximum load There are instances when the propeller selected cannot cover the complete range of boat applications for example from water skiing to high speed performance In such cases it may be necessary to change propellers to suit each particular situation e Propeller prevents engine RPM from attaining the specified Full Throttle Operating Range Engine is laboring install lower pitch ropeller e Propeller allows engine RPM above the specified Full Throttle Operating Range Engine is overspeeding
58. oil reaches proper level stop filling and screw in the level plug and gauge This will create an air lock to prevent excessive oil loss while drain plug is installed 6 SX Models Only Apply Volvo Penta Gasket Sealing Compound to the drain plug and tighten to 60 84 in Ib 6 8 9 5 N m Apply Volvo Penta Gasket Sealing Compound to the level plug and gauge Tighten them to 48 72 in Ib 5 4 8 1 N m 140 VPA 7743008 07 2003 Upper Gear Housing 7 DP S Models Only Apply GL5 Synthetic gear lubricant to the drain plug O ring Install and tighten drain plug to 10 15 ft Ib 14 20 N m 8 Install the sterndrive and adjust the shift system following the instructions under Sterndrive Removal and Installation 9 Ifthe sterndrive is not to be installed install the shift linkage access cover and secure with three screws Tighten the screws to 108 132 in Ib 12 15 Nm 10 After drive has been run recheck oil level Add make up oil i through gauge opening to bring oil up to the proper level some where in the range on the dipstick 33836 VPA 7743008 07 2003 141 Upper Gear Housing Specifications Description Bearing retainer ring Nut Upper driveshaft Screw Drain Single Proper Drain Dual Prop Lower to upper gear housing 3 8 16 7 16 14 Oil level gauge and plug Pinion bearing carrier Shift actuator housing Shift linkage access cove
59. studs flat side against transom Install three flat wash ers five new locknuts Lightly coat the threads of the two long screws with Volvo Penta Gasket Sealing Compound Thread the two long screws and two flat washers into the top holes of the tran som plate Tighten nuts and screws until they just contact plate and transom Do not tighten nuts and screws at this time 83 Transom Shield Assembly SX MHP 34655 34656 DR2955 84 6 Position ground wire on transom bracket stud Install washer and locknut Do not tighten nut at this time 7 Lightly coat the alignment screw threads with Volvo Penta Gasket Sealing Compound then screw them completely in only finger tight Do not tighten the alignment screws at this time 8 Tighten the six locknuts in a cross pattern starting with the two center nuts Tighten them to of 20 25 ft Ib 27 34 N m 9 Tighten the two alignment screws to 12 14 ft Ib 16 19 N m VPA 7743008 07 2003 Transom Shield Assembly SX MHP 1O ROAN ia amp Ax SS 48699 Torque Specifications with screw and washer Tighten screw securely 10 Attach transom plate ground strap to the steering arm and secure Torque Description U S Metric Nut Manifold to Transom Bracket 108 132 in Ib 12 15 Nem Shift Cable Sleeve 40 45 ft Ib 54 61 Nem T
60. to improve oil draining Allow oil to drain completely 37260 8 VPA 7743008 07 2003 General Information Power Trim Tilt Fluid Level 47564 4 Remove three screws securing the shift link access cover to access the oil level plug Fill sterndrive with Volvo Penta Synthetic Gear Lubricant SAE 75W 90 through oil drain plug hole Fill slowly to purge air Sterndrive is properly filled when the oil level appears at the oil level plug hole When filled to the proper level install oil level dipstick and the oil level plug first to prevent excessive oil loss then the oil drain plug Tighten oil level gauge plug and drain plug finger tight Note Filling sterndrive too quickly may form air pockets that will cause an inaccurate oil level reading Running the sterndrive with improper oil level will result in immediate internal damage 5 Check oil level with dipstick Oil level must appear on the blade of the dipstick Add oil if required through the dip stick hole See Adding Lubricant to Sterndrive on page 8 6 Tighten drain screw to 60 84 in Ib 6 8 9 5 N m Tighten oil level dipstick and gauge plug to 48 72 in Ib 5 4 8 1 N m 7 Install shift link access cover and tighten screws to 108 132 in Ib 12 2 14 9 N m If lubricant has been completely changed oil level must be rechecked after unit has been run and trapped air purged Improper oil level will result in serious inter
61. to 35 60 ft Ib 45 75 N m 6 Apply 3M Adhesive sealant to the groove around the steering cav ity and install a new sealing ring 7 Remove the protective back off two new foam rubber seals and place them over the holes in the gimbal housing cover 48674 8 Set the gimbal housing cover in place Install four mounting screws and tighten them to 60 84 in Ib 7 9 N m 48675 VPA 7743008 07 2003 67 Transom Shield Assembly SX MHP 48676 48694A 48696 68 9 Apply Volvo Penta Gasket Sealing Compound to two screws Install screws and washers and tighten them to 20 25 ft Ib 27 34 N m Attach ground wire to steering arm inside transom Apply Volvo Penta Grease P N 828250 to large pin Pull hydraulic arm assembly over steering arm Align holes and install large pin from top of arm Install cotter pin Spread prongs of cotter pin to secure large pin Apply Volvo Penta Grease P N 828250 to the nylon thrust washer and lower pivot post Slide nylon washer between gimbal ring and gimbal housing Align pivot post hole of the gimbal ring gimbal housing and thrust washer then slide lower support bracket into position until it is seated Apply upward pressure to gimbal ring and support bracket Use lower thrust washers as a gauge to determine how many will fit space between upper surface of support bracket and lower sur face of gimba
62. to correct opening If lines are switched trim tilt mechanism will not function properly 5 Connect the two wire pump power connector the engine wiring harness 6 Connect the three wire pump connector to the instrument cable connector 7 Fill trim tilt system with hydraulic fluid and purge air following the procedure See Filling and Bleeding Dry System on page 256 49638 Servicing Trim Tilt Cylinders Disassembly 1 Follow the instructions in the respective Transom Bracket section of this service manual and remove the trim tilt cylinders from the transom bracket 2 Before disassembling trim tilt cylinder drain remaining fluid from it by extending and retracting rod Oe 7 A Warning Wear safety glasses Turn cylinder ports down and place a container under both ports before piston is moved 49676 252 VPA 7743008 07 2003 Trim Tilt Hydraulic System 49677 49680 VPA 7743008 07 2003 Hydraulic fluid expelled from cylinder can result in injury to you and others nearby Remove cylinder pivot bushings if they are to be replaced To remove cylinder end cap clamp cylinder in a soft jaw vise Using Spanner Wrench Volvo Penta P N 3854365 unscrew cap A light tap with a mallet is often more effective than force to remove an end cap that is stuck Unscrew end cap until held by one thread then extend rod Piston is more easily withdrawn if en
63. water solution or submerge in water to find source if drive looses pressure Make repairs as nec essary and repeat test Drive must hold pressure before making vacuum test and must not loose more than 1 PSI 6 9 kPa in 3 minutes Attach a vacuum tester such as a Stevens V 34 to the oil level hole and pull vacuum to 3 5 inches of mercury 10 16 8 kPa Rotate propeller and Universal Joint shaft to check sealing If drive does not hold vacuum apply a heavy oil to seal surfaces to find source Make necessary repairs then repeat test No loss of vac uum should occur on low test If vacuum loss is not indicated increase vacuum to 14 16 inches of mercury 47 54 kPa Again apply heavy oil to find source if drive will not hold vacuum Make repairs as necessary and repeat test Drive must not loose more than 1 inch of mercury 3 4 kPa in 3 minutes Note Do not fill sterndrive with oil until it passes both pressure and vacuum tests Drives that fail either test will allow water entry when in use and cause subsequent damage to internal parts Place drive in a vertical position Remove the rear plastic cover to allow access to the oil level plug if installed Remove the oil level plug VPA 7743008 07 2003 DP S Lower Gearcase 3 Remove the dipstick at top of drive to help vent the drive Discard and dipstick O ring Replace with new one 4 Remove drain screw at the back of the gearcase Discard O ring and replace w
64. 0 84 in Ib 6 8 9 5 N m Apply Volvo Penta Gasket Sealing Compound to the level plug and gauge Tighten them to 48 72 in lb 5 4 8 1 N m 5 Install the sterndrive and adjust the shift system see Sterndrive Installation on page 230 6 Ifthe sterndrive is not to be installed install the shift linkage access cover and secure with three screws Tighten the screws to 108 132 in Ib 12 15 N m 7 After drive has been run recheck oil level Add make up oil through gauge opening to bring oil up to the proper level within range on the dipstick Anode erosion or disintegration in salt or brackish water indicates they re performing their function Anodes should be inspected and or replaced at intervals or corrosion of the drive will increase The lower gearcase has an anode located at the front of the gearcase above the anti ventilation plate Note If any anode has been reduced to two thirds its original size one third eroded it must be replaced 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 Be sure anode surface is clean to make good contact Ohmmeter should indicate a very low reading Zero If not VPA 7743008 07 2003 SX Lower Gearcase remove the anode and clean the mounting screws the anode and the area where the anode is installed Install and retest the anode Note Do not paint or otherwise coat the a
65. 1338 zi 2380 B 9 5 3740 22 0 8661 1 3 0512 ve 1360 29 6 1 2401 9 53 3750 3 8 22 23 8750 7 8 ade 0520 55 3 5 1378 ies 2420 Cc od 3770 V 22 5 8858 1 35 0513 o 1405 28 6 2 2441 9 6 3780 22 62 8906 57 64 ox 0550 54 3 57 1406 9 64 6 25 2460 D 9 7 3819 23 0 9055 1 4 0551 3 6 1417 6 3 2480 9 75 3838 23 02 9062 29 32 1 45 0570 Pn 1440 27 6 35 2500 1 4 E 9 8 3858 23 42 9219 59 64 1 5 0591 3 7 1457 6 4 2520 sich 3860 WwW 23 5 9252 ei 0595 53 at 1470 26 6 5 2559 9 9 3839 23 81 9375 15 16 1 55 0610 3 75 1476 ue 2570 9 92 3906 25 64 24 0 9449 1 59 0625 1 16 si 1495 25 6 6 2598 10 0 3937 24 21 9531 61 64 1 6 0629 3 8 1496 ite 2610 G ee 3970 X 24 5 9646 coe 0635 52 ie 1520 24 6 7 2638 be 4040 Y 24 61 9687 31 32 1 65 0649 3 9 1535 6 75 2657 17 64 10 32 4062 13 32 25 0 9843 1 7 0669 i 1540 23 6 75 2657 tee 4130 Z 25 03 9844 63 64 T 0670 51 3 97 1562 5 32 a 2660 H 10 5 4134 25 4 1 0000 1 VPA 7743008 07 2003 15 General Information Periodic Maintenance Chart 16 Service Point Gimbal Bearing Every 25 Hours or as Specified Every 50 Hours or as Specified Lubricate seasonally NOTE Do not Use a power operated grease gun Recommendations Use EP Wheel Bearing Grease or equivalent Trim Tilt Pump Seasonally check fluid level in reservoir Check for leaks and proper operation Use Volvo Penta Power Trim Tilt and Steering
66. 2 If the etched number is 5 you would SUBTRACT 0 005 in from the actual dimension in Step 2 If the etched number is 5 you would ADD 0 005 in to the actual dimension in Step 2 If the etched number is zero 0 you add or subtract nothing from the actual dimension in Step 2 Example Add Subtract 0 097 in actual dimension in Step 2 0 000 in etched number 0 on gear 0 097 in total 4 Subtract the total figure in Step 3 from a nominal dimension of 0 106 in This new total is the number of shims required to position the propshaft gear Example Subtract 0 597 in measurement to end of gear shaft 0 500 in thickness of shim fixture 0 097 in actual dimension 1 Select the correct number of shims to equal your recorded mea surement Place shims into recess of bearing cup bore Note No less than one shim but no more then three shims should be used VPA 7743008 07 2003 SX Lower Gearcase 2 Apply alight coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the bearing cup Place bearing cup on top of shims in lower gear case Screw Bearing Cup Installer Volvo Penta P N 3850616 onto Handle Volvo Penta P N 3850609 3 Slide Alignment Plate Volvo Penta P N 3850613 onto handle NOTE Use a wooden 2x4 or 2x6 to cushion forward gearcase edge Drive bearing cup in until seated 20777 Pinion Bearing Installation 1 Apply Volvo Penta Grease P N 828250 to the roller bearings and install bearings into pinio
67. 200 200 sees 248 Troubleshooting With In Line Pressure Tester 249 How to Install Tester 020 0c eee eee eee 249 System Hydraulic Tests 00 0 2c e eee 249 Test No 1 Complete Up Circuit 249 Test No 2 Pump Isolation Up Circuit 250 Test No 3 Complete Down Circuit 250 Test No 4 Pump Isolation Down Circuit 250 Servicing Motor and Pump 2 5 251 Removing Motor and Draining Reservoir 251 Separation of Reservoir and Motor 252 Separation of Pump and Manifold 255 Installation of PUMP 0 02 e eee eee ee 256 Installation of Motor and Reservoir 55 256 Installation of Pump Assembly 2000eeeeeee 257 Servicing Trim Tilt Cylinders 259 Filling and Bleeding Dry System 0055 262 Trim Cylinders sss ve ctne ene tos ede ale 262 Trim Motor and Reservoir 22000eeeeeeee 263 Hydraulic Pressure Specifications 263 Volvo Penta Thread Locking Fluid P N 1161053 Black Neoprene Dip Loctite Primer Volvo Penta Grease P N 828250 Volvo Penta Power Trim Tilt amp Steering Fluid Dexron Automatic Transmission Fluid Cleaning Solvent Dexron Automatic Transmission Fluid Cleaning Solvent Before working on any part of the trim tilt system read the section called Safety at the end of this manual W
68. 3 DP S Lower Gearcase 884789 my OWL DY S mm N l 43470 Installation lt 3855865 884789 43511 fii e E 3855865 43536 3855866 VPA 7743008 07 2003 2 Clamp a bearing separator into position to catch the tapered roller bearing Thread Puller Volvo Penta P N 884789 onto the outer propeller shaft to protect the threads Position the outer propeller shaft in a press and remove the bearing and sleeve NOTE The sleeve may require heat to break the adhesive loose Screw Puller Volvo Penta P N 884789 onto the outer propeller shaft to protect the threads and position in a press Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the bearing race Press the race into the gear using Race Installer Volvo Penta P N 3855865 Place the outer propeller shaft in a press supported by Race Installer Volvo Penta P N 3855865 Lightly oil the inside surface of the tapered roller bearing with GL 5 Synthetic gear lubricant SAE 75W 90 and place it on the outer propeller shaft tapered side up Press the bearing into place using Bearing and Sleeve Installer Volvo Penta P N 3855866 Apply Loctite Primer to the inside of the sleeve and it s position on the outer propeller shaft and allow to air dry Apply a small amount of Loctite 609 to the ou
69. 584 Gimbal Housing Disassembly gt 49082 FN 34471 Anode Replacement 70 48697A With the pivot housing pushed in towards the gimbal housing check adjustment of sending unit between pins A and C Rotate sending unit to obtain a 11 1 ohm reading on the meter then tighten mounting screws to 18 24 in Ib 2 0 2 7 N m Remove trim tilt cylinders pivot housing and gimbal ring following instructions elsewhere in this section Water Hose and Bellows Removal 1 2 Unscrew clamps and pull off the U joint and exhaust bellows Loosen clamp on upper end of water inlet hose and remove hose from water tube The sacrificial zinc anode need not be removed unless it s 2 3 deteriorated and needs to be replaced 1 2 Remove the four screws and anodes Clean the mounting surface then install the new anode and the attaching hardware Tighten the screws to 5 7 ft Ib 6 9 Nm VPA 7743008 07 2003 Transom Shield Assembly SX MHP Trim Sender Removal 1 Disconnect rubber connector at wiring harness on engine Record the position of the sending unit wires before removing Use Socket Removal Tool Volvo Penta P N 3854350 to push terminals out of rubber plug Note The use of alcohol will make socket installation into the rubber plug easier 2 Remove the retaining clip from the grommet 48677 3 Push the grommet out with a screwdriver Pull the
70. 80 Water Tube Installation 20 002s 80 Water Hose Installation 0 200 cee eee eee 80 U joint and Exhaust Bellows Installation 81 Gimbal Housing and Transom Plate Removal 82 Shift Cable Sleeve Replacement 83 Transom and Exhaust Seal Replacement 84 Gimbal Housing and Transom Plate Installation 85 Torque Specifications 000e eee eens 87 Sealants Lubricants Adhesives 0 55 88 Service Chart 2 2 ic siwisisgasereianetienes 89 Before working on any part of the transom bracket assembly read the section called Safety at the end of this manual When replacement parts are required use genuine Volvo Penta or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or passengers Some screw holes have special Heli Coil inserts that provide a thread locking feature Do not clean Heli Coi holes with a thread tap This will damage the Heli Coil inserts and force their replacement 53 Transom Shield Assembly SX MHP Special Tools Owatonna Service Tools Order From Sealants Lubricants and Adhesives 54 Tool Name Volvo P N Panel Location Drive Handle 3850609 A Driver 3854356 E Insert Tool 3854349 B Installer 3854359 E Installer 3854360 E Installer K Remover Installer 3854355 E Remover Installe
71. Coat a new O ring with Volvo Penta Gasket Sealing Compound and place it on the manifold Lubricate two new O rings with hydraulic fluid and place them on the hydraulic line tips 75 Transom Shield Assembly SX MHP 34503 34507 76 3 4 Hold the manifold as shown and attach the lines Make sure the tagged line goes in its proper location Route both lines parallel and at the angle shown Line routing is important otherwise mani fold will be difficult or impossible to install Tighten the fittings to 84 108 in Ib 9 5 12 2 N m and discard the reference tag Tagged line must attach to the correct inlet If lines are switched trim tilt mechanism will malfunction When properly connected the lower manifold line will attach to the UP inlet on the pump valve body and the upper manifold line will connect to the starboard inlet on the pump body Feed the lines through the manifold opening pulling them from inside the transom if necessary Seat the manifold over its mount ing stud Use a new locknut and tighten nut to 108 132 in Ib 12 15 N m Coat new O rings with hydraulic fluid and place them on hydraulic lines Attach the lower port line A to the manifold first then the upper one Tighten the fittings to 84 108 in Ib 9 5 12 2 N m Attach the short starboard line to the lower port B of the manifold Attach the long starboard line to the upper port C of the manifold Tighten the fittings to
72. Gearcase 6 Place Protection Sleeve Volvo Penta P N 884976 into the seals of the outer propeller shaft Slide the tube gear into place on the inner propeller shaft Remove the sleeve 43579 7 Place Protection Sleeve Volvo Penta P N 884807 into the seals of the propeller shaft housing Slide the housing into position over the outer propeller shaft with out O rings Seat the housing into the gearcase 8 Make sure the oil drain hole is facing the skeg 43571 9 Install the bearing housing retainer into position with the tab into the hole in the gearcase VPA 7743008 07 2003 211 DP S Lower Gearcase 10 Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the threads of the retaining ring Thread the retaining ring without O rings into the end of the gearcase Use Spanner Tool Volvo Penta P N 3855877 and Spline Socket Volvo Penta P N 3850598 to turn driveshaft and tighten the retaining ring This will set final rolling torque for the lower gearease Set rolling torque at 18 26 in lb 2 0 2 9 N m for 1 95 and 2 32 gear ratio sterndrives and 26 35 in Ib 2 9 4 0 N m for 1 68 and 1 78 gear ratio sterndrives Record the rolling torque measurement Gear Lash Note Verify that there is Zero end play on the vertical driveshaft and both propeller shafts before attempting to check gear lash 1 Lock the vertical driveshaft in place using Driveshaft Puller Volvo Penta P N 3855923 Tighten
73. PA 7743008 07 2003 DP S Lower Gearcase 3 Remove inlet water tube seal and retainer If seal or retainer are damaged replace them 4 Remove and discard oil passage O ring Driveshaft and Pinion Removal 1 Remove the pinion nut from the vertical driveshaft Retain the nut for shimming the vertical driveshaft 2 Remove the driveshaft bearing retainer using Spanner Volvo Penta P N 3850601 Remove and discard the O ring 3 Place Driveshaft Puller Volvo Penta P N 3855923 onto the drive shaft Tighten two Allen head set screws securely Tighten the two screws alternately to remove the driveshaft from the pinion Remove the driveshaft from the gearcase 3855923 43439 VPA 7743008 07 2003 187 DP S Lower Gearcase 4 Remove the forward gear and bearing and pinion from the gearcase 43456 Gearease Bearing and Race Removal Lower Driveshaft Bearing 1 Assemble Remover Tip Volvo Penta P N 3855859 Rod Nut and Washer Volvo Penta P N 3855860 and Guide Plate Volvo Penta 3855860 P N 3850619 Place the remover tip into the driveshaft cavity under the lip of the lower driveshaft bearing race 3850619 43457 2 Lightly oil the threads of the rod Tighten the nut and remove the lower driveshaft bearing race and shims The shims may be dam aged during bearing race removal and should be discarded Pinion Bearing Note Remove the pinion bearing onl
74. Steering Gimbal Bearing and Seal Removal 37 Gimbal Housing Cleaning and Inspection 37 Gimbal Housing Assembly 2005 38 Steering Bearing Gimbal Bearing and Seal Installation 38 Hydraulic Lines and Manifold Installation 40 Trim Sender Installation 0 00sec eee eee 41 Water Tube Installation cee eee eee 42 Water Hose Installation 0 cece eee 43 U joint and Exhaust Bellows Installation 43 Gimbal Housing Removal 2005 44 Shift Cable Sleeve Replacement 2 2 005 45 Transom and Exhaust Seal Replacement 46 Gimbal Housing Installation 47 Torque Specifications 000ee eens 50 Sealants Lubricants and Adhesives 05 51 Service Chart ccesteeiice iinan ienei 52 Before working on any part of the transom shield assembly read the section called Safety at the end of this manual When replacement parts are required use genuine Volvo Penta or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or passengers Some screw holes have special Held Coil inserts that provide a thread locking feature Do not clean Heli Coil holes with a thread tap This will damage the Heli Coil inserts and force their replacement 17 Transom Shield Assembly SX M
75. Tilt Cylinder Removal on page 18 pivot housing see Pivot Housing Removal on page 21 and gimbal ring see Gimbal Ring Removal on page 26 Water Hose and Bellows Removal 34493 Ey pei Zw Anode Replacement 34494 34 Unscrew clamps and pull off the U joint and exhaust bellows Loosen clamp on upper end of water inlet hose and remove hose from water tube The sacrificial zinc anode need not be removed unless it s 2 3 deteriorated and needs to be replaced Remove the two screws lock washers flat washers and the Clean the mounting surface then install the new anode and the attaching hardware Tighten the screws to 12 14 ft Ib 16 19 VPA 7743008 07 2003 Transom Shield Assembly SX M Trim Sender Removal 1 Disconnect rubber connector at wiring harness on engine Record the position of the sending unit wires before removing Use Socket Removal Tool Volvo Penta P N 3854350 to push terminals out of rubber plug Note The use of alcohol or equivalent will make socket installa tion into the rubber plug easier 2 Remove the retaining clip from the grommet 3 Push the grommet out with a screwdriver Pull the wires through the hole cut tie straps securing wires to the trim tilt lines and remove the trim sender 1 Remove the two screws from the water tube retainer Pull the water tube and grommet out of the gimbal housing If the grommet sticks go to the
76. Upper Gear Hous ing 34977 34979 VPA 7743008 07 2003 If the dye pattern shows contact as shown in figure 5 the shim thickness behind the double bearing box must be increased i e the drive gear is moved away from the driven gears The driven gears must be shimmed inward to maintain the correct backlash Remove the pinion bearing carrier and top cover from the upper gear housing Coat a surface of a new top cover gasket with Volvo Penta Gasket Sealing Compound Place the gasket around the upper output gear assembly Orient the tab with the hole in it over the oil circu lating passage as shown Check the position of the shims to make sure they are in position for cover installation Install the top cover and secure with four screws coated with Volvo Penta Gasket Sealing Compound Tighten the screws to 16 18 ft Ib 22 24 N m Coat a new O ring with GL5 Synthetic gear lubricant and place it in the O ring groove in the pinion bearing carrier Check the position of the plastic shims to make sure they are in position for carrier installation 129 Upper Gear Housing 5 Install the pinion bearing carrier and secure with four screws coated with Volvo Penta Gasket Sealing Compound Tighten the screws to 12 14 ft Ib 16 19 Nm 6 Install universal joints following instructions found elsewhere in this section i 42606 Shift Actuator Housing Disassembly 1 Note the position of the shift shoe f
77. ae 0980 40 5 1990 8 is 3230 P 16 67 6562 21 32 79 0312 1 32 2 5 0984 5 1 2008 8 25 3248 17 0 6693 8 0315 fe 0995 39 ar 2010 7 8 3 3268 17 06 6719 43 64 ae 0320 67 kee 1015 38 5 16 2031 13 64 8 33 3281 21 64 17 46 6875 11 16 bs 0330 66 2 6 1024 a 2040 6 8 4 3307 17 5 6890 85 0335 A 1040 37 5 2 2047 st 3320 Q 17 86 7031 45 64 ase 0350 65 2 7 1063 P 2055 5 8 5 3346 18 0 7087 9 0354 i 1065 36 5 25 2067 8 6 3386 18 26 7187 23 32 0360 64 2 75 1082 5 3 2086 oa 3390 R 18 5 7283 oh 0370 63 2 78 1094 7 64 ay 2090 4 8 7 3425 18 65 7344 47 64 95 0374 bss 1100 35 5 4 2126 8 73 3437 11 32 19 0 7480 wt 0380 62 2 8 1102 ive 2130 3 8 75 3445 19 05 7500 3 4 bee 0390 61 ase 1110 34 5 5 2165 8 8 3465 19 45 7656 49 64 1 0 0394 ae 1130 33 5 56 2187 7 32 ywi 3480 S 19 5 7677 ja 0400 60 2 9 1141 5 6 2205 8 9 3504 19 84 7812 25 32 R 0410 59 a 1160 32 ase 2210 2 9 0 3543 20 0 7874 1 05 0413 3 0 1181 5 7 2244 es 3580 T 20 24 7969 51 64 ae 0420 58 io 1200 31 5 75 2263 9 1 3583 20 5 8071 T 0430 57 3 1 1220 Jii 2280 1 9 13 3594 23 64 20 64 8125 13 16 1 1 0433 3 18 1250 1 8 5 8 2283 9 2 3622 21 0 8268 1 15 0452 3 2 1260 5 9 2323 9 25 3641 21 04 8218 53 64 m 0465 56 3 25 1279 a 2340 A 9 3 3661 21 43 8437 27 32 1 19 0469 3 64 si 1285 30 5 95 2344 15 64 es 3680 U 21 5 8465 1 2 0472 3 3 1299 6 0 2362 9 4 3701 21 83 8594 55 64 1 25 0492 3 4
78. age the three recorded feeler gauge readings by adding them together then dividing by three Example Table 2 Add Divide Slot no 1 0 017 in 0 052 in 3 0 0173 in Slot no 2 0 018 in Round off to 0 017 in Slot no 3 0 017 in Total 0 052 in 4 Loosen the pinion nut several turns Do not remove the nut Clamp the upper portion of the shim fixture in a vice Strike the nut and shaft with a mallet to loosen the pinion from the shaft Remove and discard the nut 5 Add or subtract the shimming allowance number etched on the gear from the number found in Step 3 If the number is etched 5 you would ADD 0 005 in to the number If the etched number is 5 you would SUBTRACT 0 005 in from the number If the num ber is zero 0 you would add or subtract nothing from the num ber Example Add Subtract 0 017 in figure from Step 3 0 004 in etched number 4 on gear 0 013 in shims required 6 6 Record dimension example 0 013 in for the shims required to set pinion position Note No less than one shim but no more than five shims should be used to obtain the average required shim thickness Forward Gear Shimming Note This procedure determines the amount of shims required to properly position the forward gear in relation to the pin ion Record the following shimming measurement for the final gear lash check 198 VPA 7743008 07 2003 DP S Lower Gearcase
79. ainst the anchor bracket tighten it securely DR4977 Throttle arm pin is for or Pull To Open throttle operation Check the operation of your remote control before attaching the throttle cable to the throttle arm Improper matching of the remote control throttle operation to the throttle arm will result in an engine that will accelerate when you are attempting to stop 3 Throttle arm connector must have a minimum of 9 full turns or 1 4 in of throttle cable thread engagement Install throttle arm connector onto the throttle cable Pull connector forward to remove all end play from remote control throttle cable then turn the connector in until hole aligns with the throttle arm Note If throttle arm connector hole cannot be adjusted to align DR5095 with the throttle arm check for proper cable installation in the remote control box 4 Install connector onto throttle arm Install washer and cotter pin Spread prongs of cotter pin for a secure attachment Tighten jam nut against connector 23051 240 VPA 7743008 07 2003 Trim Tilt Hydraulic System Trim Tilt Hydraulic System Table of Contents Sealants Lubricants and Adhesives Safety Warnings Special Tools Sealants Lubricants and Adhesives 5 247 Special Tools lt s 0 30 cere Pee ee eee 247 System Description 0 ccc eee eee eee 248 Reservoir Checking Filling and Bleeding 248 Troubleshooting General
80. amount of shims required to position the forward gear from the average depth measurement from Step 9 Example Subtract 0 040 in average depth from Step 9 0 009 in forward gear shims 0 031 in total 11 On later models the gear markings are on the outer propeller shaft The Rear gear marking will be found in the box with R indi cating the Rear gear etching 22459B 12 Add or subtract the shimming allowance number etched on the gear from the actual dimension in Step 10 If the etched number is 5 you would ADD 0 005 in from the actual dimension in Step 10 If the etched number is 5 you would SUBTRACT 0 005 in to the actual dimension in Step 10 If the etched number is zero 0 you add or subiract nothing from the actual dimension in Step 10 Example Add Subtract 0 031 in actual dimension in Step 10 0 002 in etched number 2 on gear 0 033 in total shims required 13 Record dimension example 0 033 in for the outer propeller shaft shims required Note Use the least number of shims possible to obtain the required shim thickness VPA 7743008 07 2003 203 DP S Lower Gearcase Oil Screen Service Upper Housing Exhaust Cover Service 43626 43626 204 Remove the oil screen from the upper gear housing Clean and replace as necessary Install the oil screen into the oil passage in the upper gear housing Make sure the screen is secure
81. an excess grease out of drain hole and drain groove Note Do not place an O ring in the drain hole groove This would prevent water draining out during winterization and could result in freeze damage 6227 78 VPA 7743008 07 2003 Transom Shield Assembly SX MHP 3 Slide a clamp onto the upper end of the hose Position the screw head so that it will be behind the port hydraulic lines as shown Push the hose onto the water tube then rotate it until the nipple points directly outward Slide the ground strap clip under the hose clamp Tighten the clamp securely Note Clamp s screw head must be behind hydraulic lines to prevent it contacting the pivot housing when drive is ina full tilt position Improper clamp position may limit tilt range and damage clamp and hose 4 Check the position of the nipple drain hole If it s not facing down loosen the nipple clamp and rotate nipple until the drain hole is facing down Tighten clamp securely 34471 U joint and Exhaust Bellows Installa tion 1 Coat the outside surface of the gimbal bearing bore with Volvo Penta Gasket Sealing Compound Sealer is not required on the outside of the exhaust opening Note Clamp s screw position is important If not properly posi tioned steering radius will be reduced because of gimbal ring contacting clamp head when turning 34475 VPA 7743008 07 2003 79 Transom Shield Assembly SX MHP Gimbal Housing and Tra
82. ank slot 47133 238 VPA 7743008 07 2003 Sterndrive Removal and Installation 11 Install flat washer and cotter pin Bend prongs of cotter pin for a 7 secure attachment Install jam nut and tighten securely bs against cube to keep cable from turning in cube OV 3995444 01 47134A 12 Reinstall shift linkage access cover and secure with three original S pa screws LJ 47557 Note V6 and V8 Carbureted Models Only The engine throttle cable anchor block bracket has several sets of anchor block holes The sets of holes marked with a V are used for Volvo Penta remote controls Check the anchor block position for your particular engine and remote control operation Change as necessary Move remote control handle to the NEUTRAL detent position Turn propeller shaft and shift into the forward gear detent position and then pull HALFWAY BACK towards NEUTRAL This positions the control for proper throttle cable adjustment Failure to follow this procedure can bind the shift linkage in the control and produce hard shifting DRC7279A 1 Align internal bosses of trunnion with throttle cable groove Press trunnion on throttle cable until seated VPA 7743008 07 2003 239 Sterndrive Removal and Installation 2 Install open end of trunnion in anchor block Install screw in anchor block and position throttle cable assembly in selected set of holes Locknut must be ag
83. ar bearing The vertical clear ance should be 0 002 0 010 in 0 05 0 25 mm If the clearance is high install a thicker nut If the clearance is low install a thinner nut The thickness of the nut can be determined by the number on the top of the nut Table 1 Number Thickness niet 0 0 000 in 3852301 2 0 008 in 3852302 4 0 016 in 3852303 6 0 024 in 3852375 4 Retighten the nut to the specified torque and measure the clear ance again Note Ifthe proper clearance is not obtainable with any of the nuts make sure the upper gear bearing and bearing sup port ring are correctly assembled If the components are correctly assembled the bearing is defective and must be replaced Pinion Bearing Carrier Installation 1 Install the predetermined plastic shims that set pinion gear posi tion on the pinion bearing carrier Do not install an O ring at this time Note Plastic shims will only fit on the pinion bearing carrier and align with the carrier bolt holes in one direction Misalign ment of the holes will destroy the shims and possibly cause the pinion gear to be out of position 2 Install the pinion bearing carrier into the upper gear housing and secure with four screws Tighten the screws to 12 14 ft Ib 16 19 N m 42605 122 VPA 7743008 07 2003 Upper Gear Housing Top Cover Shimming 1 Place 0 040 in of shims or any other amount on top of the upper bearing and re
84. arrier in a press large diameter down Press out the small bearing race 11 Place Sleeve Volvo Penta P N 884938 in a press Turn the pinion bearing carrier over and place it on the tool Press the large bear ing out using the tools in the previous step VPA 7743008 07 2003 Upper Gear Housing Upper Housing Stud Replacement Dual Prop Models Only 1 Remove the stud to be replaced 2 Apply Loctite Primer to the threads on the short end of the stud and let air dry Apply Volvo Penta Thread Locking Compound P N 1161053 to the threads Screw the stud into the housing until 1 140 1 144 in 28 95 29 05 mm remains exposed 1 140 1 144 DRC6395 Upper Gear Housing Oil Screen Remove the oil screen from the upper housing Clean and replace as necessary Install the oil screen into the oil passage in the housing Make sure the screen is secure 1 Remove the upper gear housing from the holding fixture Check the width across the thrust plates with a Vernier Caliper Make sure all space between the shims and the thrust plates are removed This is a shimmed dimension that should be greater than 5 007 inches 12 72 cm but not exceed 5 036 inches 12 79 cm Note Do not remove the thrust plates unless the dimension is incorrect If the dimension is less than 5 007 inches 12 72 cm add one shim to each side If more than 5 036 inches 12 79 cm subtract one shim f
85. ars on their convex sides A with gear marking compound as shown You can access the gears through the hole of the shift mecha nism The convex side of the gear teeth should be lightly covered from heel to toe and from crest to root Note The Sliding sleeve should not be installed during this pro 3 cedure Insert a piece of wood approximate size 1 in X 2 in X 6 in through the shift mechanism hole between the upper and lower gear cups Load the gears with the piece of wood while turning the input gear at least six times in the direction of engine rotation clockwise as viewed from the front of the drive This procedure will require the assistance of another person to turn the input gear Dismantle the gear set and compare the contact pattern to that of the picture This Picture shows the desired contact pattern for the drive side of the forward and reverse gear The drive side is the convex side of the gear The dye pattern should be nearly oval in form and be positioned half way up on the gear tooth It should be displaced towards the small end of the tooth If the dye pattern shows contact as shown in figure 4 the shim thickness behind the double bearing box must be reduced i e move the drive gear toward the driven gears The driven gears must shimmed outward the same amount to maintain the correct backlash VPA 7743008 07 2003 Upper Gear Housing lt a Se LA AA GR990876 Final Assembly of
86. as they were removed for lon gevity 5 Remove cone clutch and spring Note the word TOP on the top side of the cone clutch This must face up during reassembly 34611 6 Use Spanner Wrench Volvo Penta P N 3850604 4 to unscrew the bearing retainer ring that holds the lower gear and bearing assem bly in place Insert the tool into the housing Use two upper gear housing cover screws to secure the spring loaded arm to the top of the gear housing As the screws are turned down alternate between the two screws every two turns Seat the screws com pletely then tighten them securely Note Tighten the holding fixture securely The bearing retainer ring is tightened to 145 165 ft Ib 197 224 N m VPA 7743008 07 2003 95 Upper Gear Housing 34600 96 7 Attach a 3 4 in breaker bar to the spanner tool and break the retainer ring free 8 After it turns easily detach the spring loaded arm from the top of the housing Unscrew the retainer ring and lift it out Note Be careful removing the screws The arm is under tension 9 Remove the lower bearing and shaft assembly Remove the shims at the bottom of the housing The shims can be reused if undam aged 10 Turn the lower bearing and shaft assembly over Push up on shaft to disengage upper driveshaft C clips from ring spacer VPA 7743008 07 2003 Upper Gear Housing 11 Remove the upper driveshaft C clips and ring spacer from the shaf
87. at O ring with Volvo Penta Power Trim Tilt and Steering Fluid or Dexron Automatic Transmission Fluid Position O ring on motor 2 Place two O rings onto screws and washers and insert screws through motor Place the remaining two O rings onto the screws 3 Align the motor shaft with the two mounting screws Install the motor onto the manifold and tighten screws to 40 in Ib 5 4 N m 4 Coat anew O ring with Volvo Penta Power Trim Tilt and Steering Fluid or Dexron Automatic Transmission Fluid and place it on the manifold VPA 7743008 07 2003 Trim Tilt Hydraulic System 22881 Installation of Pump Assembly 49654 49653 VPA 7743008 07 2003 5 Align reservoir locating pin and manifold tab Install reservoir and secure with four 6 allen head screws Tighten screw to 20 25 in Ib 2 2 2 8 N m Apply Loctite Primer to two trim tilt assembly mounting screws and allow to air dry Apply Volvo Penta Thread Locking Fluid P N 1161053 to the threads Mount the trim tilt pump assembly on the bracket and secure with the two screws Tighten the screws to 120 in Ib 13 6 N m Connect the trim tilt motor to the wiring harness Attach trim tilt unit to transom with two lag screws 251 Trim Tilt Hydraulic System 4 Connect tagged hydraulic line to UP port of the manifold Con nect remaining line to unmarked outlet Tighten fittings to 84 108 in Ib 9 5 12 2 N m Tagged line must attach
88. cess cover and tighten screws to 108 132 in Ib 12 2 14 9 N m If lubricant has been completely changed oil level must be rechecked after unit has been run and trapped air purged Improper oil level will result in serious internal sterndrive damage Add make up oil through dipstick opening to bring oil up to proper level General Information Sterndrive Lubrication DP S Models Adding Lubricant to Sterndrive Occasionally check oil level in sterndrive Screw dipstick fully into hole Remove and read oil level in reference to mark on dipstick If oil level is low add oil through dipstick opening Add only enough lubricant to bring the oil level to the proper level somewhere in the range on the dipstick 33836 Sterndrive Oil Capacity Change Lubricant Every 100 Hours or Once Each Season Use Volvo Penta Synthetic Gearcase Lubricant or Mobilube 1 SHC Fully Synthetic SAE 75W 90 gear lubricant All DP S Models 81 oz 2400ml Draining and Filling Sterndrive When a complete change of lubricant is required in the sterndrive proceed as follows 1 Remove both propellers See Propeller Removal and Installa tion DP S Models on page 263 2 Place sterndrive in the run full down position Place a 4 quart drain pan under lower gear case skeg to catch oil 3 Remove the oil drain plug inside lower gear case and the oil level dipstick top of sterndrive Removing dipstick vents drive
89. cord this figure This will raise the cover enough to make a feeler gauge measurement 2 Being careful not to displace the shims install the top cover and push down lightly Take several feeler gauge readings to deter mine an average clearance Record this figure 3 The specified top cover clearance is 0 002 0 004 in 0 05 0 10 mm Take the midpoint of this range 0 003 in 0 075 mm and add it to the initial amount of shims Example 0 040 in Initial Amount of Shims Step 1 0 003 in Midpoint Of Specified Clearance 0 043 in Total 4 Subtract the dimension determined in Step 2 from the total of Step 3 The resulting figure will be the shims needed to set top cover clearance to the specified range Example 0 043 in Total of Step 3 0 027 in Clearance Measurement Step 2 0 016 in Amount Of Shims To Be Placed Under Top Cover Note Use at least one shim but no more than four shims 5 Place the correct amount of shims on top of the upper bearing Being careful not to displace the shims install the top cover and secure with four screws Tighten the screws to 16 18 ft Ib 22 24 N m Checking Gear Lash This procedure will check the relative clearance between the pinion gear and the upper and lower output gears VPA 7743008 07 2003 123 Upper Gear Housing Lower Gear 1 Attach a dial indicator to the upper gear housing Place the indica tor tip at the vertical horizontal midpo
90. crew securely VPA 7743008 07 2003 49 Transom Shield Assembly SX M Torque Specifications O e j e Nut Manifold to Transom Shield 108 132 in Ib 12 15 Nem Shift Cable Sleeve 40 45 ft Ib 54 61 Nem Steering Arm Studs 13 15 ft Ib 18 20 Nem Transom Shield Mounting 20 25 ft Ib 27 34 Nem Trim Line to Cylinder Manifold 84 108 in Ib 9 5 12 2 Nem Trim Tilt Pivot Pin 120 144 in Ib 14 16 Nem Water Nipple 96 120 in lb 11 14 Nem Alignment Inner Transom Plate 12 14 ft Ib 16 19 Nem Anode 12 14 ft Ib 16 19 Nem Cover Gimbal Housing 60 84 in Ib 7 9 Nem Pivot Housing to Gimbal Ring 105 120 ft Ib 142 163 Nem Support Bracket Gimbal Ring 18 20 ft Ib 24 27 Nem Trim Sender 18 24 in Ib 2 0 2 7 Nem Water Outlet 120 144 in Ib Bolt 14 16 Nem Steering Arm 65 72 ft Ib VPA 7743008 07 2003 88 98 Nem Transom Shield Assembly SX M Sealants Lubricants and Adhesives VPA 7743008 07 2003 Adhesives Where used Volvo Penta Thread Locking Fluid P N 1161053 Stud Gimbal Housing Lubrication Tube Stud Manifold 3M Adhesive Seal Water Passage Seal Ring Gimbal Housing Cover 3M Scotch Grip Rubber Adhesive 1300 Lubricants Seal Exhaust Opening Transom Seal Where Used Volvo Penta Greas
91. cribe in these instructions are effective methods to be followed when installing Volvo Penta stern drive products Some of these methods require the use of tools specially designed for the purpose The special tools should be used when and as recommended Special Tools Table 1 Panel Tool Name Volvo P N Location Alignment Tool 3851083 K Universal Handle 3850609 A Sterndrive Removal Special Tools Required e Hoist Capable of Lifting at Least 500 Ib 227 kg or Sterndrive Dolly e Lifting Eye 1 2 13 thread e Sterndrive Holding Fixture Note The boat must be out of the water on a trailer or in a cra dle for removal of the sterndrive When a sterndrive dolly is used for removal omit steps 1 and 2 VPA 7743008 07 2003 227 Sterndrive Removal and Installation 1 Remove and retain the three shift linkage access cover screws and cover 2 Remove dipstickdipstick from upper gear housing 43677 3 Fully thread a lifting eye into upper gear housing oil indicator hole 35056 228 VPA 7743008 07 2003 Sterndrive Removal and Installation 4 Remove jam nut 2 from shift cable Remove cotter pin 1 and washer from cube Un thread the cube 3 from the shift cable 3885444 01 5 Loosen screw securing cable anchor clamp Slide the anchor to starboard to unfasten the shift cable Turn the sterndrive to port 4 and remove the
92. d cap is left threaded one turn in cyl inder until rod is fully extended Unscrew end cap and remove piston To replace internal O ring and scraper in end cap the piston must be removed from the rod Thoroughly de grease rod and holder Clamp the piston rod assembly in a vise using Rod Holder Volvo Penta P N 3854367 Remove piston by removing bolt that secures the piston to the rod If rod slips in special tool a piece of paper or thin card will increase grip on rod Pull end cap off rod then pry scraper out of end cap and discard 253 Trim Tilt Hydraulic System 8 Remove both external and internal O rings from end cap and discard 13339 O 13330 9 Carefully remove two split ring retainers 2 and O ring 1 from piston and discard Do not remove or disassemble piston there are no service parts Reassembly 1 Clean all hydraulic cylinder components in fresh solvent Blow dry with compressed air It is essential that all components are kept 2 2 absolutely clean and dust free Any dirt on internal components could cause scoring of the cylinder bore 49688 Note Lubricate all internal components with Volvo Penta Power Trim Tilt amp Steering Fluid or Dexron Automatic Transmis sion Fluid 2 Face scraper lip toward tool and use Seal Installer Volvo Penta m P N 3854364 or socket to install new scraper in end cap 13333 254 VPA 7743008 07 2003 Trim Tilt Hydraulic System 3 Insert a n
93. d continue to see Final Propshaft Bearing Housing Shimming on page 168 33826 VPA 7743008 07 2003 165 SX Lower Gearcase Correcting When Gear Lash Measurement Is Less Than 0 005 in When Gear Lash Measurement Is More Than 0 012 in Checking Gear Contact SX Lower Unit 166 GR990868 1 If dial indicator reading is less than 0 005 in 0 13 mm or more than 0 012 in 0 30 mm all shimming operations must be remea sured If corrections are made in the rechecking of the shimming operations and a gear lash of 0 005 0 012 in 0 13 0 30 mm is obtained continue to see Final Propshaft Bearing Housing Shimming on page 168 2 If all rechecked shimming operations are the same as the original recorded shimming operations and the recorded gear lash is still less then 0 005 in 0 13 mm or more then 0 012 in 0 30 mm continue with the following procedure Subtract the gear lash measurement from 0 0085 in optimum gear lash measurement and divide by two Example Only 0 0085 in Optimum gear lash measurement 0 003 in Gear lash measurement 0 0055 in Result Divide 0 0055 in 2 0 00275 in correction needed Round off to nearest thousandths of an inch i e 0 003 in if needed This example requires the addition of 0 003 in shim under the lower driveshaft bearing cup and 0 003 in shim removed from behind the propeller gear bearing cup The optimum gear lash measurement is 0 0085 in Sub
94. d to retain upper driveshaft bearing cup Turn the gearcase so the inner propeller shaft is vertical Thread Propeller Shaft Adaptor Volvo Penta P N 3855919 onto the end of the inner propeller shaft VPA 7743008 07 2003 DP S Lower Gearcase 3 Assemble Pusher Tip Volvo Penta P N 3855921 and Tube Volvo 3855921 3855922 Penta P N 3855922 Tighten set screw securely 4 Slide the assembled tools over the inner propeller shaft Align the notch in the end of the pusher tip with the pinion nut Turn the ver tical drive shaft to help the alignment Thread Nut Volvo Penta P N 3855920 onto the adaptor and tighten enough to secure the tools to the inner propeller shaft 43432 Note Tightening the nut too much will start to pull the inner pro peller shaft out of the forward gear 5 Place Spline Socket Volvo Penta P N 3850598 onto the drive shaft Tighten the pinion nut to the figure recorded during the shimming procedure Note This procedure will ensure bearing life by setting the driveshaft rolling torque The inner propeller shaft must be pS vertical for this procedure This will ensure the forward gear and inner propeller shaft will not interfere with the ie pinion rolling torque measurement Record the following jijiji measurement for the final rolling torque setting 6 Turn driveshaft several times to ensure bearings are seated before each torque reading
95. de the fixture and rest on the three feet 43560 4 Place the forward gear assembly inside the fixture and rest it on the bearing race cay D 43563 VPA 7743008 07 2003 201 DP S Lower Gearcase 43562 43567 884976 43566 43569 202 5 Slide Shim Fixture Volvo Penta P N 3855871 down the inner driveshaft and seat it on the bearing flange 6 Slide the outer gear bearing onto the inner prop shaft and seat it on the shim fixture 7 Place Protection Sleeve Volvo Penta P N 884976 over the outer propeller shaft seals Place the outer propeller shaft onto the inner prop shaft and position it into the shim fixture Remove the seal protector 8 Spin both shafts to seat the gears Load the assembly by pressing down on the outer propeller shaft Finger tighten the three set screws to stabilize the outer propeller shaft VPA 7743008 07 2003 DP S Lower Gearcase 9 Position a depth micrometer to take a measurement from the top of the shim fixture to the machined ring on the outer propeller shaft Take a measurement by each of the three set screws Aver age the measurements by adding them together and dividing by three Example Table 4 Add Divide No 1 0 039 in 0 121 in 3 0 0403 in 43531 No 2 0 043 in Round off to 0 040 in No 3 0 039 in Total 0 121 in 10 Subtract the
96. e P N 828250 Sealants Alignment Tube Inner Transom Plate Bushing Upper Steering Post Friction Washer Pivot Housing Grommet Trim Sender Lead Nylon Bushing Trim Cylinder O ring Upper Steering Post O ring Water Nipple Pivot Pin Trim Tilt Cylinder Seal Lip Gimbal Housing Thrust Washer Lower Steering Post Thrust Washer Pivot Bolt Thrust Washer Upper Steering Bearing Gimbal Bearing Driveshaft Where Used Volvo Penta Gasket Sealing Compound P N 1161099 Alignment Screw Transom Plate Gimbal Housing Lip U joint Bellows Lubrication Tube O ring Hydraulic Manifold O ring Shift Cable Tube Pivot Housing Lip U joint Bellows Pivot Pin Threads Trim Tilt Seal Case Gimbal Housing Studs Gimbal Housing 51 52 Transom Shield Assembly SX M Service Chart A 3M Scotch Grip rubber adhesive 1300 B Volvo Penta P N 1141644 grease C Volvo Penta P N 1161099 gasket 60 84 in Lb sealing compound 65 72 ft Lb Nem D 3M Adhesive 88 98 Nem E Volvo Penta P N 1161053 Thread 13 15 ft Lb Locking Compound 18 20 Nem F Marine Wheel Bearing Grease 120 144 in Lb PA 14 16 Nem 40 45 ft Lb 108 132 in Lb 54 61 Nem 12 15 Nem 20 25 ft Lb g 84 108 in Lb 0 9 5 12 2 Nem 27 34 Nem A 105 120 ft Lb 142 163 Nem 12 14 ft Lb 16 19 Nem SD LN B o 18 20 ft Lb P 24 27 Nem Lore in Lb 2 0 2 7 Nem 96 120 in Lb 1 14 Nem
97. e Volvo 3855921 3855922 Penta P N 3855922 Tighten set screw securely 3 Thread Propeller Shaft Adaptor Volvo Penta P N 3855919 onto the end of the inner propeller shaft 3855919 43433 4 Slide the assembled tools over the inner propeller shaft Align the notch in the end of the Pusher Tip with the pinion nut Turn the sterndrive shaft to help the alignment Seat the tools onto the for ward gear Place Spline Socket Volvo Penta P N 3850598 onto the vertical driveshaft Loosen the pinion nut several turns but do not remove it at this time 43436 VPA 7743008 07 2003 185 DP S Lower Gearcase 5 Apply grease to the end of the tube Thread Nut Volvo Penta P N q 3855919 3855920 onto the adaptor Tighten the nut to remove the inner propeller shaft from the forward gear Remove the tools from the shaft 3855920 D cg 43434 6 Place Pusher Tip Volvo Penta P N 3855921 in a press with the notch facing down Place the inner propeller shaft into the Pusher Tip Thread a used rear propeller nut onto the shaft to protect the threads Press the small tapered bearing off the shaft Remove the shims They may be reused if they are not damaged 43441 Water Tube Guide and Anode Removal 1 Remove inlet water tube and grommet Discard grommet 2 Remove anode and inspect it if anode is 2 3 its original size 1 3 deteriorated replace it 43443 186 V
98. e cylinder and set aside to drain 6 Remove the ground wire and hydraulic lines from the remaining cylinder 48625 VPA 7743008 07 2003 19 Transom Shield Assembly SX M Trim Tilt Cylinder Installation 1 Remove the remaining E clip and washer form the pivot pin the pivot pin then coat it with Volvo Penta Grease P N 828250 Replace the gimbal ring s bushings if they re damaged then slide 48638 the pivot pin through the cylinders and gimbal ring 2 Center the pivot pin Install both washers and E clips 3 Place a new O ring on the trim tilt cylinder line fittings and attach lines to cylinder Tighten line fittings to 84 108 in Ib 9 5 12 2 N m 4 Install pivot pin caps 20 VPA 7743008 07 2003 Transom Shield Assembly SX M 5 Attach ground wires to front of trim tilt cylinders Tighten screws securely Note To fill and bleed the trim cylinders and trim motor reser voir see Filling and Bleeding Dry System in Trim Tilt Hydraulic System section of this manual Remove the sterndrive following the procedure in Sterndrive Removal and Installation section in this manual 1 Turn Sterndrive to port Loosen anchor clamp screw and slide clamp to starboard disengaging the remote control shift cable 34616a 2 Remove shift cable from the pivot and gimbal housing Remove the small and large seals From inside of boat pull shift cable out of the sleeve and connector assembly 34617 3 Turn th
99. e eee eee eee 129 Checking Gear Lash 2000 e eee eee eee 129 Lower Gear eect is ee ee epee ee ete eds 130 Correcting Gear Lash 000 e eee eee eee 131 Checking the Gear Teeth Contact Pattern 134 Final Assembly of Upper Gear Housing 135 Shift Actuator Housing Disassembly 136 Shift Actuator Housing Assembly 2 005 138 Shift Actuator Housing Installation 140 Shimming Shift Actuator Housing 2 5 140 Assembly of Sterndrive 0 00 eee e eee eee eee 142 Pressure and Vacuum Testing Sterndrive 143 Pressure Testing 2000s cece cece eee eee eens 144 Sterndrive Filling 00 cece eee eee eee 144 Specifications aiar 08s ie isos veneer ein 148 Sealants Lubricants and Adhesives 149 Service Chart i552 toe seek wow eee eee et 150 Before beginning work in this section read Safety chapter at end of this manual When replacement parts are required use genuine Volvo Penta Failure to do so may result in product malfunction and possible injury to the operator and or passengers Several of the following procedures require use of an arbor or hydraulic press Always wear safety glasses when using this device to perform these procedures 89 Upper Gear Housing Special Tools Tool Name Volvo Penta Panel Location P N Assembly Tool 884932 F Bracket Assembly 3850057 J Disassembly Tool 884933 F D
100. e gimbal to port and remove the two screws holding the trim sender Do not attempt to pull out the sender as its leads are secured to the transom shield 19475 VPA 7743008 07 2003 21 Transom Shield Assembly SX M 4906 J Ca Y lt 34531 48616 22 4 Disengage the U joint bellows from the lip of the pivot housing and push it inside 5 Wear safety glasses Use Retaining Ring Pliers Volvo Penta P N 3850608 to remove the retainer from inside of the exhaust boot then push the boot inside the housing 6 Unscrew the nut securing the water hose nipple and push the nip ple through the housing as far as possible 7 Turn gimbal ring to the starboard Remove screw and both ground straps VPA 7743008 07 2003 Transom Shield Assembly SX M 8 Use a 1 2 in hex drive wrench or socket and remove both pivot pins as Pivot Housing Disassembly 1 Remove and discard the cooling passage O ring e 34521 2 Inspect the nylon friction washer on the pivot bosses Peel them off and discard them if they re damaged Remove and inspect the thrust washer underneath 12961 Cleaning and Inspection Clean housing in solvent and dry thoroughly Remove sealer and or adhesive from the cooling passage opening U joint bellows opening and pivot bosses Note Clean screw holes with solvent only A thread tap would damage the Heli Coil inserts and force their replacement
101. e of gear case skeg and oil level gauge at top of drive Remove the oil level plug at the back of the gearcase VPA 7743008 07 2003 137 Upper Gear Housing Pressure Testing Vacuum Testing Sterndrive Filling 138 47119 1 Attach a pressure tester Such as a Stevens S 34 to oil level hole and pressurize drive to 3 5 PSI 20 7 34 5 kPa Rotate propeller shaft and universal joint shaft to check sealing If pressure loss is indicated use a soapy water solution or submerge drive in water to find source Make necessary repairs then repeat test 2 If pressure loss is not indicated increase pressure to 16 18 PSI 110 124 kPa Again use a soapy water solution or submerge in water to find source if drive looses pressure Make repairs as nec essary and repeat test Drive must hold pressure before making vacuum test and must not loose more than 1 PSI 6 9 kPa in 3 minutes 1 Attach a vacuum tester such as a Stevens V 34 to oil level hole and pull vacuum to 3 5 inches of mercury 10 16 8 kPa Rotate propeller and universal joint shaft to check sealing If drive does not hold vacuum apply a heavy oil to seal and gasket surfaces to find source Make necessary repairs then repeat test No loss of vacuum should occur on low test 2 If vacuum loss is not indicated increase vacuum to 14 16 inches of mercury 47 54 kPa Again apply heavy oil to find sou
102. e upper gear housing Install a cotter pin into the pivot pin between the washer and bellcrank Bend the ends of the cotter pin for a secure attachment 47113 Pinion Bearing Carrier Assembly 1 Place the pinion bearing carrier in a press with the large opening up Lightly oil the outside diameter of the small bearing race with GL5 Synthetic gear lubricant SAE 75W 90 and set it in the carrier Press the race in until it seats using Assembly Tool Volvo Penta lt G 9991801 P N 884932 5 large diameter up and Shaft Volvo Penta P N 9991801 3 884932 VPA 7743008 07 2003 107 Upper Gear Housing 2 Turn the pinion bearing carrier over and set it in the press Lightly oil the outside of the large bearing race with GL5 Synthetic gear lubricant SAE 75W 90 and set it in the carrier Assemble the spe cial tools used in the previous step with the large diameter of Assembly Tool Volvo Penta P N 884932 facing down Press the race in until it seats 884932 34682 3 Coat the pinion gear shaft with GL5 Synthetic gear lubricant SAE 75W 90 and set it in the press Protect the gear teeth Position the large tapered roller bearing on the input gear and press it until it seats using Drift Volvo Penta P N 884263 34680 4 Place a new pretension sleeve on the input shaft Note A new pretension sleeve must be used to achieve proper rolling torque 34679 108 VPA 7743008 07 2003 Upper Gear Housing
103. earcase 3 8 16 22 24 ft Ib 30 33 Nem 7 16 14 32 40 ft Ib 43 54 Nem Oil level dipstick and plug 48 72 in lb 5 4 8 1 Nem Shift Lever Access Cover 108 132 in Ib 12 15 Nem VPA 7743008 07 2003 223 DP S Lower Gearcase Sealants Lubricants and Adhesives 224 Table 6 Type Chemical Where Used Primer Loctite Primer Exhaust cover screws Magnet screw Outer propeller shaft sleeve Vertical driveshaft sleeve Upper gear housing stud Adhesive Volvo Penta Thread Locking Fluid Exhaust cover screws P N 1161053 Magnet screw Outer propeller shaft sleeve Vertical driveshaft sleeve Upper gear housing stud 3M Gasket Adhesive yellow Exhaust cover seal Lubricants Volvo Penta Grease P N 828250 All Seal lips Shim ring propshaft bearing housing GL 5 Synthetic Gear Lubricant All bearings gears SAE 75W 90 Threads retainer ring All O rings Sealants Volvo Penta Gasket Sealing O D all metal case seals Compound Dipstick and plug gearcase oil level Screw drain Screws lower to upper gearcase Screw propshaft bearing hous ing retainer Seal water tube O D all rubber case seals VPA 7743008 07 2003 DP S Lower Gearcase Service Chart D gee ZF i S G SS 2 es i Wp 72 87 ft Lb 98 118 Nem _ _ a _ _ _ ss ae
104. earing until it seats Note This procedure determines the amount of shims required to properly position the pinion in relation to the propshaft gear Record the following shimming measurement for the final gear lash check VPA 7743008 07 2003 SX Lower Gearcase 1 Clamp Spline Socket Volvo Penta P N 3850598 into a vice and slide driveshaft into socket Install small bearing cup onto bearing Slide Pinion Shim Fixture Volvo Penta P N 3855098 onto drive shaft with the three slots facing threaded end of driveshaft 33850 2 Install pinion and pinion nut Tighten pinion nut to150 160 ft Ib 203 217 N m Rotate shim fixture to seat bearing for shimming purposes 33813 3 Check all three slots with feeler gauge and record each reading Average the three recorded feeler gauge readings by adding them together then dividing by three Example Table 2 Add Divide Slot no 1 0 011 in 0 028 in 3 0 0093 in Slot no 2 0 009 in Round off to 0 009 in 33812 Slot no 3 0 008 in Total 0 028 in 4 Remove pinion gear and discard the nut 5 Add or subtract the shimming allowance number etched on the gear from the number found in Step 3 If the number is etched 5 you would add 0 005 in to the number If the etched number is 5 you would subtract 0 005 in from the number If the number is zero 0 you would add or subtract nothing from the number
105. engine This includes engine servic ing procedures to keep the engine in prime operating condition Complete disassembly and overhaul such as major service or rebuilding a unit It is important to determine before disassembly just what the trouble is and how to correct it quickly with minimum expense to the owner When repairing an assembly the most reliable way to ensure a good job is to do a complete overhaul on that assembly rather than just to replace the bad part Wear not readily apparent on other parts could cause a malfunction soon after the repair job Repair kits and seal kits contain all the parts needed to ensure a complete repair to eliminate guesswork and to save time Repair time can also be minimized by the use of special tools Volvo Penta Special Tools are designed to perform service procedures unique to the product that cannot be completed using tools from other sources They also speed repair work to help achieve service flat rate times In some cases the use of substitute tools can damage the part Note Do not operate engine out of water even momentarily If operated in test tank use proper test wheel Failure to do so can damage water pump overheat engine or allow excessive engine RPM Proper preparation is extremely helpful for efficient service work A clean work area at the start of each job will minimize tools and parts becoming misplaced Clean an engine that is excessively dirty before work starts C
106. er when boat is operated in REVERSE 261 Propellers Left Hand Rotation SX Models All SX models covered in this manual have a sterndrive capable of both right and left hand rotation Left hand rotation is accomplished in the remote control Refer to the installation instructions of the remote control for this information The propeller propeller shaft and vertical driveshaft are the only parts that rotate to the left The engine always rotates to the right Right hand rotation propellers rotate clockwise as viewed from the rear of the boat to propel a boat forward Right hand propellers are considered standard rotation propellers To identify a right hand rotation propeller note the angle of the blade as viewed from the port side This propeller is used on single engine boats or on the starboard engine of a twin engine boat Left hand rotation propellers rotate counterclockwise as viewed from the rear of the boat to propel a boat forward Left hand propellers are considered counter rotation propellers To identify a left hand rotation propeller note the angle of the blade as viewed from the port side This propeller is used ONLY on the port engine of a twin engine boat A Never interchange a right hand rotation propeller with a left hand rotation propeller This would result in the boat being propelled in reverse when the motors are operated in forward gear and forward when the engin
107. es are oper ated in reverse gear After having the propellers remote control or shift cables serviced shift into FORWARD or REVERSE at idle speed to determine if the boat moves in the direction indicated by the position of the control handle If A q the boat moves OPPOSITE the direction indicated by control handle check for correct propeller and check installation and adjustment of the remote control and shift cables A Failure to perform the above test could result in loss of boat control Propeller Selection DP S The selection of propellers is essential for obtaining the best performance from a boat equipped with a DP S sterndrive Volvo Penta offers a selection of twin propeller sizes for use with the DP S product line Propellers are available in both aluminum and stainless steel Restriction on the use of specific propellers sometimes apply DP S propellers are coded D for aluminum propellers and F for stainless steel A number follows the letter As the number increases the pitch increases The opposite is also true as the number decreases so does the pitch The sets of propellers have been factory matched to provide optimum performance on a given engine sterndrive combination The propellers are sold as sets and must not be mixed Actual on water testing of the boat is recommended as the only way to accurately determine the best engine and propeller combi
108. esult in damage to the transom shield and sterndrive The gimbal bearing is lubricated by a grease fitting located on the starboard side of the gimbal housing Volvo Penta recommends that lubrication of the gimbal bearing be done with sterndrive removed This will allow observation of old grease as it s being replaced by the new If there is evidence of water the bearing should be inspected and replaced Lubricate gimbal bearing with EP Wheel Bearing Grease or equivalent Apply grease until all old grease has been removed and new grease appears The sterndrive must be removed to lubricate the universal joint shaft splines When the sterndrive is removed wipe old grease and dirt off universal joint shaft splines then thoroughly clean splines before applying new grease The universal joint shaft splines 2 must be lubricated with Moly Lubes grease or equivalent and light oil applied to the shaft O rings 1 The bellows should be checked for damage and deterioration Replace if necessary Engine alignment must also be checked See Sterndrive Removal on page 227 A All antifouling paints that prevent marine growth are poisonous and may harm our marine environment The legislation concerning antifouling paints has changed in many countries and others have announced coming changes in their legislation In general the legislation is or will be considerable more restrictive as far as the allowed leakage of the active ingredients in the pain
109. ew O ring inside end cap and place a new O ring around end cap Lubricate O rings with trim tilt fluid 13336 4 Place a new O ring 1 on piston and lubricate it with trim tilt fluid Position split ring retainers 2 on either side of O ring making sure ends match as shown The retainers are fragile and easily dis torted or broken Take care while installing them CORRECT 7 INCORRECT DR1737 5 Lubricate internal O ring scraper and piston rod Slide end cap onto rod 49686 6 Clamp rod in a vise with Rod Holder Volvo Penta P N 3854367 3854367 or Attach piston and rod secure with bolt Tighten bolt to 63 87 ft lb 85 118 N m VPA 7743008 07 2003 255 Trim Tilt Hydraulic System O 49673 49674 Filling and Bleeding Dry System Trim Cylinders Trim Motor and Reservoir 256 49675 7 Clamp cylinder trunnion in soft jaw vise Lubricate cylinder bore piston and O ring with trim fluid Compress split ring retainers with your fingers and push piston rod into cylinder bore 8 Push piston rod all the way down into the cylinder Fill the cham ber with Power Trim Tilt amp Steering Fluid or Dexron II Automatic Transmission Fluid 9 Thread end cap into cylinder and tighten using Spanner Wrench P N 912084 Tighten end cap to 25 30 ft Ib 84 41 N m Rotate eyelet hole until it s parallel to trim tilt rod hole in base of cylinder 10 Attach trim tilt cylinders to transom bracket
110. f the other bearing If bushing around upper steering post is damaged it can be removed by splitting it down one side with a sharp tool Note When replacing steering post bushing check upper bear ing inside gimbal housing to see if it also needs replace ment If upper steering post bushing was removed lubricate inside diam eter of a new bushing with Volvo Penta Grease P N 828250 and place bushing on top of steering post Install steering arm and cen ter bolt Tighten center bolt until bushing seats then remove cen ter bolt and steering arm Coat a new O ring with Volvo Penta Grease P N 828250 and place it around the base of the upper steering post Coat the thrust washer with Volvo Penta Grease P N 828250 and set it over the upper pivot bearing inside the top of the gimbal housing From inside of boat position steering arm over the thrust washer VPA 7743008 07 2003 Transom Shield Assembly SX M 3 Guide gimbal ring steering post up engaging steering arm and install center bolt finger tight Note When the gimbal ring is properly centered in the upper bearing the gimbal studs must be flush or above the top of the steering arm when the bolt is finger tight If the studs are not at the position described the upper bearing will be damaged when the center bolt is tightened 48627 4 Tighten the center bolt to 65 72 ft Ib 88 98 N m 5 Place the washer on top of the steering arm Insta
111. following procedure in Transom Bracket section Attach cylinders to sterndrive following procedure in Sterndrive Removal and Installation section 11 Fill and bleed reservoir and trim system See Filling and Bleed ing Dry System on page 256 If trim components have been disassembled or are known to be empty follow this filling and bleeding procedure 1 Move trim rods to their fully retracted down position 2 Unscrew cylinder end caps and fill the low volume chambers with Power Trim Tilt amp Steering Fluid or Dexron Automatic Transmis sion Fluid Install cylinder end caps and tighten to 25 30 ft Ib 34 41 N m 3 Install trim cylinders and securely attach hydraulic lines 1 Mount motor and reservoir assembly on transom Securely attach hydraulic trim lines 2 Remove reservoir cap Fill reservoir with Power Trim Tilt amp Steer ing Fluid or Dexron Automatic Transmission Fluid until level reaches the MAX line 3 While continuing to fill reservoir activate trim in UP direction Make several stops as drive raises to give fluid time to stay close to the MAX line Continue this fill stop fill sequence until trim rods are fully extended and drive is in full tilt position 4 Add fluid until it s level with the MAX line then install and tighten the cap VPA 7743008 07 2003 Trim Tilt Hydraulic System 5 Run drive through a minimum of five up and down cycles to purge air Top off
112. for reference and note their direction of routing 72 VPA 7743008 07 2003 Transom Shield Assembly SX MHP 6 Unscrew both lines then discard the fitting O rings Remove the AN manifold O ring and discard it 34503 Steering Bearing Gimbal Bearing and Note Do not remove the gimbal bearing or upper steering bear Seal Removal ing unless they need to be replaced Removal of the gim bal bearing and seal do not require disassembly of the transom bracket Access can be gained by going through the U joint bellows on an assembled transom bracket 1 Use a three jaw puller such as Owatonna Tool P N 1176 to pull out the gimbal housing bearing Spread the tool jaws between the bearing and inner seal and expand them tightly behind the bear ing Remove and discard the bearing 2 Pull the inner seal out in a similar manner and discard it 3 Remove the thrust washer from around the top of the upper steer ing bearing Use Installer Volvo Penta P N 3854360 and Driver Volvo Penta P N 3854356 to remove the bearing Insert the driver into the installer and position the tool underneath the bearing as shown Drive the bearing up and out of the bracket 34504 Gimbal Housing Cleaning and Inspec Clean grease and sealer from bearing cavity seal seat and manifold tion cavity Check inner bore diameter for scoring or discoloration that indicates a spinning bearing e Pivot Bearing Inspect Teflon surface for wear or cor
113. ft from the pinion bear ing carrier 5 Wear eye protection Remove the seal C clip from the pinion bearing carrier by using Retaining Ring Pliers Volvo Penta P N 3850608 5 6 Place Sleeve Volvo Penta P N 884938 2 large diameter up ina press Place a rag inside the tool to protect the gear during disas sembly Place pinion bearing carrier into the tool gear side down Press out the input gear using Drift Volvo Penta P N 884266 8 34630 7 Remove the pretension sleeve from the input gear shaft and dis card it Note Pretension sleeves must not be reused Proper rolling torque cannot be achieved with a used pretension sleeve VPA 7743008 07 2003 101 Upper Gear Housing 884266 102 34693 9991801 884933 34692 8 Clamp the input gear and bearing in a bearing separator placing the curved side of the jaws behind the bearing Remove the gear from the bearing using Drift Volvo Penta P N 884266 Note Do not remove the bearing from the input gear unless it is damaged Removal will destroy the bearing When replac ing any tapered roller bearing the corresponding bearing race must also be replaced 9 Place pinion bearing carrier in a press with the seal facing down Press out the seal and roller bearing using Drift Volvo Penta P N 884263 10 Install Disassembly Tool Volvo Penta P N 884933 on to the end of Shaft Volvo Penta P N 9991801 Place the pinion bearing c
114. g Position Bearing Installer Volvo Penta P N 3855861 in a press with the recessed side up Place the bearing on top of the installer Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the inside surface of the bearing Press the gear into position until it seats 3855861 43477 Driveshaft Service Removal NOTE Bearings should not be removed unless they are to be replaced Removal will damage the bearings 1 Note size position and direction of taper of the driveshaft bear ings for installation Using a bearing separator and a press remove both bearings 43478 2 Clamp a bearing separator onto the driveshaft so it will catch the sleeve and place in a press Thread an old pinion nut onto the driveshaft to protect the threads and press the sleeve from the driveshaft NOTE The sleeve may require heat to break the adhe sive loose VPA 7743008 07 2003 195 DP S Lower Gearcase Installation 43481 3855869 3850617 43501 Magnet Service Removal 43493 196 Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the I D of the small bearing Protect threads of driveshaft by plac ing Sleeve Installer Volvo Penta P N 3855869 onto driveshaft Slide bearing onto driveshaft with taper facing pinion end Rest Bearing Installer Volvo Penta P N 3850617 on open jaws of a press support Position raised lip of Installe
115. g Marine Wheel Bearing Grease Gimbal Bearing Driveshaft Sealants Volvo Penta Gasket Sealing Compound P N 1161099 Alignment Screw Transom Plate Gimbal Housing Lip U joint Bellows Lubrication Tube O ring Hydraulic Manifold O ring Shift Cable Tube Pivot Housing Lip U joint Bellows Pivot Pin Threads Trim Tilt Seal Case Gimbal Housing Studs Gimbal Housing 86 VPA 7743008 07 2003 Transom Shield Assembly SX MHP Service Chart A 3M Scotch Grip rubber adhesive 1300 B Volvo Penta Grease P N 828250 20 25 ft Lb C Volvo Penta gasket sealing com cen pound P N 1161099 conan D 3M Adhesive Goosen 0O A E Volvo Penta Thread Locking re ene Fluid P N 1161053 18 20 Nem F Marine Wheel Bearing Grease 120 144 in Lb a 14 16 Nem 40 45 ft o 54 61 Nem 20 25 ft Lo s 27 34 Nem ff Z f 108 132 in Lb l P1218 Nem 84 108 in Lb o 9 5 12 2 Nem 105 120 ft Lb 142 163 Nem 42 14 ft Lb Pi N 16 19 Nem pn xs as pi E l DAAT Nen a FY atv 96 120 in Lb 1 14 Nem DRC7453 VPA 7743008 07 2003 87 Upper Gear Housing Upper Gear Housing Table of Contents Safety Warnings VPA 7743008 07 2003 Special Tools eede riana ee Vad we a 96 Sealants Lubricants and Adhesives 055 96 Sterndrive Removal 002 cece eee eee 97 Sterndrive Disassembly 000 00e006 97 Upper Gear Housing D
116. g Clean off magnet and let vertical drive drain completely before removing the lower gear case 21141 VPA 7743008 07 2003 147 SX Lower Gearcase 4 Use the trim tilt system to raise sterndrive to the full tilt up position A Caution Be prepared to support the lower gear case When the last screw retaining the lower gear case to the upper gear housing is removed the lower gear case will be free to drop down 5 Remove six screws two on either side and two aft Pull off lower gear case assembly and mount it into a suitable holding fixture 6 Mark the location of the trim tab if one is used with a felt tipped marker for future reference Remove the trim tab screw and trim tab 34130B Lower Gearcase Disassembly Propshaft Bearing Housing Service 1 Remove screw and inner propshaft bearing housing retainer 21491A 2 Remove propshaft bearing housing set screw using a Torx T 27 bit 20553 148 VPA 7743008 07 2003 SX Lower Gearcase 3 Using Propshaft Bearing Housing Remover installer Volvo Penta P N 3850707 unscrew propshaft bearing housing counter clock wise Note Care must be used to prevent damaging the propshaft bearing housing threads Damaged bearing housing threads can damage the internal gearcase threads making removal of the bearing housing difficult or impossible 20551 4 Remove clean and inspect shim It may be reused if it s not dam
117. g This will trap any oil as the fitting is loosened Spray could cause eye injury Catch any oil with a shop cloth and drip pan 1 Before disconnecting any hydraulic lines tag the line connected to the port marked UP for identification This test will provide running and stall PSI for the trim out tilt up circuit 1 Disconnect hydraulic line from the UP port of the pump manifold 2 Connect tester hydraulic line to UP port in pump manifold and to outlet A on tester body 3 Connect hydraulic line removed from the UP port to opening B in tester body 4 Open tester shut off valve one to two turns Do not open more than two turns valve retaining ring may unseat and cause hydraulic fluid spray 5 Run drive through a complete trim out tilt up cycle Record run ning and stall PSI and compare to specifications 243 Trim Tilt Hydraulic System Test Results Test No 2 Pump Isolation Up Circuit Test Results Test No 3 Complete Down Circuit Test Results Test No 4 Pump Isolation Down Cir cuit 244 If system fails to meet specifications perform Test No 2 This test will isolate the pump manifold trim out tilt up components from the trim cylinders It will help determine whether defective components are in the pump manifold or in the trim tilt cylinders 1 Follow Steps 1 5 under How to Install Tester and connect the tester as described in Test N
118. g Installer 3855861 M Shim Fixture 3855870 M Bearing Installer 3855928 L Shim Fixture 3855871 M Dismantling Tool 884803 L Shim Fixture 3855872 M Drift 884143 L Sleeve Installer 3855869 M Driveshaft Puller 3855923 L Spacer 3855867 M Fill Adaptor 3855932 L Spanner Wrench 3850601 H Front Propeller 3855876 L Spanner Tool 3855877 L Remover Installer Guide Plate 3850619 G Spline Socket 3850598 H Guide Plate 3855863 M Standard Shaft 9991801 H Installation Tool 884975 L Support Base 3855926 L Lash Tool 3855873 M Tube 3855922 L Nut 3855920 L Pinion Nut Holder 3855930 L Note Special tools are available from Volvo Propeller Shaft Adap 3855919 L Penta Parts individually or in service level kits The Level 1 Kit Volvo Penta tor P N 3855955 includes all the tools nec Protection Sleeve 884807 L essary to properly disassemble and reassemble the DP S lower gearcase Protection Sleeve 884976 L for reseal and inspection The Level 2 Kit Volvo Penta P N 3856041 3 con Puller 884832 M tains all the fixtures required to prop Puller 884789 L erly shim the DP S lower gearcase when bearings or gear sets have been Pusher Tip 3855921 L changed The Level 2 Kit must be used in conjunction with the Level 1 Kit to Race Installer 3855864 M disassemble shim and reassemble the Race Installer 3855865 M DP S lower gearcase Race Remover 3855862 M Remover and Installer 3855868 M Tip Remover Tip 3855859 M VPA 7743008 07 2003 181 DP S Lower Gearcase
119. h GL5 Synthetic gear lubri cant Install the needle bearings onto the upper driveshaft with the same top to bottom orientation as when disassembled to ensure longevity New bearings can be installed with either end up Push the bearing all the way into the gear and bearing assembly 4 Place the ring spacer on to the upper driveshaft with the recess facing up 116 VPA 7743008 07 2003 Upper Gear Housing Lower Output Gear Installation 34963 VO isa sS I VPA 7743008 07 2003 34964 5 6 1 2 Place the two upper driveshaft C clips into the groove on the drive shaft Move the driveshaft down to capture the C clips in the recess of the ring spacer Place the required amount of shims determined in a previous step into the upper gear housing Rest the shims on the ledge at the bottom of the bore as shown 117 Upper Gear Housing 34959 FJ WwW lt 42583 42603 118 3 Place the lower output gear assembly into the upper gear housing and rest it on the shims Do Not let the driveshaft drop down into the housing 4 Loosen the locking screw and adjust the height of the fixture shaft to engage the upper driveshaft This will now support the upper driveshaft and retain the C clips Note Failure to support the driveshaft will allow the C clips to fall out Removal of the output gear assembly will be required to reinstall the C clips 5 Lig
120. h side up ina press Position the housing on the base Place Seal and Bearing Remover Volvo Penta P N 3855924 with Standard Shaft Volvo 3855924 Penta P N 9991801 into the propeller shaft housing Press out and discard the bearing and seals 9991801 3855926 43446 2 Push Race Remover Volvo Penta P N 3855862 until it snaps into z position behind the bearing race 3855862 D p 43447 3 Position the housing onto the base Use Puller Volvo Penta P N 9991801 884789 to press the race out of the housing 3855924 3855926 43475 Installation 1 Place Support Base Volvo Penta 3855926 notch side up in a press Position the housing on the support Apply a light coating of GL 5 Synthetic gear lubricant SAE 75W 90 to the outside surface of the bearing race Position the race into the propeller shaft hous ing Press the race squarely into the housing until it seats using Race Installer Volvo Penta P N 3855864 190 VPA 7743008 07 2003 DP S Lower Gearcase 2 Turn the housing over and set it on the support base Apply a light coating of GL 5 Synthetic gear lubricant SAE 75W 90 to the out side surface of the bearing Place the bearing into the housing amp 3855925 numbered side facing up Use the large diameter end of Seal and Race Installer Volvo Penta P N 3855925 8 to install the bearing Press the bearing squarely into the housing until the tool seats 3855926 43462
121. he down position Sterndrive must be in a full trim in position before adjusting the trim send ing unit 1 Turn steering wheel to full port for access to trim gauge sending unit Loosen trim gauge sending unit screws on starboard side of gimbal ring ____ 19514 2 Unplug the trim sending unit connector from the wiring harness Connect an ohmmeter to the connector Rotate trim gauge send ing unit to obtain a 11 1 ohm reading on the ohmmeter 3 3 Tighten trim gauge sending unit screws to 24 in lb 2 7 N m 42584 Shift and Throttle Cable Installation 1 Ifthe remote control shift and throttle cables are installed in the remote controls proceed to Check Remote Control Shift Cable Stroke 2 If the remote control shift and throttle cables have not been installed refer to the installation instructions of the remote control for installation of the shift and throttle cables Note Check installation of shift cables Shift cable should PULL for forward gear on right hand rotation SX and DP S propeller applications Shift cable should PUSH for forward gear on left hand rotation SX propeller appli cations This change is accomplished by cable installation in the remote control box Check Remote Control Shift Cable Stroke 1 Move remote control handle to the wide open throttle position in the direction needed to retract the shift cable Pull out cable core wire to remove end play Mark cable core
122. he etched number is zero 0 you ADD or SUBTRACT nothing to from the feeler gauge measurement taken in Step 1 Example Add Subtract Feeler Gauge Measurement Shimming Allowance Etched On Gear Amount Of Shims Required Note All mating thrust and bearing faces must be clean Shims to be used during assembly must be clean and undam aged No less than one shim but no more than four shims should be used 114 VPA 7743008 07 2003 Upper Gear Housing Pinion Bearing Carrier Shimming 3850600 VPA 7743008 07 2003 34978 34888 1 Position Shim Fixture Volvo Penta P N 3850600 on top of the pin ion gear recessed side facing up Using a vernier caliper or depth micrometer measure the actual dimension from the top of the tool to the surface of the pinion bearing carrier Measure in several places then take an average Stay away from the bolt holes to get an accurate reading Subtract 0 500 in from this measurement Example Subtract 2 489 in Dimension 0 500 in Thickness of Shim Fixture 1 989 in Actual Dimension 2 Ashimming allowance figure is etched on the pinion input gear Add or subtract the shimming allowance to from the actual dimen sion in Step 1 Note Because of the location of shims in relation to the gear use the following information when adding or subtracting the etched allowance figure from the dimension found in Step 1 If the etched number is 5 you would ADD 0 005 in
123. hem together to form a watertight junction at the top of the gimbal housing Apply 3M Scotch Grip Rubber Adhesive 1300 in the exhaust groove and install a new O ring seal Remove the protective back off two new foam rubber seals and place them over the holes in the gimbal housing cover VPA 7743008 07 2003 Transom Shield Assembly SX MHP Gimbal Housing and Transom Plate Installation 34684 34650 18121 18119 VPA 7743008 07 2003 Thoroughly clean outer transom surface where gimbal housing seal makes contact If trim pump and lines are already attached to housing insert them through transom cutout then install gimbal housing Do not use sealer between housing seal and transom and do not attach washers or nuts at this time If trim lines were previously disconnected attach them to the hydraulic manifold A Note Line from pump UP outlet must attach to lower manifold opening otherwise trim system will not function properly Route the lines above the alignment tube B and over the uppermost port stud C as shown Lightly coat the six gimbal housing studs with Volvo Penta Gasket Sealing Compound 4 Apply alight coat of Volvo Penta Grease P N 828250 to the inside of the transom plate alignment tube Position the two hydraulic lines above the uppermost port stud and mount the transom plate Place the transom bearing plate over the two bottom
124. hen replacement parts are required use genuine Volvo Penta or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunctions and possible injury to the operator and or passengers Tool Name Volvo P N Panel Location Adaptor Pressure Tester 3854366 6 K In Line Pressure Tester 3854368 2 K Rod Holder 3854367 4 K Seal Installer 3854364 1 K Spanner Wrench 3854365 8 A VPA 7743008 07 2003 241 Trim Tilt Hydraulic System System Description Reservoir Checking Filling and Bleeding fl 47564 Troubleshooting General 242 The trim tilt unit consists of a valve body oil pump and electric motor assembly connected to two hydraulic cylinders A trim sending unit is mounted to the starboard side of the gimbal ring and connected to a dash mounted trim gauge To operate the trim tilt push the switch to the desired bow up bow down position Holding the switch in the desired position will activate the system until the switch is released Holding the switch in the bow up position the electric motor drives the hydraulic oil pump forcing oil into the base of the hydraulic cylinders The force developed by the cylinder moves the sterndrive through an unlimited trim range The dash mounted trim gauge indicates the bow position that is controlled by the trim angle of the sterndrive Continued operation in the bow up directio
125. housing Install six locknuts three on each side DR2023 13 Tighten the nuts in two steps Use a 3 8 in drive 5 8 in swivel socket to tighten nuts to an initial setting of 25 ft Ib 34 N m Start i with the center nut and work in a crisscross pattern to secure the I l x i sterndrive to the pivot housing Use the same crisscross pattern to 6 S f 3 tighten all six locknuts to a final setting of 50 ft Ib 68 N m 2 amp TSE 47129A VPA 7743008 07 2003 233 Sterndrive Removal and Installation 234 47551 47549 47550 47552 14 If a sterndrive cart has been used remove it at this time for instal lation of the trim tilt cylinders Apply Volvo Penta Grease P N 828250 to the trim tilt pivot pin 15 Install bushings in upper housing boss Note Use care when installing trim tilt pivot pin bushings can be damaged 16 Align trim tilt cylinder end with upper housing boss Slide trim tilt pivot pin through trim tilt cylinder and upper gear housing 17 Align and slide pivot pin through trim tilt cylinder end Install flat washer and E clip Note The e clip must be installed in the inner groove of the pivot pin The washer must be installed between the e clip and the rod end 18 Install rod end covers onto pivot pin VPA 7743008 07 2003 Sterndrive Removal and Installation Check and Adjust Trim Sending Unit Note Push trim tilt switch to t
126. housing fol lowing the instructions found elsewhere in this section Check the tooth contact pattern on the outer propeller shaft The contact pattern should be located towards the big end with a slight displacement towards the root of the tooth If the tooth contact pattern and gear lash are within specifications proceed with the reassembly of the gearcase If either the pattern or the lash are out of specifications proceed with Adjusting Tooth Contact Pattern and Gear Lash VPA 7743008 07 2003 DP S Lower Gearcase Adjusting Tooth Contact Pattern and Gear Lash Tooth Contact Pattern Note Contact pattern must be corrected before attempting to correct gear lash If the contact pattern is too far up towards the top of the tooth and towards the inside of the gear change the shims as follows e Subtract shims from position 1 e Subtract shims from position 2 e Add shims to position 3 DRC6397 If the contact pattern is too far down at the root of the tooth and towards to outside of the gear change the shims as follows Add shims to position 1 e Add shims to position 2 e Subtract shims from position 3 DRC6398 DRC6406 VPA 7743008 07 2003 215 DP S Lower Gearcase Gear Lash Note Contact pattern must be correct before attempting to cor rect gear lash If the contact pattern on the outer propeller shaft is correct the outer propeller shaft lash wi
127. htly oil the bearing retainer ring with Volvo Penta GL5 Synthetic gear lubricant SAE 75W 90 6 Install the ring in the upper gear housing Thread the ring all the way in by hand until it seats VPA 7743008 07 2003 Upper Gear Housing 7 When fully seated the bearing retainer ring will be below the bot tom edge of the pinion bearing carrier opening 8 Install Spanner Wrench Volvo Penta P N 3850604 and secure the tension arm with two upper gear housing top cover screws Tighten the cover screws down evenly alternating every two turns Tighten the screws securely 9 Tighten the bearing retainer ring to 145 165 ft Ib 197 224 N m Remove the two retaining screws then remove the wrench Note Use caution when removing the retaining screws as the arm is under spring tension 1 Place the cone clutch spring around the upper driveshaft Slide the spring down into the housing until it rests on the spring spacer VPA 7743008 07 2003 119 Upper Gear Housing Ss Upper Output Gear Installation 34971 120 2 Identify the end of the cone clutch that is marked with the word TOP 3 Install the cone clutch with the word TOP facing UP onto the upper driveshaft Slowly let the cone clutch spin down the drive shaft helix until it rests on the spring 1 Place the predetermined amount of shims to locate the upper out put gear into position o
128. ile tightening pivot screws O7 48634 24 VPA 7743008 07 2003 Transom Shield Assembly SX M 4 The drain hole in the nipple must face down when installed in the pivot housing 34579 5 Pull the water tube through the pivot housing as far as it will go Screw on the water nipple nut If the nipple turns with the nut or if the nipple end does not protrude through the nut when it s seated then the square nipple collar is not located properly behind the housing Loosen the nut and rotate the nipple to reposition it Make sure the drain hole in the nipple faces down Tighten the nut to 96 120 in Ib 11 14 N m 6 Apply Volvo Penta Gasket Sealing Compound around the com plete inner V shaped lip of the pivot housing to seal the U joint bellows against water entry 34582 7 Pull the U joint bellows through the opening and seat the lip in the groove Bellows must seal the entire circular opening any flat spot on the lip indicates the bellows has not engaged the V groove 34583 VPA 7743008 07 2003 25 Transom Shield Assembly SX M 8 Pull top of exhaust bellows through the pivot housing Tilt the pivot housing and push the bottom of exhaust bellows through the pivot housing seating the bellows channel around the lip of the pivot housing opening Any flat spot on the bellows indicates the bel lows has not engaged the lip 9 Wear safety glasses Insert the retaining ring in
129. int of a lower gear tooth Proper indicator placement is important for an accurate reading DR3231 2 Zero the indicator With your finger gently rotate the gear first in one direction until tooth contact is felt then in the other direction Do not turn the gear far enough to rotate the universal joint just far enough to contact the pinion gear in both directions Correct gear lash is 0 006 0 011 in 0 15 0 28 mm Record your measure ments 34980 Upper Gear 1 Reposition the dial indicator to contact the vertical horizontal mid point of an upper gear tooth DR3231 2 Zero the indicator With your finger gently rotate the gear first in one direction until tooth contact is felt then in the other direction Do not turn the gear far enough to rotate the universal joint just far enough to contact the pinion gear in both directions Correct gear lash is 0 006 0 011 in 0 15 0 28 mm Record your measure ments 124 VPA 7743008 07 2003 Upper Gear Housing Correcting Gear Lash If both readings are different yet within each gear s specified range C gear lash is correct Gear lash measurements that are incorrect will fall j into one of the categories below Refer to chart and drawing when determining how to change gear lash Make all shim changes at Position A first then at B C D and E in that order Determine amount of change by either subtracting range mid point from reading or by subtracti
130. ir dry but if you must wipe the sur face to speed up drying use lint free wipes not treated with anything that may contaminate the surface Do not scrub the surface wipe very lightly Do not blow dry with shop air unless it is completely free of dirt oil and water Do not heat the part above 150 F before painting Do not touch the treated surface with bare bands before painting 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 PPGe Super Koropon epoxy primer Do not apply primer over hard finish coat Primer solvents must be allowed time to evaporate and the primer must harden before applying the finish coat Allow 8 to 12 hours drying time Apply finish coat The parts catalogs list numbers for finishing products See Engine Service Manual for Engine specific information The gimbal bearing and universl joint splines MUST be lubricated each year Lubricate the gimbal bearing and universal joint splines inspect VPA 7743008 07 2003 General Information 34109 Recommendations For Antifouling Paints VPA 7743008 07 2003 the bellows when preparing your boat for off season storage This requires the removal of the sterndrive Note Failure to lubricate the gimbal bearing universal joint shaft splines and inspect the bellows each year will r
131. isassembly 98 Shift Actuator Housing Removal 00005 99 Pinion Bearing Carrier Removal 000200eeees 99 Output Gear Removal 002 eee e eee 100 Upper and Lower Output Gear Disassembly 103 U joint Replacement 2000 eee eee eee 104 U Joint Installation 0 00 0 eee 105 Pinion Bearing Carrier Disassembly 106 Upper Housing Stud Replacement 109 Upper Gear Housing Oil Screen 109 Shimming Thrust Plates 0000e eee 109 Shift Linkage Disassembly 0 200ee eens 111 Water Passage Plate Service 2 05 112 Shift Linkage Assembly 202 cece eeeeeeeee 112 Pinion Bearing Carrier Assembly 2 00055 113 Upper and Lower Output Gears Assembly 118 Lower Output Gear Shimming 0 2000005 119 Upper Output Gear Shimming 120 Pinion Bearing Carrier Shimming 2 120 Upper Gear Housing Assembly 121 Lower Output Gear and Shaft Assembly 121 Lower Output Gear Installation 123 Cone Clutch Installation 00 cee eee eee 125 Upper Output Gear Installation 126 Shimming Vertical Movement Of Upper Driveshaft 127 Pinion Bearing Carrier Installation 128 Top Cover Shimming 0 200e eee
132. ise too many shims will be measured and installed B LB al A These washers will preload gimbal ring a D After determining number add one extra then install them in position 22784 Use a minimum of one but no more than five washers to shim gimbal ring 11 Attach the trim cylinder ground wires to the two forward screws then install the lock washers Screw in all three mounting screws and tighten them to 18 20 ft Ib 24 27 N m 12 Install trim tilt cylinders see Trim Tilt Cylinder Installation on page 20 and pivot housing following instructions see Pivot Hous ing Installation on page 24 32 VPA 7743008 07 2003 Transom Shield Assembly SX M Trim Sender Adjustment 1 Connect an ohm meter to the sending unit connector Turn the sending unit control nut until the meter reads 11 1 ohm 19766a 2 With lower edge of pivot housing pushed in towards the gimbal housing insert sending unit control nut into pivot bolt head Install two trim sender mounting screws finger tight 19513a 19514 3 With the pivot housing pushed in towards the gimbal housing check adjustment of sending unit between pins A and C of the sending unit connector Rotate sending unit to obtain a 11 1 ohm reading on the meter then tighten mounting screws to 18 24 in Ib 2 0 2 7 Nm 42584 VPA 7743008 07 2003 33 Transom Shield Assembly SX M Gimbal Housing Disassembly Remove trim tilt cylinders see Trim
133. ith a new one Install Fill Adaptor Volvo Penta P N 3855932 43638 5 Fill drive with GL 5 Synthetic gear lubricant SAE 75W 90 from drain hole Fill slowly to purge trapped air Stop filling when the oil level reaches the bottom of the oil level hole Do not overfill Note Filling drive too quickly may form air pockets that will cause an inaccurate oil level reading Running drive with improper oil level can result in immediate internal damage 6 When oil reaches proper level stop filling and screw in the level plug and dipstick This will create an air lock to prevent excessive oil loss while drain plug is installed 7 Apply GL 5 Synthetic gear lubricant SAE 75W 90 to the drain plug O ring Install and tighten drain plug to 10 15 ft Ib 14 20 N m 8 Apply Volvo Penta Gasket Sealing Compound to the level plug and dipstick Tighten them to 48 72 in Ib 5 4 8 1 N m 9 Install the sterndrive and adjust the shift system following the instructions under Sterndrive Removal and Installation 10 Refer to the Propeller Selection section found elsewhere in this manual for procedures to install the propellers VPA 7743008 07 2003 221 DP S Lower Gearcase he Ny Ny 47557 lt gt 33836 Anode Testing and Replacement 222 11 If the sterndrive is not to be installed install the shift linkage access cover and secure with three screws Tighten the screws to
134. k 2 Remove the rear plastic cover if it hasn t been removed ed Remove the oil level plug so the oil reservoir vents when draining Discard the O ring 3 Place a 4 quart drain pan under the lower gear case Remove the lower drain plug discard the O ring and let the sterndrive drain completely 91 Upper Gear Housing 42588 Upper Gear Housing Disassembly 39389 3850605 42574 92 Remove six screws two on either side and two aft Remove the upper gear housing Remove the water tube and grommet from the upper housing Dis card the grommet Attach Spline Socket Volvo Penta P N 3850598 to the Upper Gear Housing Holder Volvo Penta P N 3856163 Tighten the set screw securely Mount the upper gear housing on the holding fixture Loosen lock ing screw A Rotate and lift fixture shaft B to engage housing upper driveshaft splines Install and securely tighten the four mounting screws C VPA 7743008 07 2003 Upper Gear Housing Shift Actuator Housing Removal 1 Remove cotter pin and washer retaining shift link to eccentric pis ton arm Move shift link out of the way 47112 2 Remove four screws securing shift actuator housing Remove the housing from the upper gear housing 3 Note the position of the shift shoe during removal It must be prop erly positioned during installation or the shift system will not func tion correctly 34639 1 Remove
135. l ring Note The support bracket has a protruding lip on its upper sur 13 face where it fits over the pivot pin When checking fit washer insertion must be done at this point only other wise too many shims will be measured and installed These washers will preload gimbal ring After determining number add one extra then install them in position Use a minimum of one but no more than five washers to shim gimbal ring Apply Volvo Penta Gasket Sealing Compound to the five support bracket screws Attach the trim cylinder ground wires to the two middle screws and install them Screw in the remaining three remaining screws Tighten all screws to 22 33 ft lb 30 46 N m VPA 7743008 07 2003 Transom Shield Assembly SX MHP 15 Position the anode and sensor housing and the two anodes Install Ne C the four anode retaining screws and tighten to 5 7 ft Ib 6 9 N m 16 Install trim tilt cylinders and pivot housing following instruc tions elsewhere in this section 1 Connect an ohm meter to the sending unit connector Turn the sending unit control nut until the meter reads 11 1 ohm 19766A 2 With lower edge of pivot housing pushed in towards the gimbal housing insert sending unit control nut into pivot bolt head Install two trim sender mounting screws finger tight so that the sender may be adjusted 19513A VPA 7743008 07 2003 69 Transom Shield Assembly SX MHP 42
136. l ring when the arm comes free 48620 9 Remove the steering arm from inside the boat Remove thrust washer from the gimbal housing 48626 Gimbal Ring Disassembly 1 Remove and discard the O ring around the upper steering post 28 VPA 7743008 07 2003 Transom Shield Assembly SX M 2 Face the large diameter end of Remover Installer Volvo Penta P N 3854385 toward the gimbal ring Insert the tool into either tilt bearing and drive it out Remove the other tilt bearing in a similar manner 19646 3 Insert small end of Remover Installer Volvo Penta P N 3854355 into bearing and drive out bearing 1 Lightly oil the outside of a new lower pivot bearing and place it in the bore Use Installer Volvo Penta P N 3854358 to seat the bear ing into the bottom of the gimbal ring 2 Install two new trim tilt nylon pivot pin bushings into the gimbal ring 17684 3 Apply Volvo Penta Grease P N 828250to the inside of both trim tilt nylon bushings 4992a VPA 7743008 07 2003 29 Transom Shield Assembly SX M 3854358 19717a gt 34511a 48626 30 Lightly oil the outside of two new tilt bearings Insert a bearing into the gimbal ring from the outside Insert the blunt end of Remover Installer Volvo Penta P N 3854358 into bearing Using a soft face hammer seat bearing flush to 0 010 in 0 254 mm below inner surface of gimbal ring Repeat procedure for installation o
137. leaning will occasionally uncover trouble sources Obtain tools instruments and parts needed for the job before work is started Interrupting a job to locate special tools or repair kits is a needless delay Use proper lifting and handling equipment Working on stern drives without proper equipment can cause damage and personal injury Always use clean fresh fuel when testing engines Troubles can often be traced to the use of old or dirty fuel VPA 7743008 07 2003 General Information Service Policy Replacement Parts Parts Catalogs Special Service Tools VPA 7743008 07 2003 It is a policy to provide dealers with service knowledge so they can give professional service demanded by today s consumer The Volvo Penta Training Centers frequent mailing of Service Bulletins Letters and Promotions Special Tools and this Service Manual represent our continuing efforts to assist dealers in giving consumers the best and most prompt service possible 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 model number and serial number Be sure that you are familiar with the warranty statement supplied with the product If you have any questions write the Volvo Penta Service Department If other than genuine Volvo Penta replacement components or parts are used subsequent wa
138. legislation prevailing in the area where you are going to use the boat The product must contain the correct properties for the boat hull type Aluminum hulls often require an initial treatment with an etching primer Use a pure copper bases antifouling paint containing copper tiocyanate not copper oxide Tin based TBT paints are no longer allowed Make sure to prepare the hull in accordance with the directions of the paint manufacturer A Caution Leave a 1 in 25 mm strip unpainted around the transom bracket Contact with bottom paint may cause sever cor rosion of the transom and sterndrive assembly VPA 7743008 07 2003 General Information Metric Conversion Chart LINEAR FUEL ECONOMY AND FUEL CONSUMPTION inches millimeters mm miles gal X 0 42514 kilo metres liter km l X 0 3048 metres m Note 235 2 mi gal liters 100 km 235 2 liters 100 km mi gal yards X 0 9144 metres m LIGHT miles X 1 6093 kilo metres km footcandles X 10 76 lumens metree Im m2 inches X 2 54 centimeters cm PRESSURE OR STRESS AREA inches HG 60 F X 3 377 kilo pascals kPa inches2 X 645 16 millimetres2 mm2 pounds sq in X 6 895 kilo pascals kPa inches2 x 6 452 centimetres2 cm2 inches H2O 60 F
139. letely before the pressure is relieved 1 Disconnect the three wire trim tilt connector going to the remote control 2 Disconnect the two wire trim tilt power connector 3 Tag the hydraulic line going to the UP port of the trim tilt pump VPA 7743008 07 2003 245 Trim Tilt Hydraulic System A Warning Wear safety glasses Cover the hydraulic lines with a shop towel to prevent dangerous spray and carefully remove There could be some residual pressure remaining in the line Place line in container to catch fluid 4 Place plugs in valve body to prevent dripping of residual fluid 5 Unscrew hardware holding pump assembly to transom Remove the pump assembly from the boat 49632 6 Drain any oil remaining in reservoir into a suitable container This fluid should not be reused Dispose of the fluid in an appropriate manor Note It is necessary that the outside surface of the trim tilt unit be completely free of dirt prior to disassembly Wipe with a cleaner if necessary Always use a lint free cloth when handling trim tilt components 49697 Separation of Reservoir and Motor 1 Disconnect pump motor from trim tilt wiring harness 49633 2 Remove two screws securing trim tilt assembly to bracket 49635 246 VPA 7743008 07 2003 Trim Tilt Hydraulic System 3 Remove four 6 allen screws securing reservoir to manifold 22881
140. ling and Bleeding 2 Battery The battery must be fully charged for some of the follow ing tests A fully charged battery will have a specific gravity of 1 260 to 1 280 VPA 7743008 07 2003 Trim Tilt Hydraulic System Troubleshooting With In Line Pres sure Tester How to Install Tester System Hydraulic Tests Test No 1 Complete Up Circuit VPA 7743008 07 2003 The Trim Tilt In Line Pressure Tester P N 3854368 provides a method for checking the performance of the trim tilt unit The pressure tester can measure running pressure stall pressure and pressure leak down The tester can isolate the trim tilt cylinders from the valve body to help locate a component causing leak down The trim tilt in line pressure tester consists of a pressure gauge and adapter 1 a tester body and shut off valve assembly 2 anda hydraulic line assembly 3 The tester body is designed so the hydraulic port stamped A is always connected to the gauge Hydraulic port stamped B opposite the valve C can be shut off by closing the valve If you suspect that a valve or cylinder is leaking the tester may be connected to the trim tilt valve body four different ways to isolate and test components of the trim tilt circuit A Warning Wear safety glasses Some residual pressure may be present in the trim tilt system when the hydraulic line is loosened Always wrap a shop cloth around the hydraulic fitting before loosenin
141. ll also be will generally need to be corrected If the forward gear lash must be increased without changing the tooth contact pattern change the shims equally as follows 1 e Subtract shims from position 1 R within specifications Therefore only forward gear lash 2 i i e Add shims to position 3 LI If the forward gear lash must be decreased without changing the tooth contact pattern change the shims equally as follows JA Add shims to position 1 l 3 e Subtract shims from position 3 DRC6406 Final Assembly 1 Reinstall the outer propeller shaft See Propeller Shaft Housing and Propeller Shaft Installation on page 209 2 Apply alight coating of GL 5 Synthetic gear lubricant SAE 75W 90 to the two large A and one small O rings B Install them in their grooves Coat the flange of the propeller shaft housing with gear lube also 3 Reinstall the propeller shaft housing See Propeller Shaft Housing and Propeller Shaft Installation on page 209 4 Apply alight coating of GL 5 Synthetic gear lubricant SAE 75W 90 to the large and small O rings Install them in their grooves Also coat the threads of the retaining ring with gear lube 5 Reinstall the retaining ring into the housing 43429 216 VPA 7743008 07 2003 DP S Lower Gearcase 6 Use Spanner Tool Volvo Penta P N 3855877 and Spline Socket Volvo Penta P N 3850598 to turn driveshaft and tighten the retain
142. ll four new lock nuts and tighten them to 13 15 ft Ib 18 20 N m 6 Apply 3M Adhesive to the groove around the steering cavity and install a new sealing ring 7 Set the gimbal housing cover in place Install four mounting screws and tighten them to 60 84 in Ib 7 9 N m VPA 7743008 07 2003 31 Transom Shield Assembly SX M 8 Attach ground wire to steering arm inside transom Apply Volvo Penta Grease P N 828250 to large pin Pull hydraulic arm assem bly over steering arm Align holes and install large pin from top of arm Install cotter pin Spread prongs of cotter pin to secure large pin 9 Apply Volvo Penta Grease P N 828250 to the nylon thrust washer and lower pivot post Slide nylon washer between gimbal ring and gimbal housing Align pivot post hole of the gimbal ring gimbal housing and thrust washer then slide pivot post assembly through the gimbal ring and gimbal housing until it is seated 48632 10 Install the lower steering support bracket Seat it with a mallet if necessary Apply upward pressure to gimbal ring and support J bracket Use lower thrust washers as a gauge to determine how O y many will fit space between upper surface of support bracket and lower surface of gimbal ring Vv Note The support bracket has a protruding lip on its upper sur face where it fits over the pivot pin When checking fit gt washer insertion must be done at this point only other w
143. lowing instructions elsewhere in this section D N I INT Gimbal Housing Removal 44 Remove engine lower exhaust pipe and steering cylinder following instructions in Stern Drive Engine Removal and installation section in the Engine Service Manual Note The transom shield assembly can be removed without complete disassembly Since the gimbal housing is attached to the trim lines and pump decide whether to disconnect trim lines at hydraulic manifold after inner transom plate is removed or to unscrew trim pump from transom and feed pump and lines through cutout as gim bal housing is removed 1 Remove the screw and washer securing the transom plate ground strap to the steering arm VPA 7743008 07 2003 Transom Shield Assembly SX M 2 Remove the two screws and four nuts and washers securing the transom plate inside the boat Lift the plate off the studs Note that the hydraulic lines route above the uppermost port stud and through a relief in the inner transom plate 3 Remove the two remaining nuts washers and transom bearing plate Pull the gimbal housing off the transom 48640 Shift Cable Sleeve Replacement 1 Unscrew the shift cable sleeve and connector assembly Discard the connector O ring 34673 2 Apply Volvo Penta Gasket Sealing Compound to a new O ring Slide it onto the connector and position it against the hex
144. m tie down pressure applied at the bow and transom only VPA 7743008 07 2003 Propellers Boat Trim SX and DP S Propeller Hub Replacement High Altitude Operation VPA 7743008 07 2003 The power trim tilt system allows for trimming the sterndrive in or out to compensate for a major change in boat loading and weight distribution DP S sterndrives should limit trim to 5 Serious propeller and vertical drive damage can occur if the sterndrive is operated at trim angle that is too high or low A rubber hub in the propeller is the shock absorber which minimizes the chance of damaging the propeller lower gearcase or drive train components during shifting or striking an underwater object If the hub should become damaged and slip it can be replaced by an authorized service dealer or propeller station A performance loss at altitudes above 3500 ft can be expected If you are boating above 3500 ft elevation for a short term a lower pitch propeller will restore some of the lost performance Long term use above altitudes of 3500 ft may require a change in gear ratio Contact your dealer regarding installation of a high altitude gear set To avoid permanent engine damage be sure that a boat modified for high altitude operation is properly identified Return it to its original gear ratio if operated for prolonged periods at or near sea level 265 265 VPA 7743008 07 2003 00c L0 ysi uy 800EVLL
145. n bearing race Needle Bearing Assembly Grease 21431 2 Apply alight coat of GL5 Synthetic Gear Lubricant SAE 75W 90to pinion bearing Install pinion bearing onto Pinion Installer Volvo 3855860 gt Penta P N 3850620 Slide Guide Plate Volvo Penta P N 3850619 3850619 gt gt onto Rod Nut and Washer Volvo Penta P N 3855860 Insert rod into gearcase and screw into installer 3 Turn nut until pinion bearing is seated then unscrew and remove A os 43426 VPA 7743008 07 2003 161 SX Lower Gearcase 3854864 3850609 3850613 20730 Driveshaft and Gear Installation 33841 42663 162 Note If Installer turns in bearing screw Pinion Nut Holder Volvo Penta P N 3854864 onto Handle Volvo Penta P N 3850609 Slide Alignment Disc Volvo Penta P N 3850613 onto handle Insert into gearcase and hold pinion installer 1 Install propshaft gear and bearing assembly into gearcase Posi tion pinion above propshaft gear in gearcase pinion pocket Engage pinion teeth with propshaft gear teeth Install driveshaft into gearcase and engage pinion splines Note Insert driveshaft carefully so pinion bearing rollers aren t dislodged 2 Apply alight coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the upper bearing cup Place cup in housing and push down until it seats on driveshaft bearing VPA 7743008 07 2003
146. n tilts the sterndrive to the full tilt up position The trim gauge indicates full bow up position when in the tilt range Holding the switch in the bow down position the sterndrive will move down through the tilt range into the trim range If the trim switch is not released the sterndrive will move through the trim range to the full bow down position At the beginning of each boating season check the fluid level in the reservoir as follows e Level should be between the MIN and MAX marks on the reservoir e If necessary add Volvo Penta Power Trim Tilt and Steering Fluid or Dexron Automatic Transmission Fluid Add as required Replace the cap and tighten securely When checking fluid level inspect the trim tilt unit for leaks and proper operation Note In situations where air has entered pump and hydraulic lines because of low fluid level or any part of system has been disassembled it will be necessary to bleed purge air from system To remove air from hydraulic system cycle trim tilt system a minimum of five times adding fluid as required In many cases an inspection or test of the easy things first will reveal the problem quickly and save valuable troubleshooting time 1 Visual inspection Look for indications of external oil leaks Repair as necessary Check reservoir oil level Note Do not remove fill plug unless the sterndrive is in the full tilt up position Fill as required see Reservoir Fil
147. n top of the upper gear housing 2 Place the upper output gear on top of the housing and seat the assembly Be careful not to disturb the shims when installing the bearing assembly Note You may have to loosen the four screws that secure the upper housing to the holding fixture to center the hous ing and shaft This will make installation of the upper out put bearing assembly easier VPA 7743008 07 2003 Upper Gear Housing 3 Apply GL5 Synthetic gear lubricant to the upper needle bearings Place the bearing on top of the upper driveshaft Maintain the same top to bottom orientation as during disassembly to ensure longevity New bearings can be installed with either end up Push the bearing all the way into the gear and bearing assembly Shimming Vertical Movement Of Upper Driveshaft In order to obtain the correct vertical clearance up and down movement of the upper driveshaft there are four upper driveshaft nuts with shoulders of different thicknesses 1 Apply GL5 Synthetic gear lubricantto the upper driveshaft threads to prevent galling Select an upper driveshaft nut and install it on the upper driveshaft Note Nut has a eft hand thread 2 Tighten the nut to 96 110 ft Ib 130 149 N m VPA 7743008 07 2003 121 Upper Gear Housing 3 Push up on the holding fixture shaft to remove the end play in the upper driveshaft Measure the clearance between the upper drive shaft nut and the upper output ge
148. nal sterndrive damage Add make up oil through dipstick opening to bring oil up to proper level The trim tilt assembly contains an electric motor hydraulic pump and reservoir At the beginning of each boating season check the fluid level in the reservoir as follows Level should be between the MIN and MAX marks on the reservoir e If necessary add Volvo Penta Power Trim Tilt and Steering Fluid Power Trim Tilt and Power Steering Fluid Replace the cap and tighten securely When checking fluid level inspect the trim tilt unit for leaks and proper operation If service is necessary see your authorized dealer Off Season Storage Preparations All Models Painting VPA 7743008 07 2003 1 Change Sterndrive Lubricant Drain and refill with fresh Volvo Penta Synthetic Gearcase Lubricant SAE 75W 90 2 Lubricate Gimbal Bearing and universal joint splines and inspect bellows for wear or leaks Refer to information elsewhere in this section 3 Inspect Sterndrive Water Pickup Screens for Obstructions See Engine Service Manual for additional engine off season storage procedures 1 Remove all marine growth General Information Preparation for Boating After Storage Gimbal Bearing and Inspect Universal Joint bellow 10 2 Remove all loose paint and corrosion by sanding or sandblasting If sandblasting use an aluminum oxide blasting media with a par ticulate size of 0 008 0 028 in 0 2 0 7 mm
149. nation 262 VPA 7743008 07 2003 Propellers Propeller Removal and Installa tion DP S Models Removal VPA 7743008 07 2003 When choosing a set of propellers it is sometimes difficult to select a size that returns the rated RPM of the engine under varying conditions of sea and load As a rule of thumb the boat that is heavier and more difficult to push through the water should use a propeller set with a smaller pitch number This type of boat may benefit by operation at the lower end of the rated RPM range The opposite is true for light fast boats with refined hulls in that a higher pitch propeller operating at the maximum rated RPM may be the best choice Note Ifa propeller set does not allow the engine RPM to fall in the desired range select to next set either one number higher to decrease RPM or one number lower to increase RPM A change in propeller set number should change the engine RPM about 200 to 250 RPM Many factors influence the way a propeller set functions hull shape load engine output range of use etc Practical tests are the best way of determining whether the correct propeller set has been selected Regardless of the full throttle speed which has been obtained the best overall economy will be achieved with a cruising speed about 15 to 25 below the maximum speed obtained A To avoid accidental starting of engine be sure remote control is in NEUTRAL position and ignition key is removed Protec
150. nd Remover Volvo Penta P N 3850622 4 Wear Safety Glasses Install remover into pinion bearing Using a hammer drive pinion bearing down and out of gearcase Clean and inspect gearcase Note Do not remove driveshaft bearings unless you intend to replace them Removal process may damage bearings 155 SX Lower Gearcase 33811 33810 dL U A 33809 Pinion Shimming 156 Note size position and direction of taper of the driveshaft bear ings for reinstallation Using a bearing separator and press remove bearings Apply a light coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the I D of the small bearing Protect threads of driveshaft by installing a pinion nut onto driveshaft Slide bearing onto driveshaft with taper facing pinion end Rest Bearing Installer Volvo Penta P N 3850617 on open jaws of a press support Position raised lip of Installer up it must contact backside of bearing Insert driveshaft into Installer and press driveshaft into bearing until it seats Apply a light coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the I D of the large bearing Slide bearing onto driveshaft with taper facing away from small bearing Rest Bearing Installer Volvo Penta P N 3850617 on open jaws of a press support Posi tion raised lip of Installer up it must contact nose of bearing Insert driveshaft into Installer and press driveshaft into b
151. ne growth slime barnacles or other foreign matter which will accumulate in fresh or salt water will cut down on performance and speed The boat bottom should be cleaned periodically in accordance with manufacturer s recommendations If your boat is in water where marine growth is a problem the use of an anti fouling paint will reduce the growth rate See your dealer for an anti fouling paint that is suitable for your area e Tin base anti fouling paint TBTA or TBTF is recommended where its use is permitted Copper base anti fouling paint may be used but will require more frequent inspection and replacement of sacrificial anodes DO NOT PAINT any part of the vertical drive with copper base anti fouling paint Tributyl Tin Adipate or Tributyl Tin Fluoride Note Painting the sterndrive with copper base paint will accel erate galvanic corrosion Vinyl butyl base anti fouling paint is a recommended alternative e DO NOT USE any graphite base anti fouling paint Note Never paint anti corrosion anodes or their effectiveness will be lost See the Volvo Penta Parts Catalog for anode kits that provide further corrosion protection for the sterndrive assembly It is extremely important that the trailer fits the boat properly Loss of boat performance and speed may be due to improper trailer support and excessive tie down pressure which has caused the boat bottom to hook The boat should rest firmly on the trailer with maximu
152. ng Paints 11 Painting The Stern Drive With Antifouling Paint 12 Paints For Stern drives 000 cece eee eee 12 Painting The Hull With Antifouling Paint 12 Metric Conversion Chart 00 0 eee ee eee 13 Periodic Maintenance Chart 0 00eeee eee 16 Before working on any part of a Volvo Penta sterndrive read the section called Safety at the end of this manual This service manual is divided into sections concerning various systems and assemblies Refer to the Contents to locate the section covering the system or assembly requiring service Each section title page has an additional listing that will describe the section s contents in more detail Be sure to read the Safety Section at the end of this manual and pay special attention to all safety warnings as they appear throughout the text Since models are subject to change at any time some photos may not depict actual product General Information Good Service Practice Preparation for Service Service required for this product is generally one of three kinds Normal care and maintenance which includes putting a new stern drive into operation storing engines lubrication and care under special operating conditions such as salt water and cold weather Operating malfunctions due to improper engine or drive mounting propeller condition or size boat condition or the mal function of some part of the
153. ng reading from range mid point A change to shim affects gear lash of both upper and lower output gears Note A change to shim affects gear lash of upper output gear only A change to shim affects gear lash of lower output gear only DR5061 One Gear Correct One Gear Requires Change Add or subtract same amount of shims at each location indicated Table 2 Positions Requiring Shim Change Condition A B Cc D E Lower gears less than range min Subtract Re shim Upper gear within range Lower gear greater than range max Add i Re shim Upper gear within range Upper gear less than range min i Re shim Lower gear within range Upper gear greater than range max Add Re shim Re shim Lower gear within range j Subtract Re shim Re shim No Change Required VPA 7743008 07 2003 125 Upper Gear Housing DR5061 Both Gears Incorrect By Same Amount Add or subtract same amount of shims at each location indicated Table 3 Positions Requiring Shim Change Condition A B Cc D E Upper gear greater than range max Subtract Subtract Re shim Re shim Lower gear less than range min Lower gear greater than range max Add Add Re shim Re shim Upper gear less than range min Lower gear less than range min 7 Add Upper gear less than range min Lower gear greater than range max i Add
154. nge 15996 2 From inside the boat insert the hooked end of the tube through the gimbal housing Hold the tube vertically then install the two mounting screws and tighten them to 120 144 in Ib 14 16 N m Water Hose Installation 1 Remove and discard the nipple O ring Clean all grease from the nipple making sure the drain hole is clear If the nipple needs to be replaced remove the clamp and pull it out of the hose Install a new nipple and secure with a clamp Tighten the clamp securely 2 Coat anew O ring with Volvo Penta Grease P N 828250 Slide it onto the nipple and position it in the groove closest to the square at the end of the fitting Clean excess grease out of drain hole and drain groove Note Do not place an O ring in the drain hole groove This would prevent water draining out during winterization and could result in freeze damage 42 VPA 7743008 07 2003 Transom Shield Assembly SX M 3 Slide a clamp onto the upper end of the hose Position the screw head so that it will be behind the port hydraulic lines as shown Push the hose onto the water tube then rotate it until the nipple points directly outward Slide the ground strap clip under the hose clamp Tighten the clamp securely Note Clamp s screw head must be behind hydraulic lines to prevent it contacting the pivot housing when drive is ina full tilt position Improper clamp position may limit tilt range and damage clamp and hose
155. nodes This will pre vent them from functioning properly If anode appears to be corroded on its surface but is not deteriorating it should be replaced Specifications Table 5 Description U S Metric Propshaft bearing housing 200 225 ft Ib 271 305 Nem Nut Pinion gear 150 160 ft Ib 203 217 Nem Screw Anode 60 84 in Ib 6 8 9 5 Nem Drain 60 84 ft Ib 6 8 9 5 Nem Lower to upper gearcase 3 8 16 22 24 ft Ib 30 33 Nem 7 16 14 32 40 ft Ib 43 54 Nem Oil level gauge and plug 48 72 in Ib 5 4 8 1 Nem Retainer propshaft bearing housing 20 25 ft Ib 27 34 Nem Set screw propshaft bearing housing 42 60 in Ib 4 8 6 8 Nem Shift Linkage Access Cover 108 132 in Ib 12 15 Nem Trim tab to gearcase 14 16 in Ib 19 22 Nem VPA 7743008 07 2003 175 SX Lower Gearcase Sealants Lubricants and Adhesives 176 Table 6 Type Chemical Where Used Primer Loctite Primer Lower driveshaft pinion nut threads Set screw propshaft bearing housing Adhesive Volvo Penta Thread Locking Fluid Set screw propshaft bearing P N 1161053 housing Lubricants Volvo Penta Grease P N 828250 Seal lips Shim ring propshaft bearing housing GL5 Synthetic Gear Lubricant Threads propshaft bearing SAE 75W 90 housing O ring forward oil passage O ring driveshaft bearing retainer Sealants Volvo Penta Gasket Sealing O D all metal case seals Compound Gauge and plug gearcase oil level Screw
156. nsom Plate Removal 48699 80 2 Place clamp on the small end of the U joint bellows There is an internal rib that must engage a corresponding groove around the opening s surface Push the bellows on and engage the groove then rotate the clamp until the screw fitting is in the one or two o clock position Slide ground strap clip under hose clamp Tighten the clamp securely The large end of the exhaust bellows has an internal rib similar to the U joint bellows Place clamp on this end Bellows must be positioned with exhaust relief cutout facing down Push the bel lows onto the exhaust tube until it engages the groove Turn the clamp screw to the three o clock position Slide ground strap clip under hose clamp and tighten the clamp securely Install gimbal ring see Gimbal Ring Installation on page 66 trim tilt cylinders see Trim Tilt Cylinder Installation on page 56 and pivot housing see Pivot Housing Installation on page 60 Remove engine lower exhaust pipe and steering cylinder following instructions found in Engine and Sterndrive Installation Manual Note The transom bracket assembly can be removed without complete disassembly Since the gimbal housing is attached to the trim lines and pump decide whether to disconnect trim lines at hydraulic manifold after inner transom plate is removed or to unscrew trim pump from transom and feed pump and lines through cut
157. nsom Shield Assembly SX MHP Pivot Housing Assembly Pivot Housing Installation 48633A 60 3 Apply 3M Adhesive to the groove around the water passage and install a new O ring seal If the old pivot boss friction washers were removed make sure a thrust washer coated with Volvo Penta Grease P N 828250 is installed in each pivot Install two new friction washers and coat them with Volvo Penta Grease P N 828250 Position the pivot housing in the gimbal ring Guide the water tube nipple through the housing and position the bellows behind their respective openings Align one gimbal ring pivot pin hole with the hole in the pivot hous ing Look inside to see if the thrust washer is still in position and not blocking the hole Screw in the pivot pin until it seats but do not tighten it at this time Align and install the other pivot pin Tilt the housing up and down to see if it moves freely Use a 1 2 in hex socket and tighten the pivot screws to 105 120 ft lb 142 163 N m Note Hold pivot housing to keep housing from over rotating 4 and damaging bellows and water hose while tightening pivot screws The drain hole in the nipple must face down when installed in the pivot housing VPA 7743008 07 2003 Transom Shield Assembly SX MHP 5 Pull the water tube through the pivot housing as far as it will go Screw on the water nipple nut If the nipple turns with the nut or if the nipple end
158. o 1 2 Run the drive to the full tilt position Momentarily activate the trim switch in the DOWN direction to relieve pressure on gauge 3 Completely close the tester shut off valve 4 Run pump in the trim out tilt up direction and record the stall PSI Release the trim switch and check the leak down rate and final PSI Compare the results to the specifications If the pressure gauge shows a stall PSI less than specifications or a leak down rate greater than specifications the problem lies within the pump manifold If the stall PSI and leak down figures are within specifications the problem is with either or both trim tilt cylinders A Warning Do not disconnect any lines if pressure still registers on gauge This may cause a hazardous spray of high pres sure hydraulic fluid To relieve pressure momentarily acti vate trim in opposite direction of last use Watch gauge to make sure it registers zero before removing lines This test will provide running and stall PSI for the trim in tilt down circuit 1 Disconnect hydraulic line from the DN port of the pump manifold 2 Connect tester hydraulic line to DN pump port and to opening A on tester body 3 Connect hydraulic line removed from the DN port to opening B on tester 4 Open tester shut off valve one to two turns A Warning Do not open more than two turns valve retaining ring may unseat and cause a hydraulic fluid spray 5 Run
159. of drive and the magnetic drain plug on the side of the gearcase skeg Pressure Testing 1 Attach a pressure tester such as a Stevens S 34 to the oil level hole and pressurize drive to 3 5 PSI 20 7 34 5 kPa Rotate pro peller shaft and Universal Joint shaft to check sealing If pressure loss is indicated use a soapy water solution or submerge drive in water to find source Make necessary repairs then repeat test 2 If pressure loss is not indicated increase pressure to 16 18 PSI 110 124 kPa Again use a soapy water solution or submerge in water to find source if drive looses pressure Make repairs as nec essary and repeat test Drive must hold pressure before making vacuum test and must not loose more than 1 PSI 6 9 kPa in 3 minutes 47120 Vacuum Testing 1 Attach a vacuum tester such as a Stevens V 34 to the oil level hole and pull vacuum to 3 5 inches of mercury 10 1 6 8 kPa Rotate propeller and Universal Joint shaft to check sealing If drive does not hold vacuum apply a heavy oil to seal and gasket sur faces to find source Make necessary repairs then repeat test No loss of vacuum should occur on low test 2 If vacuum loss is not indicated increase vacuum to 14 16 inches of mercury 47 54 kPa Again apply heavy oil to find source if drive will not hold vacuum Make repairs as necessary and repeat test Drive must not loose more than 1 inch of mercury 3 4 kPa in 3 min
160. or reassembly Remove shift shoe and spring from the shift actuator housing 34982 2 Remove and discard the shift actuator housing O ring 3 Drive the tension pin into the eccentric piston until the eccentric piston pin can be removed 130 VPA 7743008 07 2003 Upper Gear Housing 4 Remove the eccentric piston pin with a pair of pliers 5 Note the eccentric piston s orientation then remove the piston from the housing 6 Turn the piston over and tap out the tension pin Note The tension pin must be removed before installation Do am yy not install a new tension pin without removing the old one from the eccentric piston Having two pins in the hole will make removal of the new one almost impossible 34987 7 Remove the shift actuator seal by inserting a screwdriver behind the seal Twist the screwdriver and remove the seal Discard the seal 8 Clean all parts in solvent and dry with air Inspect all parts for wear Replace any defective components VPA 7743008 07 2003 131 Upper Gear Housing Shift Actuator Housing Assembly 1 Identify the side of the seal that has the larger space between the case and lip This side must face outwards during installation Coat the outside case of a new seal with Volvo Penta Gasket Sealing Compound 2 Place the shift actuator housing in a press with the seal cavity fac ing up Place the seal in the cavity with the large space facing up 34991
161. otection On the inside of each Universal Joint arm is a retaining ring Use a small drift and mallet to remove all eight retaining rings Discard the old retaining rings and replace them with new ones 2 Remove the Universal Joints requiring replacement Press out the Ujoints with Owatonna Tool P N 7068 or equivalent Pilot the bearing cap with open adaptor from Universal Joint Kit Volvo Penta P N 3850628 Follow the instructions provided by the tool manufacturer 98 VPA 7743008 07 2003 Upper Gear Housing 3 Do not press any bearing cap completely through its yoke When the pressure side cap is almost through the yoke remove the Uni versal Joint shaft from the tool and pull off the exposed cap with pliers Rotate the Universal Joint 180 and press the cross bar in the opposite direction to remove the remaining cap 34673 4 Remove the remaining caps and other Universal Joint using the Owatonna tool as previously described 34636 universal joint Installation Note Remove all bearing caps from a new Universal Joint Do not add any grease to the bearing caps The grease is a permanet lubricant and may be damaged by using incom patable grease 1 Insert Universal Joint lobes into center coupler of driveshaft 2 Install both bearing caps by hand Slide Universal Joint back and forth between caps to be sure they re aligned 3 Press bearing caps on with Owatonna Tool or equivalent Place open adaptor from
162. ough the gimbal bearing and into engine coupler with ease If the alignment tool binds going into engine coupler the front engine mount s must be adjusted either up or down or side to side as required until alignment tool slides in and out of engine coupler with ease 47547 5 Remove and retain the three shift linkage access cover screws and cover 42674 VPA 7743008 07 2003 231 Sterndrive Removal and Installation 6 Shift sterndrive into gear by rotating the eccentric piston arm either up or down 47135A 7 Apply White Sealing Compound For Drives to the six studs 47548 8 Lubricate the driveshaft splines with Molybdenum Trioxide Moly Grease 2743A 9 Lightly lubricate the two driveshaft O rings with Motor Oil Grease in the O ring grooves can hydraulically lock the O rings and cause difficulty starting the driveshaft into the gimbal bearing 35058 232 VPA 7743008 07 2003 Sterndrive Removal and Installation 10 Lift the trim tilt hydraulic cylinders and rest them on the spray plates Slide driveshaft and universal coupler into Universal Joint bellows 34055 11 To align the driveshaft splines rotate propeller shaft until the driveshaft splines engage the flywheel coupler 12 Slide sterndrive onto the six studs until it is completely seated against the pivot
163. ousing VPA 7743008 07 2003 SX Lower Gearcase 5 Unscrew propshaft bearing housing and remove Shim Ring Volvo Penta P N 3850626 3850626 21486 Install propshaft and bearing housing Use Housing Remover installer P N 3850707 and Spline Socket P N 3850598 to turn driveshaft and tighten bearing housing This will set final rolling torque for the lower gearcase Set rolling torque at 14 23 in Ib 1 58 2 60 N m for 1 43 1 1 51 1 1 60 1 1 79 1 and 1 89 1 gear ratio sterndrives and 11 18 in Ib 1 24 2 03 N m for 1 66 1 1 97 1 and 2 18 1 gear ratio sterndrives Gear Lash Checking 1 The propeller must not turn when checking gear lash If final rolling torque is high enough to make the propeller shaft hard to turn by hand no additional steps are necessary If the propeller shaft turns freely install a propeller without the thrust washer Install the brass spacer and prop nut Tighten the prop nut by hand until the propshaft does not rotate freely 2 Slide Gear Lash Extension Volvo Penta P N 3850602 onto drive shaft splines 3 Clamp or hold base of dial indicator onto machined surface of gearcase Position dial indicator perpendicular to flat surface of gauge arm Dial indicator must contact groove on gauge arm for an accurate reading Rotate gauge arm and dial indicator should read between 0 005 0 012 in 0 13 0 30 mm If a reading between 0 005 0 012 in 0 13 0 30 mm is obtained remove propeller an
164. out as gim bal housing is removed Remove the screw and washer securing the transom plate ground strap to the steering arm Remove the two screws and four nuts and washers securing the transom plate inside the boat Lift the plate off the studs Note that the hydraulic lines route above the uppermost port stud and through a relief in the inner transom plate VPA 7743008 07 2003 Transom Shield Assembly SX MHP 34673 Casket seali ompound 4949 34671 VPA 7743008 07 2003 3 Remove the two remaining nuts washers and transom bearing plate Pull the gimbal housing off the transom 1 Unscrew the shift cable sleeve and connector assembly Discard the connector O ring 2 Apply Volvo Penta Gasket Sealing Compound to a new O ring Slide it onto the connector and position it against the hex then coat the connector threads with sealer 3 Install the sleeve and connector assembly and use a crowfoot adapter to tighten the connector to 40 45 ft Ib 54 61 N m 81 Transom Shield Assembly SX MHP Transom and Exhaust Seal Replace ment 1 34670 82 Remove and discard the exhaust O ring seal and the large rubber transom seal Apply 3M Scotch Grip Rubber Adhesive 1300 to the entire tran som seal groove around the gimbal housing Start at top and firmly push a new seal into the groove Also apply 3M Scotch Grip Rub ber Adhesive 1300 to the seal ends and butt t
165. outside of the transom and push it through 2 Ifthe grommet needs to be replaced slide it off the water tube It can be reused if undamaged 35 VPA 7743008 07 2003 Transom Shield Assembly SX M Hydraulic Lines and Manifold Removal 1 Remove the two clamps that secure the lines to each side of the gimbal housing 2 Unscrew all four lines and remove them from the manifold Remove and discard the fitting O rings Removal of the grease extension tube may make the servicing of the starboard side lines easier Clamp a vise grip pliers close to the bearing bore and rotate the tube to loosen it Pry against the plier head to force the tube out of the housing 3 Remove the locknut and washer that attach the manifold old to the housing 4 Since the manifold is sealed by an O ring use a small drift to drive it out of the housing from the inside of the boat 36 VPA 7743008 07 2003 Transom Shield Assembly SX M 5 Pull the manifold and lines through the hole as far as possible Tag one line for reference and note their direction of routing Unscrew both lines then discard the fitting O rings Remove the manifold O ring and discard it 34503 Steering Gimbal Bearing and Seal Note Do not remove the gimbal bearing or upper steering bear Removal ing unless they need to be replaced Removal of the gim bal bearing and seal do not require disassembly of the transom shield Access can be gained by going
166. port the eccentric piston arm and remove the shift shoe stop screw and all shims Remove the two starboard shift housing screws and set them aside Install Bracket and retain with two screws supplied with the bracket Tighten the screws to 60 84 in Ib 6 8 9 5 N m VPA 7743008 07 2003 Upper Gear Housing 3 Move the eccentric piston arm to locate the hole over the drilled and tapped hole in the bracket Install the shoulder screw sup plied with the bracket and tighten securely This will position the shift system for shimming 47137 4 Reinstall the shift shoe stop screw without shims Tighten the stop screw until it is no longer possible to turn the upper driveshaft Loosen the stop screw until the upper driveshaft just turns freely 47139 5 Take a feeler gauge measurement between the housing and the stop screw 47138 6 Remove the stop screw Add enough shims to the screw to come as close as possible to the feeler gauge measurement plus three shims Shims come in one size only Coat the screw threads with Volvo Penta Sealing Compound P N 1141570 VPA 7743008 07 2003 135 Upper Gear Housing 7 Install the stop screw with the required amount of shims Tighten the stop screw to 10 12 ft Ib 14 16 Nm The upper driveshaft must turn freely If it doesn t Re shim the stop screw Eee N 47140 8 Attach
167. r Shift shoe stop screw Top cover Water passage cover 142 U S 145 165 ft Ib 96 110 ft Ib 60 84 in Ib 10 15 ft Ib 22 24 ft Ib 32 40 ft Ib 48 72 in lb 12 14 ft Ib 60 84 in Ib 108 132 in Ib 10 12 ft Ib 16 18 ft Ib 60 84 in Ib Metric 197 224 Nem 130 149 Nem 6 8 9 5 Nem 14 20 Nem 30 33 Nem 43 54 Nem 5 4 8 1 Nem 16 19 Nem 6 8 9 5 Nem 12 15 Nem 14 16 Nem 22 24 Nem 6 8 9 5 Nem VPA 7743008 07 2003 Upper Gear Housing Sealants Lubricants and Adhesives Table 5 Primer Where Used Loctite Primer Pinion gear retainer screw Adhesive Volvo Penta Thread locking com pount P N 1161053 Pinion gear retainer screw Lubricants Volvo Penta Propeller Shaft Grease P N1141644 universal joints Volvo Penta Grease P N 828250 Seal lips Shift linkage pivot points DPL Penetrating Lubricant O D of rubber coated seals GL 5 Synthetic gear lubricant Threads upper driveshaft O ring pinion bearing carrier O ring shift actuator housing Sealants Volvo Penta Gasket Sealing Compound P N 1161099 Gauge and plug gear case oil level Screws water passage plate Screws pinion bearing housing Screw drain Screws lower to upper gear case Screws shift actuator housing Screws shift linkage access cover Screws top cover Volvo Penta White Sealing Com pound for Drives P N 1141570 Shift shoe stop screw
168. r 3845358 E Retaining Ring Pliers 3850608 B Rod 3854351 C Socket Removal Tool 3854350 B Same panel position as obsoleted Installer P N 912279 OEM 4184Slide Hammer OTC Division of SPX Corporation 655 Eisenhower Drive Owatonna Minnesota 55060 USA Toll free order line 1 800 533 5338 or 1 800 533 0492 http www otctools com Cleaning Solvent Volvo Penta Gasket Sealing Compound P N 1161099 Loctite Primer N Volvo Penta Thread Locking Compound P N 1161053 Volvo Penta Grease P N 828250 3M Adhesive Wheel Bearing Grease Remove the sterndrive following the procedure in Sterndrive Removal and Installation section in this manual If the complete transom bracket assembly is being rebuilt or replaced remove engine following procedure in the Installation Manual VPA 7743008 07 2003 Transom Shield Assembly SX MHP Trim Tilt Cylinder Removal VPA 7743008 07 2003 1 Remove screw and ground wire from the front of the cylinder 2 Carefully remove pivot pin cap 3 Wear safety glasses Cover fittings with a shop cloth and discon nect trim tilt lines 4 Remove and discard trim tilt line O rings 55 Transom Shield Assembly SX MHP 48625 Trim Tilt Cylinder Installation 48638 56 Wear safety glasses Remove pivot pin E clip and flat washer Pull pivot pin out of cylinder gimbal ring and cylinder on opposite side Remove bushing from gimbal ring and replace if necessary Remove cylinde
169. r Gear Housing 12 Carefully insert the universal joint shaft through the seal and engage the splines of the input gear 13 Spray the threads of the universal joint shaft and a new pinion gear retainer screw with Loctite Primer N and allow to air dry 14 Place the pinion gear retainer onto the top of the input gear Apply Volvo Penta Thread Locking Fluid P N 1161053 to the screw threads 34758 15 Install the screw and tighten a little at a time using Torx Bit P N FTX500 Turn the pinion bearing carrier while tightening the screw to seat the bearings Frequently remove the assembly from the vise to check the rolling torque Stop when the rolling torque reaches 9 14 in Ib 1 0 1 6 N m Note Ifthe rolling torque is exceeded the pinion bearing carrier will have to be disassembled and a new pretension sleeve installed VPA 7743008 07 2003 111 Upper Gear Housing Upper and Lower Output Gears Assembly 1 Place the lower gear in a press Protect the gear face Lightly oil the inside diameter of the bearing with GL5 Synthetic gear lubri cant 34755 Place the bearing with the square stepped surface facing the gear on the top of the gear U T X pyl A 7 X UL D 2 A Press the bearing in place until it seats using Drift Volvo Penta P N 884168 4 Repeat steps 1 2 and 3 for upper gear Place Sleeve Volvo Penta P
170. r and set aside to drain Remove the ground wire and hydraulic lines from the remaining cylinder Remove the remaining E clip and washer form the pivot pin Clean the pivot pin then coat it with Volvo Penta Grease P N 828250 Replace the gimbal ring s bushings if they re damaged then slide the pivot pin through the cylinders and gimbal ring Center the pivot pin Install both washers and E clips Place a new O ring on the trim tilt cylinder line fittings and attach lines to cylinder Tighten line fittings to 84 108 in Ib 9 5 12 2 N m VPA 7743008 07 2003 Transom Shield Assembly SX MHP Pivot Housing Removal 34616A 34617 VPA 7743008 07 2003 5 Install pivot pin caps 6 Attach ground wires to front of trim tilt cylinders Tighten screws securely To fill and bleed the trim cylinders and trim motor reser voir see Filling and Bleeding Dry System in Trim Tilt Hydraulic System section of this manual Remove the sterndrive following the procedure in Sterndrive Removal and Installation section in this manual 1 Turn sterndrive to port Loosen anchor clamp screw and slide clamp to starboard disengaging the remote control shift cable 2 Remove shift cable from the pivot and gimbal housing Remove the small and large seals From inside of boat pull shift cable out of the sleeve and connector assembly 57 Transom Shield Assembly SX MHP 58 19475 4906 48616 3 4
171. r up it must contact backside of bearing Insert driveshaft into Installer and press driveshaft into bearing until it seats Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the I D of the large bearing Protect threads of driveshaft by plac ing Sleeve Installer Volvo Penta P N 3855869 8 onto driveshaft Slide bearing onto driveshaft with taper facing away from small bearing Rest Bearing Installer Volvo Penta P N 3850617 on open jaws of a press support Position raised lip of Installer up it must contact nose of bearing Insert driveshaft into Installer and press driveshaft into bearing until it seats Apply Loctite Primer to the inside of the sleeve and it s position on the driveshaft and allow to air dry Apply a small amount of Loctite 609 to the driveshaft Position the sleeve on the driveshaft and press into position using Sleeve Installer Volvo Penta P N 3855869 Remove the screw retaining the two magnets and three spring washers from inside of the front of the gearcase Remove any metal chips from the magnets VPA 7743008 07 2003 DP S Lower Gearcase Installation Apply Loctite Primer to the retaining screw and let air dry Apply Loctite 242 to the screw threads Arrange the washers and magnets as shown J muf and install them in the gearcase Secure with the retaining screw 43494 Tighten the screw securely Upper Housing Stud Replacement 1 Remove the stud to be replaced 2 Apply Loc
172. ransom Bracket Mounting 20 25 ft Ib 27 34 Nem Trim Line to Cylinder Manifold 84 108 in Ib 9 5 12 2 Nem Water Nipple 96 120 in lb 11 14 Nem Screw Alignment Inner Transom Plate 12 14 ft Ib 16 19 Nem Anode 5 7 ft Ib 6 9 Nem Cover Gimbal Housing 60 84 in Ib 7 9 Nem Gimbal Ring Support Large screw 38 59 ft Ib 51 81 Nem Gimbal Ring Support Small screw 13 28 ft Ib 18 38 Nem Pivot Housing to Gimbal Ring 105 120 ft Ib 142 163 Nem Steering Arm Center 35 60 ft Ib 45 75 Nem Support Bracket Gimbal Ring 22 33 ft Ib 30 46 Nem Transom Bracket Mounting 20 25 ft Ib 27 34 Nem Trim Sender 18 24 in Ib 2 0 2 7 Nem Water Outlet 120 144 in Ib 14 16 Nem VPA 7743008 07 2003 85 Transom Shield Assembly SX MHP Sealants Lubricants Adhesives Volvo Penta Thread Locking Compound P N 1161053 Adhesives Stud Gimbal Housing Lubrication Tube Stud Manifold 3M Adhesive Seal Water Passage Seal Ring Gimbal Housing Cover 3M Scotch Grip Rubber Adhesive 1300 Seal Exhaust Opening Transom Seal Lubricants Volvo Penta Grease P N 828250 Alignment Tube Inner Transom Plate Bushing Upper Steering Post Friction Washer Pivot Housing Grommet Trim Sender Lead Nylon Bushing Trim Cylinder O ring Upper Steering Post O ring Water Nipple Pivot Pin Trim Tilt Cylinder Seal Lip Gimbal Housing Thrust Washer Lower Steering Post Thrust Washer Pivot Bolt Thrust Washer Upper Steering Bearin
173. rce if drive will not hold vacuum Make repairs as necessary and repeat test Drive must not loose more than 1 inch of mercury 3 4 kPa in 3 minutes Do not fill sterndrive with oil until it passes both pressure and vacuum tests Drives that fail either test will allow water entry when in use and cause subsequent damage to internal parts VPA 7743008 07 2003 Upper Gear Housing 1 Place drive in a vertical position Remove the rear plastic cover to allow access to the oil level plug Remove the oil level plug Also remove the level indicator gauge at top of drive to help vent the oil reservoir Discard the plug and gauge seal Replace them with new ones 2 SX Models Only Remove magnetic drain screw on side of skeg Discard screw seal and replace with a new one 3 DP S Models Only Remove drain screw at the back of the gear case Discard screw O ring and replace with a new one Install Fill Adaptor Volvo Penta P N 3855932 43638 VPA 7743008 07 2003 139 Upper Gear Housing 4 Fill drive with GL5 Synthetic gear lubricant from drain hole Fill slowly to purge trapped air Stop filling when the oil level reaches the bottom of the oil level hole Do not overfill Note Filling drive too quickly may form air pockets that will cause an inaccurate oil level reading Running drive with improper oil level can result in immediate internal dam age 5 All Models When
174. reassembly Do not remove propshaft gear bearing unless you intend to replace it Removal process may damage bearing Use a bear ing separator to support the bearing Insert Bearing Remover Volvo Penta P N 3850625 and Handle Volvo Penta P N 3850610 into gear then press gear out of bearing Do not remove oil slinger from gear unless you intend to replace it Removal process may damage oil slinger Use a bearing separator to support the oil slinger and press gear out of oil slinger VPA 7743008 07 2003 SX Lower Gearcase Pinion Bearing Removal AB a on Ss 3 3855860 3855859 385061 A E 3850623 3850622 _ mee ma ee 42656 42657 Driveshaft Bearing Removal and Installation VPA 7743008 07 2003 1 Assemble Remover Tip Volvo Penta P N 3855859 Rod Nut and Washer Volvo Penta P N 3855860 and Guide Plate Volvo Penta P N 3850613 Place the remover tip into the driveshaft cavity under the lip of the lower driveshaft bearing race 2 Tighten the nut and remove the lower driveshaft bearing race and shims The shims may be damaged during bearing race removal and should be replaced 3 To remove pinion bearing apply Grease to the bearing rollers and place them in the bearing case Use Pusher Puller Volvo Penta P N 3850623 Guide Plate Volvo Penta P N 3850613 a
175. red end of the tube and housing hole with Loctite Primer and allow to air dry c Sparingly apply Volvo Penta Thread Locking Fluid P N 1161053 to the tapered end of the tube and drive the tube into the housing until it seats Wipe away any excess adhesive that may enter the bearing cavity or the end of the tube Install the grease fitting 34508 1 Apply Volvo Penta Grease P N 828250 to the trim tilt sender lead grommet Feed the wires through the opening in the rear of the gimbal housing and out through the transom plate Push the grommet into the hole until it seats Note Do not route trim tilt sender leads under extension tube or hydraulic lines Leads must be free to move when drive unit steers otherwise sender or wire will be damaged 34510 2 Attach the retaining clip to the grommet inside the transom plate VPA 7743008 07 2003 41 Transom Shield Assembly SX M 3 Install the RIBBED BLACK wire in the A terminal the WHITE wire in the B terminal and SMOOTH BLACK wire in the C termi nal on the Amphenal connector Use Socket Installer Volvo Penta P N 3854349 to push the wire sockets into the rubber plug until they seat Note The use of alcohol will make socket installation into the rubber plug easier 42586 Water Tube Installation 1 If the grommet was discarded face the tapered end of a new one toward the hooked end of the tube and slide it up against the fla
176. reservoir as necessary Hydraulic Pressure Specifications Mode Trim out tilt up running Tilt up stall Tilt up stall leak down Trim in tilt down running Trim in stall Trim in stall leak down Impact Valve Opening Normal Pressure 290 310 PSI 2000 2137 kPa 1350 1450 PSI 9308 9998 kPa 69 amps max 100 PSI 690 kPa maximum 590 610 PSI 4068 4206 kPa 750 850 PSI 5171 5861 kPa 1000 PSI 690 kPa maximum 1800 PSI 12411 kPa minimum Hydraulic Flow Diagram UP Notes 24 amps max 5 minutes min 36 amps max 44 amps max 5 minutes min PORT A DN PORT B THERMAL R V 2500 500 PSI UP R V 1400 100 PSI a ae ieee N Z 8 sey T eal G DN R V 650 200 PSI VPA 7743008 07 2003 DRC7603 257 258 VPA 7743008 07 2003 Propellers Propellers Table of Contents Sealants Lubricants and Adhe sives Safety Warnings Special Tools Propeller Selection SX Models VPA 7743008 07 2003 Sealants Lubricants and Adhesives 259 Special Tols esa audi Annee eee eh eee 259 Propeller Selection SX Models 259 Propeller Removal and Installation SX Models 260 Left Hand Rotation SX Models 262 Propeller Selection DP S 0000ee eee 262 Propeller Removal and Installation DP S Models 263 Condition of Boat Bot
177. rift 884168 F Drift 884259 F Drift 884263 F Drift 884266 F Remover Installer 3850606 H Retaining Ring Pliers 3850608 B Seal Installer 3850607 H Shim Tool 3850600 H Shim Tool 3850701 H Sleeve 884938 F Spanner Wrench 3850604 H Spline Socket 3850598 H Standard Shaft 9991801 H universal joint Adaptor Kit 3850628 G Upper Gear Housing Holder 3856163 Not located on tool board because of size Owatonna Service Tools OEM 4635 universal joint Tool OEM 1027 Universal Dial Indicator Set Order From OTC Division of SPX Corporation 655 Eisenhower Drive Owatonna Minnesota 55060 USA Toll free order line 1 800 533 0492 or 1 800 533 5338 http www otctools com Sealants Lubricants and Adhesives Cleaning Solvent GL5 Synthetic gear lubricant Volvo Penta Gasket Sealing Compound Loctite Primer Volvo Penta Thread locking compount P N 1161053 Volvo Penta Grease P N 828250 3M Adhesive Wheel Bearing Grease gear lubricant 90 VPA 7743008 07 2003 Upper Gear Housing Sterndrive Removal Sterndrive Disassembly VPA 7743008 07 2003 34645 To service components of the upper gear housing remove sterndrive from transom bracket Follow the procedure in Sterndrive Removal and Installation section in this manual 1 Mount the sterndrive assembly in a suitable holding fixture and clamp it securely Unscrew the lifting eye if one was used or the dipstick Discard the O ring on the dipstic
178. rndrive shaft in the direction of rotation While turning brake the propeller shaft movement to simulate a propeller load If you must load the propshaft with you hands wear leather gloves The propeller shaft has sharp edges and may cut or injure your hands 4 Remove the bearing carrier and the propshaft Inspect the prop shaft gear contact pattern Check that the contact pattern matches figure 3 The pattern should be positioned in the middle of the tooth but displaced towards the toe If the contact pattern running off the toe add equal amounts of shim thickness from 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 Gear backlash and contact pattern must be corrected in consecu tive steps The backlash MUST be correct before checking the contact pattern If adjustment is made to the shims to correct the gear contact pattern then the backlash must be rechecked before final assembly may begin Clean all marking compound from gears prior to final assembly 167 SX Lower Gearcase Final Propshaft Bearing Housing Shimming 1 Determine depth of propshaft bearing housing Measure from gearcase hub edge to top of each bearing housing rib Stay away from the bolt holes Record and average the measurements Table 4 Add Divide Rib no 1 0 408 in 1 208 in 3 0 4026 in
179. rom each side VPA 7743008 07 2003 103 Upper Gear Housing 2 3 Q 0 Gy wa O Oj N 4 42590 To reset the width pry off four retaining rings and remove the thrust plates The retaining rings can be reused unless they are broken Notice that the concave side of each ring faces inside the housing Underneath each plate is one or more shims Each shim is the same size 0 015 in 0 38 mm Shims must always be installed in pairs one on each side of the housing There must always be a minimum of one shim per side but no more than four per side If more than four per side are needed replace both thrust plates and check the dimension again To determine if shimming is necessary compare your measure ment with 5 036 12 79 cm Example 5 036 in required width 5 012 in measured width 0 024 in difference In this example no shims are required Since shims are added in pairs the difference would have to exceed 0 030 in 0 015 in X 2 before shims would be needed Note Do not exceed 5 036 in 12 79 cm when adding shims 5 104 Excessive width will cause interference between the upper gear housing and the transom bracket Place correct shims on the thrust plates and insert the plates into the housing Face the concave side of each retaining ring toward the inside of the housing Push the ring onto the plate stud Hold the ring with a 1 2 in box end wrench Tap the th
180. ropriate parts cata log Lock Ring Threads lock ring must turn freely for fulldepth Cooling Passages check for corrosion build up that would restrict water circulation Pinion Bearing Carrier Bare remove all sharp edges that would out O ring Model I D Plate transfer plate to new gear housing when replacing old housing Gears Shafts and Bearings inspect gear teeth for cracks and chips or discoloration If any gear is damaged all must be replaced They are replaced as a set Screw threads on end of shafts must be undamaged Replace shaft if lock patch is excessively worn Check for pitting corrosion and discoloration Cone Clutch and Shift Shoe replace if any signs of exces sive wear is found 1 Apply Volvo Penta Grease P N 828250 to the cube shaft Install the cube on the bellcrank arm with the slotted hole Secure with flat washer and cotter pin Bend the ends of the cotter pin for a secure attachment VPA 7743008 07 2003 Upper Gear Housing 2 Install the shift link into the bellcrank 47123 3 Apply Volvo Penta Grease P N 828250 to the bellcrank pin Place the bellcrank assembly inside the housing Insert the pin into the housing from the starboard side Note The screwdriver slot must face away from the housing 4 Place one flat washer on the pin between the housing and the starboard side of the bellcrank Push the bellcrank pin all the way through the bellcrank and into the port side of th
181. ropshaft VPA 7743008 07 2003 SX Lower Gearcase 2 To remove propshaft bearing screw propeller nut onto shaft to prevent thread damage Support bearing in a bearing splitter and press propshaft down and out of bearing Be ready to catch shaft when bearing comes free 20797 Propshaft Bearing Installation Apply a light coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the fa I D of the bearing Slide bearing onto propshaft with taper facing the threaded propeller nut end Rest Bearing Installer Volvo Penta P N J 3850617 on the open jaws of a press support Position raised lip of Installer up it must contact nose of bearing To prevent spline damage slide Driveshaft Holding Socket Volvo Penta P N 3850618 onto propshaft Insert propshaft into Installer and press propshaft into bearing until it seats a mM Ss a 20796 Intermediate Driveshaft and Water Tube Guide Removal 1 Remove intermediate driveshaft and inspect splines If damaged replace driveshaft Remove inlet water tube and grommet Discard grommet 42612 2 Remove anode and inspect it if anode is 2 3 its original size 1 3 deteriorated replace it 42614 VPA 7743008 07 2003 151 SX Lower Gearcase 3 Remove inlet water tube seal and retainer If seal or retainer are damaged replace them 42615A 4 Remove and discard oil passage O ring
182. rosion e Gimbal Bearing Rollers must spin freely and hub must pivot in all directions inner diameter must be free of corrosion e Hydraulic Manifold O ring groove must be free of nicks and burrs all fluid passages must be clear VPA 7743008 07 2003 73 Transom Shield Assembly SX MHP Hydraulic Lines must be clear and fittings undamaged Grease Fitting and Tube must be unobstructed Mounting Studs must be tight and have no thread damage Seal Grooves Check for corrosion burrs and damaged edges Anode Check amount of deterioration Clean parts in solvent and dry thoroughly Some screw holes have special Heli Coil inserts that provide a thread locking feature Do not clean Heli Coil holes with a thread tap This will damage the Heli Coil inserts and force their replacement Locking Heli Coils are available only from Volvo Penta Parts See your parts catalog Gimbal Housing Assembly Steering Bearing Gimbal Bearing and Seal Installation 1 Face the open end of a new gimbal housing seal toward Installer P N 3850038 and place it on the projecting nose of the tool Lightly coat the metal case with Volvo Penta Gasket Sealing Com pound 48639 2 Screw the installer onto Drive Handle Volvo Penta 3850609 Drive the seal into the housing until it seats Coat the seal lip with Volvo Penta Grease P N 828250 3 To ensure adequate lubrication of the gimbal bearing it must be correctly positioned prior to
183. rranty claims involving that engine may be refused When a brand name product or specific tool is called for another item may be used However the substitute must have equivalent characteristics including type strength and material You must determine if incorrect substitution could result in product malfunction and personal injury to anyone To avoid hazards equivalent products which are used must meet all current U S Coast Guard Safety Regulations and ABYC standards When replacement parts are required always use genuine Volvo Penta parts or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or passengers Parts Catalogs contain exploded views showing the correct assembly of all parts as well as a complete listing of the parts for replacement These catalogs are helpful as a reference during disassembly and reassembly and are available from Volvo Penta Parts 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 General Information Product References Illustrations amp Volvo Penta reserves the right to make
184. rust plate with a soft face hammer until the ring seats against the housing VPA 7743008 07 2003 Upper Gear Housing Shift Linkage Disassembly 1 Place a flat blade screwdriver in the slotted end of the bellcrank pin Remove and discard cotter pin 47113 2 Pull out the pin and remove bellcrank assembly and one flat washer 3 Remove shift link from bellcrank 47115a 4 Remove and discard the cotter pin securing the cube to the bellcrank Remove flat washer then the cube q SV A 47116 VPA 7743008 07 2003 105 Upper Gear Housing Water Passage Plate Service NY r geci 42580 Cleaning and Inspection Shift Linkage Assembly 106 This plate is a water passage plate and is not removed for normal service If the unit has a restricted water flow cooling system problem the plate may be removed to look for debris A new gasket coated with Volvo Penta Gasket Sealing Compound must be used for reassembly Tighten the four screws to 60 84 in Ib 6 8 9 5 N m Clean the housing in solvent to remove all sealer from screw holes gasket surfaces and O ring bores Dry the housing thoroughly Note Most threaded holes in the upper gear housing have Heli Coil inserts Do not use a thread tap to clean screw holes Tap will damage Heli Coil insert and make replacement necessary Do not replace with standard non locking Heli Coils use only those shown in the app
185. s follows 1 Place sterndrive in the run full down position Place a 4 quart drain pan under lower gear case skeg to catch oil 2 Remove oil drain plug port side of lower gear case and oil level dipstick top of sterndrive Removing dipstick vents drive to improve oil draining Allow oil to drain completely VPA 7743008 07 2003 General Information VPA 7743008 07 2003 3 Remove three screws securing the shift link access cover to access the oil level plug Fill sterndrive with Volvo Penta Synthetic Gearcase Lubricant SAE 75W 90 through oil drain plug hole Fill slowly to purge air 4 Sterndrive is properly filled when the oil level appears at the oil level plug hole When filled to the proper level install oil level dip stick and the oil level plug first to prevent excessive oil loss then the oil drain plug Tighten oil level gauge plug and drain plug fin ger tight Note Filling sterndrive too quickly may form air pockets that will cause an inaccurate oil level reading Running the sterndrive with improper oil level will result in immediate internal damage 5 Check oil level with dipstick Oil level must appear on the blade of the dipstick Add oil if required through the dipstick hole See Adding Lubricant to Sterndrive on page 8 6 Tighten drain plug to 60 84 in Ib 6 8 9 5 N m Tighten oil level dipstick to 48 72 in Ib 5 4 8 1 N m 7 Install shift link ac
186. shift cable 34038 6 Remove and retain end cover 7 Remove e clip and flat washer from trim tilt pivot rod 47551 VPA 7743008 07 2003 229 Sterndrive Removal and Installation 8 NOTE Use a soft hammer to lightly tap trim tilt pivot rod out of trim tilt cylinder Support hydraulic cylinders while removing pivot rod Carefully lower each hydraulic cylinder to rest on the spray plate after pivot rod is removed 9 Attach a hoist capable of lifting at least 500 Ib 227 kg to lift ing eye or use a dolly to hold sterndrive Remove and discard six lock nuts TA 47129A 10 Pull sterndrive away from transom bracket and support driveshaft and universal coupler ace as a Ae Se 34055 1 Remove dipstick and o ring Install a lifting eye into the dipstick hole A sterndrive cart may also be used if access is blocked by a swim platform 230 VPA 7743008 07 2003 Sterndrive Removal and Installation 2 Apply a light coat of Volvo Penta Grease P N 828250 to tapered end of pinion bearing carrier 34062 3 Inspect molded rubber seal ring for proper fit in its groove Inspect and lightly lubricate Universal Joint bellows lip with Volvo Penta Grease P N 828250 4 Assemble Alignment Tool Volvo Penta P N 3851083 and Univer sal Handle Volvo Penta P N 3850609 Slide alignment tool through gimbal bearing The alignment tool must slide thr
187. side the bellows Position the opening upward as shown for secure attachment 34587 10 Attach the ground wires with screw to the threaded hole on the port side of gimbal ring Fa 11 Install and adjust the trim see Trim Sender Adjustment on Pd page 33 48616 Remove trim tilt cylinders and pivot housing following instructions elsewhere in this section 1 Turn the gimbal to port and remove the two screws holding the trim sender Do not attempt to pull out the sender as its leads are secured to the transom shield 26 VPA 7743008 07 2003 Transom Shield Assembly SX M 2 Remove the three screws and lock washers holding the lower steering support bracket and pull the bracket off 3 If it s tight use a drift punch and mallet to tap on alternating sides of the bracket until its free 34482 4 Remove cotter pin and steering arm pin Remove ground strap from steering arm 5 Remove four screws and the gimbal housing cover 48617 VPA 7743008 07 2003 27 Transom Shield Assembly SX M 6 Remove and discard the sealing ring 7 Remove the four locknuts and retaining plate from the top of the steering arm Unscrew the center steering arm bolt 8 Rest Tiller Arm Puller Volvo Penta P N 3854361 on top of the two alignment dowels inside the steering arm and install the center bolt Tighten the bolt to remove the steering arm Be ready to catch the gimba
188. sition the propshaft gear in relation to the pinion Record the following shimming measurement for the final gear lash check Apply a light coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the propshaft gear and oil slinger Align the pins of oil slinger with the holes of the propshaft gear Use a suitable piece of flat stock or Bearing Separator and Propshaft Bearing Installer Volvo Penta P N 3850617 to press oil slinger onto gear until seated Apply a light coat of GL5 Synthetic Gear Lubricant SAE 75W 90 to the bearing Slide new bearing onto propshaft gear with taper fac ing away from gear Position nose of Remover Installer Volvo Penta P N 3850624 onto bearing and press bearing onto gear until it is seated Place gear and bearing on a flat surface Place the bearing race on top of the bearing Rotate the race to seat the bearings Posi tion Shim Fixture Volvo Penta P N 3850600 on top of the gear and bearing assembly recessed side facing down 159 SX Lower Gearcase Propshaft Gear Bearing Cup Installa tion 160 2 Using a depth micrometer measure the distance from the top of the shim fixture to the end of the gear shaft Subtract 0 500 in from this measurement Example Subtract 0 597 in measurement to end of gear shaft 0 500 in thickness of shim fixture 0 097 in actual dimension 3 Add or subtract the shimming allowance number etched on the gear from the actual dimension in Step
189. t 12 Remove lower gear and bearing assembly Remove needle bear ings from the assembly after noting bearing orientation top to bot tom Note Do not mix needle bearings with those of the upper gear and bearing assembly Premature failure will result if they are intermixed Bearings should be reinstalled in the same top to bottom orientation as they were removed for lon gevity Upper and Lower Output Gear Disas sembly 1 Place Remover Installer Volvo Penta P N 3850606 9 large diam eter end up in a press Place the upper gear and bearing assem bly has extra ring around bearing into the tool with the gear a 884263 facing up Press the ring off the bearing using Drift Volvo Penta P N 884263 5 3850606 A CZN R 34609 2 Place Sleeve Volvo Penta P N 884938 2 large diameter end up in a press Place the upper bearing assembly into the tool with the gear facing down Press the gear from the bearing using Drift Volvo Penta P N 884263 5 3 Follow the procedures in the previous step and remove the lower gear from the bearing VPA 7743008 07 2003 97 Upper Gear Housing 4 Wear eye protection The upper driveshaft may be disassembled if needed by removing the spring C clip and spring spacer 34596 Universal Joint Replacement Note Both Universal Jointuniversal joints can be replaced with out removing the pinion bearing carrier from the upper gear housing Removal 1 Wear eye pr
190. t to the water is concerned Several countries have put into practice or will put into practice a more restrictive legislation for pleasure boats that for commercial boats and vessels The reason is that pleasure boat harbors often are situated in shallow waters which are spawning grounds for fish Contrary to commercial boats pleasure boats spend most of their time tied up in the harbor which adds to the impact on the environment in these waters Since the protection of the environment is in the best interests of all concerned it is important to minimize the use of antifouling paints As far as smaller boats are concerned trailer boats which can be taken out of the water we recommend Teflon type paint only combined with cleaning a few times during the season This procedure can prove somewhat impractical as far as larger boats are concerned and therefore antifouling paints might have to be used However always take care to find out the valid legislation in the area where you intend to use the boat prior to starting the treatment of the boat The legislation can also provide rules as to the boat weight or overall length Always follow these directions 11 General Information Painting The Stern Drive With Anti fouling Paint Paints For Stern drives Painting The Hull With Antifouling Paint 12 Note It may be completely forbidden to use antifouling paints on pleasure boats in some instances e g in fresh water Clean
191. t your hands from sharp edges of propel ler blades by wearing gloves when removing or installing the propellers 1 Move the shift control to FORWARD Remove the rear propeller nut using a 30 mm socket Remove the rear propeller from the shaft Check for fish line and remove if found 2 Move the shift control to REVERSE Remove the front propeller nut using Front Propeller Tool Volvo Penta P N 3855876 263 Propellers Installation Condition of Boat Bottom Bottom Painting Boat Trailers 264 Remove the front propeller from the shaft Check for fish line and remove if found 3 Wipe both propeller shafts clean and check for damage Repair any damage 1 Coat the full length of both propeller shafts with Volvo Penta Pro peller Shaft Grease P N 1141644 2 Place the remote control in the FORWARD gear position to lock the propeller shafts 3 Install the front propeller Install the front propeller nut and tighten to 45 ft lb 60 N m using Front Propeller Tool Volvo Penta P N 3855876 4 Place the remote control in the REVERSE gear position to lock the propeller shafts 5 Install the rear propeller Install the rear propeller nut and tighten to 50 ft Ib 70 N m Note Failure to install the propellers as indicated could result in the loss of the rear propeller and damage to the drive unit when the boat is operated The condition of the boat bottom affects the boat s performance considerably Mari
192. tall Tighten the fittings to 84 108 in Ib 9 5 12 2 N m and discard the reference tag Tagged line must attach to the correct inlet If lines are switched trim tilt mechanism will malfunction When properly connected the lower manifold line will attach to the UP inlet on the pump valve body and the upper manifold line will connect to the starboard inlet on the pump body Feed the lines through the manifold opening pulling them from inside the transom if necessary Seat the manifold over its mount ing stud Use a new locknut and tighten nut to 108 132 in Ib 12 15 N m Coat new O rings with hydraulic fluid and place them on hydraulic lines Attach the lower port line A to the manifold first then the upper one Tighten the fittings to 84 108 in Ib 9 5 12 2 N m Attach the short starboard line B to the lower port of the manifold Attach the long starboard line C to the upper port of the manifold Tighten the fittings to 84 108 in Ib 9 5 12 2 Nm Route the lines together down the side of the housing Install the clamp and screw tighten the screw securely VPA 7743008 07 2003 Transom Shield Assembly SX M 7 Ifthe grease extension tube was removed install it as follows a Remove the grease fitting from the tube Apply Volvo Penta Gasket Sealing Compound P N 1161099 to the last 1 4 in of the grease fitting end of the tube Insert the tube through the outer wall of the housing b Spray the tape
193. te Driveshaft and Water Tube Guide Removal 157 Driveshaft and Gear Removal 20020e000s 158 Pinion Bearing Removal 000eee eee e eens 161 Driveshaft Bearing Removal and Installation 161 Pinion Shimming 00e0e cece eee eee 162 Lower Gearease Assembly 00 e0055 164 Propshaft Gear Bearing Installation 164 Propshaft Gear Shimming 0 000eeeeeeee 165 Propshaft Gear Bearing Cup Installation 166 Pinion Bearing Installation 0 000 cece eee 167 Driveshaft and Gear Installation 05 168 Setting Initial Rolling Torque 20200s eee 169 Initial Propshaft Bearing Housing Shimming 170 Setting Final Rolling Torque 00eeeeeeeee 171 Gear Lash Checking 00 00 cece eee eee ee eeee 171 Checking Gear Contact SX Lower Unit 172 Final Propshaft Bearing Housing Shimming 174 Propshaft Bearing Housing Retainer Installation 175 Lower Gearcase Installation 0 00eeee eee 176 Pressure and Vacuum Testing Sterndrive 178 Sterndrive Filling 00ecs cee eee eee eee 179 Specifications indies tare we Asoo ian awe tet 181 Sealants Lubricants and Adhesives 182 Service Chart foes ke od at eareGer sd eee eae 183 Before beginning work in this section read Safety chapter at end of this manual Several of the following procedures require the
194. te the lines above the alignment tube B and over the uppermost port stud C as shown 34648 3 Lightly coat the six gimbal housing studs with Volvo Penta Gasket Sealing Compound 34650 VPA 7743008 07 2003 47 Transom Shield Assembly SX M 4 Apply alight coat of Volvo Penta Grease P N 828250 to the inside of the transom plate alignment tube 5 Position the two hydraulic lines above the uppermost port stud and mount the transom plate Place the transom bearing plate over the two bottom studs flat side against transom Install three flat wash ers and five new locknuts Tighten nuts until they just contact plate and transom Do not tighten nuts at this time 6 Position ground wire on transom shield stud Install washer and locknut Do not tighten nut at this time 7 Lightly coat the alignment screw threads with Volvo Penta Grease P N 828250 then screw them completely in only finger tight Do not tighten the alignment screws at this time 48 VPA 7743008 07 2003 Transom Shield Assembly SX M 8 Tighten the six locknuts in a cross pattern starting with the two center nuts Tighten them to of 20 25 ft Ib 27 34 N m DR1074 9 Tighten the two alignment screws to 12 14 ft Ib 16 19 N m 10 Attach transom plate ground strap to the steering arm and secure with screw and washer Tighten s
195. ter propeller shaft Position the sleeve on the outer propeller shaft and press into position using Bearing and Sleeve Installer Volvo Penta P N 3855866 193 DP S Lower Gearcase 3855928 43485 884975 43473 43474 Forward Gear Service Removal 194 Apply a light coating of GL 5 Synthetic gear lubricant SAE 75W 90 to the outside surface of the needle bearing and position it in the end of the outer propeller shaft Press the bearing into position until the tool seats using Bearing Installer Volvo Penta P N 3855928 Place the double lipped seal onto Installation Tool Volvo Penta P N 884975 with the rubber case facing the stepped side of the installer Apply a light coat of Volvo Penta Gasket Sealing Com pound to the outside surface of the seal Press the seal into place until the tool seats Position the single lipped seal onto Installation Tool Volvo Penta P N 884975 with the open side of the seal facing the installer Apply a light coat of Volvo Penta Gasket Sealing Compound to the outside surface of the seal Press the seal into place until the tool seats Remove the tool and apply a light coating of Volvo Penta Grease P N 828250 to the seal lips Note Bearing should not be removed unless it is to be replaced Removal will damage the bearing VPA 7743008 07 2003 DP S Lower Gearcase Clamp a bearing separator onto the forward gear bearing Place the assembly in a press and remove the bearin
196. the four screws securing the pinion bearing carrier to the upper housing VPA 7743008 07 2003 93 Upper Gear Housing 4a S A ha Mioi PENI EWN aw 34603 34604 94 34606 2 3 1 2 Remove the pinion bearing carrier using two screwdrivers Be careful not to damage the upper housing or the bearing carrier mounting surfaces Save any undamaged plastic shims as they may be reused Remove and discard the O ring Remove the four screws securing the upper gear housing top cover Remove the cover Save any undamaged shims under the cover as they may be reused Remove and discard the cover seal VPA 7743008 07 2003 Upper Gear Housing 3 Push the holding fixture shaft up to engage the upper driveshaft splines Align the flat on the fixture shaft with the locking screw Tighten the locking screw to prevent the upper gear housing shaft from turning Remove the LEFT HAND threaded nut on top of the shaft with a 30 mm socket 42577 4 Lift upper gear and bearing assembly out of the housing Remove needle bearings from center of bearing assembly after noting bearing orientation top to bottom Remove and save shims They can be reused if they are not damaged Note Do not mix needle bearings with those of the lower gear and bearing assembly Premature failure will result if they are intermixed Bearings should be reinstalled in the same top to bottom orientation
197. the shift link to the eccentric piston arm Secure with washer and cotter pin Bend the ends of the cotter pin for a secure attachment Note Make sure the bent ends of the cotter pin do not come in contact with the shift housing Hard shifting and housing damage can occur if the pin ends are not completely bent 47141 1 Install intermediate driveshaft with the groove facing upward onto driveshaft 136 VPA 7743008 07 2003 Upper Gear Housing 2 Install and position water grommet and supply tube into upper U gear housing Check oil filter for proper installation Note Care must be used on reassembly of gear case If machined surface is damaged leakage may occur 39433 39389 3 Attach upper gear housing to the lower gear case Engage inter iN mediate driveshaft splines and water supply tube 42610 4 Apply Volvo Penta Gasket Sealing Compound to the lower gear case mounting screws Install four short screws two on either side of gear case and two longer screws aft Tighten 3 8 16 screws to 22 24 ft Ib 30 33 N m and 7 16 14 screws to 32 40 ft Ib 43 54 N m 42588 Pressure and Vacuum Testing Stern Before filling drive with gear case oil it must be pressure and vacuum drive tested to verify proper sealing during assembly Install magnetic drain plug on sid
198. the stern drive carefully Degrease and flush thoroughly with water Sand the surface with a water abrasive paper grit size 200 240 Make sure not to sand through the original paint of the stern drive Damage to drive paint must be carefully repaired with primer and paint Pure metal must be cleaned prior to the application of primer Make sure to let the primer and paint harden in accordance with the manufacturer s instructions Mask the hull around the transom bracket and spots on the sterndrive which are not to be painted Note Do not paint the anodes Important Make sure that you have a good contact between the anodes and the transom bracket or sterndrive Prior to launching the boat the anodes must be cleaned acti vated with emery cloth in order to remove the oxide layer Never use a steel brush when cleaning The steel brush reduces the galvanic protection The engine transom bracket and sterndrive must never be in contact with other metal components below the water line Electrical equipment such as charging equipment navigational aids VHF radios etc must never be grounded to the engine transom bracket or sterndrive See the parts catalog for the model in question for the part numbers for paint for the engine transom bracket or sterndrive Paint may be obtained from Volvo Penta Parts Always follow the manufacturer s instructions When making the purchase make sure that you receive the correct product meeting the
199. then coat the connector threads with sealer 4949 VPA 7743008 07 2003 45 Transom Shield Assembly SX M 3 Install the sleeve and connector assembly and use a crowfoot adapter to tighten the connector to 40 45 ft Ib 54 61 N m 34671 Transom and Exhaust Seal Replace ment 1 Remove and discard the exhaust O ring seal and the large rubber transom seal 34670 2 Apply 3M Scotch Grip Rubber Adhesive 1300 to the entire tran som seal groove around the gimbal housing Start at top and firmly push a new seal into the groove Also apply 3M Scotch Grip Rub ber Adhesive 1300 to the seal ends and butt them together to form a watertight junction at the top of the gimbal housing 46 VPA 7743008 07 2003 Transom Shield Assembly SX M 3 Apply 3M Scotch Grip Rubber Adhesive 1300 in the exhaust groove and install a new O ring seal Gimbal Housing Installation 1 1 Thoroughly clean outer transom surface where gimbal housing seal makes contact If trim pump and lines are already attached to housing insert them through transom cutout then install gimbal housing Do not use sealer between housing seal and transom and do not attach washers or nuts at this time 2 If trim lines were previously disconnected attach them to the hydraulic manifold A Note Line from pump UP outlet must attach to lower manifold opening otherwise trim system will not function properly Rou
200. through the U joint bellows on an assembled transom shield 1 Use a three jaw puller such as Owatonna Tool P N 1176 to pull out the gimbal housing bearing Spread the tool jaws between the bearing and inner seal and expand them tightly behind the bearing Remove and discard the bearing 2 Pull the inner seal out in a similar manner and discard it 3 Remove the thrust washer from around the top of the upper steer ing bearing Use Installer Volvo Penta P N 3854360 and Driver Volvo Penta P N 3854356 to remove the bearing Insert the driver into the installer and position the tool underneath the bearing as shown Drive the bearing up and out of the bracket Gimbal Housing Cleaning and Inspec Clean grease and sealer from bearing cavity seal seat and manifold tion cavity Check inner bore diameter for scoring or discoloration that indicates a spinning bearing e Pivot Bearing Inspect Teflon surface for wear or corrosion Gimbal Bearing Rollers must spin freely and hub must pivot in all directions inner diameter must be free of corrosion e Hydraulic Manifold O ring groove must be free of nicks and burrs all fluid passages must be clear VPA 7743008 07 2003 37 Transom Shield Assembly SX M Gimbal Housing Assembly Steering Bearing Gimbal Bearing and Seal Installation 38 48639 Hydraulic Lines must be clear and fittings undamaged Grease Fitting and Tube must be unobstructed
201. tite Primer to the threads on the short end of the stud and let air dry Apply Loctite 242 to the threads Screw the stud into the housing until 1 140 1 144 in 28 95 29 05 mm remains exposed 1 140 1 144 DRC6395 Pinion Shimming Note This procedure determines the amount of shims required to properly position the pinion in relation to the forward and outer propeller shafts Record the following shimming measurement for the final gear lash check 22459A 1 On later models the gear markings are on the outer propeller shaft The pinion gear marking will be found in the box with P indicating the pinion gear etching 1 Clamp Spline Socket Volvo Penta P N 3850598 into a vice and slide driveshaft into socket Install small bearing cup onto bearing Slide Shim Fixture Volvo Penta P N 3855870 onto driveshaft with the three slots facing threaded end of driveshaft 3855870 oog 3850598 43495 2 Install pinion and pinion nut Tighten pinion nut to 72 87 ft Ib 98 118 N m Rotate shim fixture to seat bearing for shimming pur poses Note Record this figure for use during reassembly Failure to reset the pinion torque during reassembly will change gear pattern and lash Jf 43487 VPA 7743008 07 2003 197 DP S Lower Gearcase 3 Check all three slots with feeler gauge and record each reading Aver
202. to the dimension found in Step 1 If the etched number is 5 you would SUBTRACT 0 005 in from the dimension found in Step 1 If the etched number is zero 0 you ADD or SUBTRACT nothing to from the dimension found in Step 1 Example Add Subtract 1 989 in Dimension found in Step 1 0 002 in Shimming Allowance Etched On Gear 1 987 in Total 3 1 79 1 1 97 1 2 18 1 and 2 32 1 Ratios Only Subtract the nom inal figure 1 898 from the Total of Step 2 All Other Ratios Sub tract the nominal figure 1 971 from Total of Step 2 This figure is the amount of shims required to properly position the pinion gear in the upper gear housing Example Subtract 1 987 in Total Of Step 2 1 971 in Nominal Figure 0 016 in Amount Of Shims Required Note Shims are to be placed between the bearing carrier and the upper gear housing No less than one shim but no more than five shims should be used Shims to be used must be clean and undamaged 115 Upper Gear Housing Upper Gear Housing Assembly Lower Output Gear and Shaft Assem bly 1 Wear Safety Glasses Install the spring spacer onto the splined end of the upper driveshaft with the recessed side facing the helix Install the spring C clip on the recess next to the helix 34596 2 Place the upper driveshaft through the lower output gear assem bly The groove must be on the same side as the bearing 3 Lightly oil the lower needle bearings wit
203. tom 0000008 264 Bottom Painting 000 cece eee ee eee eee eee 264 Boat Trailers 2 22 26 cisco ha dee ee ee eel eae eee 264 Boat Trim SX and DP S 00 0c eee eee eee 265 Propeller Hub Replacement 2000055 265 High Altitude Operation 00 cee e ee eee 265 Volvo Penta Propeller Shaft Grease P N 1141644 Before working on any part of this section read the sec tion called Safety at the end of this manual When replacement parts are required use genuine Volvo Penta Parts or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or passengers Proper installation is important for safe reliable operation of all mechanical components The procedures we recom mend and describe in these instructions are effective methods to be followed when installing Volvo Penta stern drive products Some of these methods require the use of tools specially designed for the purpose The special tools should be used when and as recommended Table 1 Panel Tool Name Volvo P N Location Front Propeller 3855876 3 L Remover Installer Selecting the correct propeller for each engine boat combination will ensure good engine service life and boat performance by permitting the engine to operate within the recommended RPM range A propeller must be carefully selected to
204. tract 0 0085 in optimum gear lash measurement from the incorrect gear lash measurement and divide by two Example Only 0 597 in measurement to end of gear shaft 0 500 in thickness of shim fixture 0 097 in actual dimension Round off to nearest thousandths of an inch i e 0 003 in if needed This example requires the removal of 0 003 in shim from under the lower driveshaft bearing cup and 0 003 in added behind the propeller gear bearing race The optimum gear lash measurement is 0 0085 in 1 In order to achieve long gear life and smooth running with mini mum noise you must obtain proper gear contact pattern The con tact pattern will give you a visual clue as to where the gear teeth are meshing with each other The pattern on the lower gear unit is checked on the convex side of the propshaft gear 2 Paint three teeth on their convex side with gear marking com pound as shown The teeth should be completely covered with marking compound light coating from heel to toe and crest to root For drives that will be used in right hand rotation applications use the convex side of the propeller shaft gear For drives that will be used in left hand applications use the concave side of the pro peller shaft gear VPA 7743008 07 2003 SX Lower Gearcase 3 GR990869 GR990870 GR990871 VPA 7743008 07 2003 6 Then reassemble the drive according the preceding procedures Turn the ste
205. uide Plate Volvo Penta P N 3850619 and Bearing Cup Installer Volvo Penta P N 3850621 8 to install bearing race Place race installer on race then seat guide plate onto gearcase 43555 4 Wear Safety Glasses Use a hammer to seat bearing race Driveshaft and Pinion Installation 1 Lightly oil the forward gear bearing with GL 5 Synthetic gear lubri cant SAE 75W 90 Install the assembly into the gearcase 43557 2 Make sure the pinion taper and splines are clean and dry Place the pinion into position inside the gearcase VPA 7743008 07 2003 207 DP S Lower Gearcase 43559 3855950 i i Setting Initial Rolling Torque 3855919 43575 208 Lightly oil all vertical driveshaft bearings with GL 5 Synthetic gear lubricant SAE 75W 90 Make sure the driveshaft pinion taper and splines are clean and dry Install the driveshaft into the gearcase and engage the pinion Place a new pinion nut into Pinion Nut Holder Volvo Penta P N 3855930 Position the nut and start to thread it onto the driveshaft Do not attempt to tighten the pinion nut with this tool The tool will be damaged Apply a light coat of GL 5 Synthetic gear lubricant SAE 75W 90 to the threads of the driveshaft retainer and upper bearing cup Place cup in housing and push down until it seats on driveshaft bearing Screw in driveshaft retainer by han
206. use of an arbor or hydraulic press Always wear safety glasses when using this device to perform these procedures 145 SX Lower Gearcase Special Tools Table 1 Too Name Volvo P N Panel Location Alignment Plate 3850613 5 F Bearing Cup Installer 3850616 8 F Bearing Cup Installer 3850621 8 G Bearing Installer E F Bearing Remover 3850625 9 G Drive Handle 3850609 3 A Drive Handle Short 3850610 1 A Driveshaft Holding Socket 3850618 4 G Gear Lash Extension 3850602 8 H Guide Plate 3850619 2 G Housing Remover Installer 3850707 5 F Pinion Bearing Installer 3850620 0 G Pinion Nut Holder 3854864 0 H Pinion Shim Fixture 3855098 8 H Propshaft Bearing Installer 3850617 6 G Puller Bridge 3850611 9 A Puller Jaws 3850612 7 A Pusher Puller 3850623 4 G Remover Installer 3850624 2 G Remover Tip 3855859 9 M Retainer Installation Tool 3850603 6 H Rod Nut and Washer 3855860 7 M Pinion Bearing Remover 3850622 6 G Seal Installer 3850627 5 G Shimming Fixture 3850600 2 H Shimming Ring 3850626 7 G Spanner Wrench 3850601 0 H Spline Socket 3850598 8 G 146 VPA 7743008 07 2003 SX Lower Gearcase Lower Gearcase Removal 1 With the sterndrive in the full tilt down position place a 4 quart oil drain pan under the gear case 0 UV TAN oe LN 42687 2 Remove the oil level dipstick so the oil reservoir can vent while draining 34132 3 Remove lower oil fill drain plu
207. utes 172 VPA 7743008 07 2003 SX Lower Gearcase Do not fill sterndrive with oil until it passes both pressure and vacuum tests Drives that fail either test will allow water entry when in use and cause subsequent damage to internal parts Sterndrive Filling Note 1 Place drive in a vertical position Remove the oil level plug Also remove the level indicator gauge at top of drive to help vent the oil reservoir Discard the plug and gauge seal Replace them with new ones 2 Remove magnetic drain screw on side of skeg Discard screw seal and replace with a new one 3 Fill drive with GL5 Synthetic Gear Lubricant 75W 90 from skeg drain hole Fill slowly to purge trapped air Stop filling when the oil level reaches the bottom of the oil level hole Do not overfill Note Filling drive too quickly may form air pockets that will cause an inaccurate oil level reading Running drive with improper oil level can result in immediate internal damage 21799 VPA 7743008 07 2003 173 SX Lower Gearcase 47557 33836 Anodes Testing and Replacement 174 4 When oil reaches proper level stop filling and screw in the level plug and gauge This will create an air lock to prevent excessive oil loss while drain plug is installed Apply Volvo Penta Gasket Sealing Compound to the drain plug and tighten to 6
208. watt hrs X 3 600 megajoules MJ VPA 7743008 07 2003 13 General Information LINEAR SYMBOLS Certain symbols or combinations of symbols may appear on your stern drive or on their accessories It is very important that you understand their meaning or purpose If any symbol is not clearly understood see your authorized dealer Safety Warning Symbols e Be Careful Poisonous e Follow instructions e Risk of serious injury Fire Hazard Contents Under Pressure Position Indicator Symbols Shift Positions NEUTRAL FORWARD REVERSE Condition Symbols Voltmeter Hour Meter e Ammeter Tachometer al an Oil Filter G Fuel Filter G l Water Temperature A Emergency Stop 0 Oil Pressure Instructional Symbols m e Use unleaded gasoline Ce Read Operator s Manural e Gasoline is present A before operating product Oil Fill 14 VPA 7743008 07 2003 General Information Table 1 Drill Size Conversion Chart SHOWING MILLIMETER SIZES FRACTIONAL AND DECIMAL INCH SIZES AND NUMBER DRILL SIZES Milli Dec Fract Num Milli Dec Fract Num Milli Dec Fract Num Milli Dec Fract Num Milli Dec Fract Meter Equiv ional ber Meter Equiv ional ber Meter Equiv ional ber Meter Equiv ional ber Meter Equiv ional 1 0039 1 75 0689 Ma 1570 22 6 8 2677 10 72 4219 27 64 15 0059 si 0700 50 4 0 1575 6 9 2716 11 0 4330 2 0079 1 8 0709 sis 1590 21 or 2720 11 11 4875
209. wire at end of casing 36560 VPA 7743008 07 2003 235 Sterndrive Removal and Installation 2 Return remote control shift handle to the neutral detent position Measure and record the distance between mark and end of casing 36561 3 Mark cable core wire at end of casing with control in the neutral detent position 36562 4 Move the remote control handle to the wide open throttle position in the direction to extend the shift cable Push in on cable core wire to remove end play Measure and record the distance S between mark and end of casing The distance between forward and neutral must be no less than 1 1 4 in 31 8 mm and no greater than 1 3 8 in 35 0 mm 36563 e The distance between neutral and reverse must be no less than 1 1 4 in 31 8 mm and no greater than 1 3 8 in 35 0 mm Note Check your remote control installation instructions if your measurements are not within these specifications Make sure the cables are attached correctly inside the control box before continuing All control boxes must meet these minimum and maximum specifications in order for the shift system to function properly Shift Cable Installation Note Remote control shift and throttle cables must be SAE type cables 1 NOTE If the throttle cable is attached to the throttle arm and anchor block remove it from both The throttle cable must be dis AN connected from the throttle arm prior to shift cable installation
210. wires through the hole cut tie straps securing wires to the trim tilt lines and remove the trim sender Anode and Sensor Housing Removal 1 Disconnect the anode and sensor housing leads from the elec tronic control unit mounted on the inside transom 2 Follow Steps 2 and 3 above to remove the leads from the gimbal housing 48678 1 Remove the two screws from the water tube retainer Pull the water tube and grommet out of the gimbal housing If the grommet sticks go to the outside of the transom and push it through 2 Ifthe grommet needs to be replaced slide it off the water tube It can be reused if undamaged VPA 7743008 07 2003 71 Transom Shield Assembly SX MHP Hydraulic Lines and Manifold Removal Remove the two clamps that secure the lines to each side of the gimbal housing 3 Unscrew all four lines and remove them from the manifold Remove and discard the fitting O rings Removal of the grease extension tube may make the servicing of the starboard side lines easier Clamp a vise grip pliers close to the bearing bore and rotate the tube to loosen it Pry against the plier head to force the tube out of the housing 4 Remove the locknut and washer that attach the manifold old to the housing Since the manifold is sealed by an O ring use a small drift to drive it out of the housing from the inside of the boat 5 Pull the manifold and lines through the hole as far as possible Tag one line
211. y if it is to be replaced The bearing may be damaged during removal 188 VPA 7743008 07 2003 DP S Lower Gearcase 1 Place Remover Installer Tip Volvo Penta P N 3855868 into the 3855860 pinion bearing Thread the rod from Rod Nut and Washer Volvo K Penta P N 3855860 into the remover installer tip dddddd 43459 2 Place Guide Plate Volvo Penta P N 3850619 over the rod and into the driveshaft bore Lightly oil the threads of the rod Place washer and nut from Rod Nut and Washer Volvo Penta P N 3850860 onto the rod Tighten the nut to remove the pinion bear ing 3850619 Forward Bearing Race 1 Assemble Race Remover Volvo Penta P N 3855862 or Joint ma Venture P N 3855862 Rod Nut and Washer Volvo Penta P N ze 3855860 3855860 and Guide Plate Volvo Penta P N 3855863 3855863 3855862 43444 2 Place the assembled tools into the gearcase Push the remover into the forward bearing race until the snap ring locks into place behind the race Lightly oil the threads of the rod Tighten the nut to remove the race Discard the shims as they may be damaged during race removal Propeller Shaft Housing Service Removal Note Bearings should not be removed unless they are to be replaced Removal will damage the bearings VPA 7743008 07 2003 189 DP S Lower Gearcase 1 Place Support Base Volvo Penta P N 3855926 notc

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