ALPHA ONE gen.2

7/27/2019 ALPHA ONE gen.2

1/43

2

74243

ALPHA ONE GENERATION IISTERNDRIVE

INDEX


2/432 - 0 Alpha One Generation II Sterndrive 90-806534970 1096

Table of ContentsPage

Installation Specifications 2 - 1. . . . . . . . . . . . . . . . . .Torque Specifications 2 - 1. . . . . . . . . . . . . . . . . .Lubricants, Sealers, and Adhesives 2 - 1. . . . . .Special Tools 2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . .Transom Specifications 2 - 1. . . . . . . . . . . . . . . . .

Installation Procedures 2 - 2. . . . . . . . . . . . . . . . . . . .

Transom Assembly Installation 2 - 2. . . . . . . . . .Power Steering Control Valve andCable Installation 2 - 3. . . . . . . . . . . . . . . . . . . . .

Power Steering Hose Connections 2 - 4. . . . . . .Stern Drive Unit Installation 2 - 4. . . . . . . . . . . . .Trim Cylinder Connection 2 - 4. . . . . . . . . . . . . . .Propeller Installation 2 - 5. . . . . . . . . . . . . . . . . . .

Drive Shaft Housing Specifications 2 - 6. . . . . . . . .Torque Specifications 2 - 6. . . . . . . . . . . . . . . . . .Upper Drive Shaft Bearing Preload 2 - 6. . . . . . .U-joint Bearing Preload 2 - 6. . . . . . . . . . . . . . . . .Gear Shimming Specifications 2 - 6. . . . . . . . . . .

Lubricants, Sealers, and Adhesives 2 - 6. . . . . .Special Tools 2 - 6. . . . . . . . . . . . . . . . . . . . . . . . . .Drive Shaft Housing Exploded Parts View 2 - 8. . .

U-Joint and Driven Gear Components 2 - 8. . . .Drive Shaft Components 2 - 10. . . . . . . . . . . . . . .

Drive Shaft Housing Shimming 2 - 11. . . . . . . . . . . .Gear Distance, Driven Gear 2 - 11. . . . . . . . . . . .Gear Distance, Drive Gear 2 - 11. . . . . . . . . . . . .

Drive Shaft HousingSpecial Information 2 - 12. . . . . . . . . . . . . . . . . . . . . .

Top Cover Bearing Cup 2 - 12. . . . . . . . . . . . . . . .Top Cover Bearing Cup Drivers 2 - 12. . . . . . . . .

Standard Rotation GearHousing Specifications 2 - 13. . . . . . . . . . . . . . . . . .

Torque Specifications 2 - 13. . . . . . . . . . . . . . . . .Shimming Specifications 2 - 13. . . . . . . . . . . . . . .Lubricants, Sealers, and Adhesives 2 - 13. . . . .Special Tools 2 - 14. . . . . . . . . . . . . . . . . . . . . . . . .

Standard Rotation Gear HousingExploded Parts View 2 - 16. . . . . . . . . . . . . . . . . . .

Drive Shaft Components 2 - 16. . . . . . . . . . . . . . .Propeller Shaft Components 2 - 18. . . . . . . . . . .Special Information For StandardRotation Gear Housing 2 - 20. . . . . . . . . . . . . . .

Page

Standard Rotation Gear HousingAssembly Specifications 2 - 21. . . . . . . . . . . . . . . .

Pre-Disassembly Inspection 2 - 21. . . . . . . . . . . .Pinion Gear Height 2 - 21. . . . . . . . . . . . . . . . . . .Shift Spool End Play 2 - 21. . . . . . . . . . . . . . . . . .Forward Gear Backlash 2 - 22. . . . . . . . . . . . . . .

Reverse Gear Backlash 2 - 22. . . . . . . . . . . . . . .Counter-Rotation Gear HousingSpecifications 2 - 23. . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Specifications 2 - 23. . . . . . . . . . . . . . . . .Shimming Specifications 2 - 23. . . . . . . . . . . . . . .Lubricants, Sealers, and Adhesives 2 - 23. . . . .Special Tools 2 - 24. . . . . . . . . . . . . . . . . . . . . . . . .

Counter-Rotation Gear HousingExploded Parts View 2 - 26. . . . . . . . . . . . . . . . . . .

Drive Shaft Components 2 - 26. . . . . . . . . . . . . . .Propeller Shaft Components 2 - 28. . . . . . . . . . .Special Information For

Counter-Rotation Gear Housing 2 - 30. . . . . . .Counter-Rotation Gear HousingAssembly Specifications 2 - 32. . . . . . . . . . . . . . . .

Pre-Disassembly Inspection 2 - 32. . . . . . . . . . . .Forward and Reverse GearIdentification 2 - 32. . . . . . . . . . . . . . . . . . . . . . . .

Pinion Gear Height 2 - 32. . . . . . . . . . . . . . . . . . .Shift Spool End Play 2 - 32. . . . . . . . . . . . . . . . . .Forward Gear Backlash 2 - 33. . . . . . . . . . . . . . .Reverse Gear Backlash 2 - 33. . . . . . . . . . . . . . .

Transom Assembly Specifications 2 - 35. . . . . . . . .Torque Specifications 2 - 35. . . . . . . . . . . . . . . . .Special Tools 2 - 35. . . . . . . . . . . . . . . . . . . . . . . . .

Lubricants, Sealers, and Adhesives 2 - 35. . . . .Alpha One Transom AssemblyExploded View 2 - 36. . . . . . . . . . . . . . . . . . . . . . . . .

Bell Housing Components 2 - 36. . . . . . . . . . . . .Gimbal Housing Components 2 - 38. . . . . . . . . .Inner Transom Plate Components 2 - 40. . . . . .Gimbal Ring and Steering Lever

Components 2 - 41. . . . . . . . . . . . . . . . . . . . . . . .

INDEX


3/43Alpha One Generation II Sterndrive 2 -90-806534970 1096

Installation Specifications

Torque Specifications

NOTE:Securely tighten all fasteners not listedbelow.

TORQUE

lb. in. lb. ft. Nm

Exhaust Pipe to GimbalHousing Screws

23 31

Propeller Nut 1 55 75

Steering Cable CouplerNut

Tighten Nut Until ItBottoms Out Against FlatWasher, then Loosen 1/2

Turn

Steering Cable CouplerNut

35 48

Steering system Pivot Bolts 50 68

Transom Assembly

Attaching Screws and Nuts 23 31

Power Steering HydraulicHose Fittings

Stern Drive Unit to BellHousing Attaching Nuts

50 68

1: Amount specified is MINIMUM.

Lubricants, Sealers, and Adhesives

DESCRIPTION PART NUMBER

Quicksilver 2-4-CMarine Lubricantwith Teflon

92825407A3

Quicksilver SpecialLubricant 101

92-13872A1

Perfect Seal 92-34227-1

Liquid Neoprene 92-25711--2

Quicksilver EngineCoupler Spline Grease

92-816391A4

Special Tools


Alignment ToolAssembly

91-805475A1

Transom Specifications

2217

a

e c

d

a

b

b

fa - Transom Thickness-2-2 1/4 in. (51-57mm)b - Transom Surfaces-Parallel to within 1/8 in. (3.2 mm)

c - Area Covered by Inner Transom Plate - Flat towithin 1/8 in. (3.2 mm)

d - Area Covered by Gimbal Housing Assembly - Flat to with1/16 in. (1.6 mm)

e - Transom Angle-10_ to 16_

f - Keel (if Equipped) - Remove 4 ft. (1.2 m) forwardof transom

INDEX



Installation Procedures

Transom Assembly Installation

! CAUTION

Steering lever ground wire MUST be positioned

as shown or wire may fatigue.

70012

70015

70011

50632

50632

70005

1

2

4

2

3

2

5

6

7

7

a2

a

a

a

700068

b

1 - Speedometer Tube Pick-up Connection2 - Locknuts and Flat Washers3 - Screw4 - Steering Lever Continuity Wire5 - Trim System Wires6 - Shift Cable7 - Trim Hoses (and MerCathode Wires, if so equipped)8 - Gear Lube Hose Fitting

Torque Specification

a 23 lb. ft. (31 Nm)

b 70-90 lb.in. (8-10 Nm)

INDEX



Power Steering Control Valve and Cable Installation

71901

71903

71906

56

8

7

4

a

1

2

3b 10

73901

9

5

A

1 - Steering Cable2 - Grease Fitting3 - Cable Coupler Nut4 - Cable Guide Tube5 - Cable End6 - Clevis7 - Clevis Pin8 - Cotter Pin9 - Flats on Guide Tube MUST Be Vertical10- Pivot Bolt


A - Quicksilver SpecialLubricant 101 92-13872A. . . . . . . . . . . .


a 35 lb. ft. (47 Nm)

b 50 lb. ft. (68 Nm)

INDEX



Power Steering Hose Connections

73786

a

Typical Hose Routing

a - Hose Fittings - Torque Both Fittings to 23 lb. ft. (31 Nm).

Stern Drive Unit Installation

USING THE ALIGNMENT TOOL

! CAUTION

Forcing the alignment tool into position may

damage the Gimbal Bearing or Engine Coupler.Do not attempt to force the alignment tool!

Raise or lower the engine as necessary until align-ment tool moves freely.

71463

a

a

c

a - Alignment Tool

b - Gimbal Bearing

c - Engine Coupler

STERN DRIVE TO BELL HOUSING CONNECTION

a b

22062

a - Locknut and Flat Washers - Torque to 50 lb. ft. (68 Nm)

b - Locknut and Continuity Circuit Washer - Torque to50 lb. ft. (68 Nm)

Trim Cylinder Connection

a

b c

d

e

70027

a - Aft Anchor Pin

b - Bushings

c - Flat Washers (2)

d - E-ring Clips (2)

e - Plastic Caps (2)

INDEX



Propeller Installation

a

b

c

e f

g

d

Typical Propeller

a - Propeller Shaft

b - Forward Thrust Hubc - Propeller

d - Continuity Washer

e - Spline Washer

f - Tab Washer

g - Propeller Nut-Torque to 55 lb. ft. (75 Nm)

70134

a

bc

e f

d

g

Propeller With Flo-Torque Hub

a - Propeller Shaft

b - Forward Thrust Hub

c - Drive Sleeve

d - Propeller

e - Drive Sleeve Adapter

f - Tab Washer

g - Propeller Nut-Torque to 55 lb. ft. (75 Nm)

INDEX



Drive Shaft HousingSpecifications


NOTE: Securely tighten all fasteners not listed be-low.

TORQUE

lb. in. lb. ft. Nm

Top Cover Screws 17-23 23-31

U-joint Retainer Nut 200 271

Oil Vent Screw 30-503.4-5.6

Upper Drive Shaft Bearing Preload

TORQUE

lb. in. Nm

New Bearings 6-150.7-1.7

Used Bearings* 3-7.50.3-0.8

*Bearings are considered used if spun under load once.

U-joint Bearing Preload

TORQUE

lb. in. Nm

New Bearings 6-100.7-1.1

Used Bearings* 3-7.50.3-0.8

*Bearings are considered used if spun under load once.

Gear Shimming Specifications

GEAR LOCATION

inches millimeters

Drive Gear .025 0.64

Driven Gear .025 0.64




92-825407A3

Quicksilver U-Jointand Gimbal Bearing

Grease

92-828052A2

3M Brand Adhesive 92-25234-1

Quicksilver BellowsAdhesive

92-86166

Quicksilver NeedleBearing AssemblyLubricant

92-825265A1

Quicksilver Perfect Seal 92-34227-1

Permatex Ultra BlueSilicone Sealant

Obtain Locally

Quicksilver SpecialLubricant 101 92-13872A1

Quicksilver HighPerformance GearLube

92-816026A4

Special Tools


Adaptor 91-38756

Bearing Cup Driver 91-38918Bearing Driver Cup 91-33493

Driver Cup 91-36577

Driver Rod 91-37323

Driver Tool 91-90774

Oil Seal Driver 91-817570

Shimming Tool(Driven Gear)

91-60526

Shimming Tool(Drive Gear)

91-60523

Slide Hammer Puller 91-34569A1

Torque Wrench (lb. in.) 91-66274

U-joint BearingRetainer Wrench

91-17256

Universal Puller Plate 91-37241

INDEX



TORQUE CONVERSION CHART

Use the following table to torque the u-joint retainerto 200 lb. ft. (271 Nm).

Torque WrenchLength

in Inches (cm)

Torque Wrench Readingin lb. ft.(Nm) to

Achieve 200 lb. ft.(271 Nm) of Torque

15 (38)16 (41)17 (43)18 (46)19 (48)20 (51)21 (53)22 (56)23 (58)24 (61)25 (64)26 (66)27 (69)28 (71)29 (74)30 (76)31 (79)32 (81)33 (84)34 (86)35 (89)36 (91)

111 (151)114 (155)117 (159)120 (163)123 (167)125 (170)127 (172)129 (175)131 (178)133 (180)135 (183)136 (184)138 (187)140 (190)141 (191)143 (194)144 (195)145 (197)147 (200)148 (201)149 (202)150 (203)

a

26363

a

a - Torque Wrench Length

INDEX


10/43

70690

1

23

4

5

6

7

8

9

10

11

11

12

13

14

15

16

17

1819

20

21

19

22

23

2526

23

24

27

2829

b

a

D

A

C

B

B

D

2 - 8 Alpha One Generation II Sterndrive 90-806534970 1096

Drive Shaft Housing Exploded Parts View

U-Joint and Driven Gear Components

INDEX



1 - Drive Shaft Housing2 - Screw3 - O-ring4 - Spring Assembly5 - Oil Seal6 - Wear Pad7 - Plug8 - Universal Joint9 - Yoke, Universal Joint - Gear End10- Socket, Center - Universal Joint11- Cross and Bearing

12- Yoke Assembly, UniversalJoint - Coupling End

13- O-ring14- Retainer15- Ring16- O-ring17- Carrier Assembly18- Oil Seal19- Roller Bearing and Cups20- Cup Spacer21- Shim22- Shim23- Drive Gear Assembly24- Roller Bearing and Cup25- Washer26- Nut27- Shims28- Ground Plate29- Screw


A - 2-4-C Marine Lubricantwith Teflon 92-825407A1. . . . . . . . . . . .

B - Quicksilver High PerformanceGear Lube 92-816025A. . . . . . . . . . . . .

C - Quicksilver SpecialLubricant 101 92-13872A. . . . . . . . . . . .

D - Quicksilver EngineCoupler Spline Grease 92-816391A. . .


a 200 lb. ft. (271 Nm) - See Chart on Page 7

Rolling Preload

b Tighten in Small Increments Until6-10 lb. in. (.07-1.1 Nm) of Rolling Preload

INDEX



Drive Shaft Components

74243

a

b

b

A

B

5

1

2

3

4

8

9

10

11

12

13

14

16

15

17

18

1 - Cover, top2 - Bearing and Cup3 - Shim4 - O-ring5 - Screw8 - Drive Shaft, upper

9 - Fil ler Wall10- Washer11- Nut12- Anodic Plate13- Screw14- Lockwasher15- Screw16- Seal17- Water Tube18- Stuffer Plug


A - Quicksilver 2-4-C MarineLubricant with Teflon 92-825407A12. . .

B - Quicksilver HighPerformance Gear Lube 92-816026A4.


a 20 lb. ft. (27 Nm)

b 35 lb. ft. (47.5 Nm)

INDEX


13/43Alpha One Generation II Sterndrive 2 - 90-806534970 1096

Drive Shaft HousingShimming

Gear Distance, Driven Gear

SHIMMING TOOL 91-60526

Overall DriveUnit Gear Ratio

ToolPosition

1.47:11.62:11.81:11.94:12.40:1

ZXYYY

23012

a

.025(0.64mm

)

a - Feeler Gauge - .025 in. (0.635mm)

Gear Distance, Drive Gear

23012

.025(0.64mm)

a

23012

SHIMMING TOOL 91-60523

Overall DriveUnit Gear Ratio

ToolPosition

ZYY

YY

1.47:11.62:11.81:1

1.94:12.40:1

a - Feeler Gauge - .025 in. (0.635mm)

INDEX



Drive Shaft HousingSpecial Information

Top Cover Bearing Cup

The later style bearing cup is thinner than the earlierstyle cup.

75240

ba

a - Earlier Style Bearing Cup 1.938 in. Diameter(Prior to S/N OF680000)

b - Later Style Bearing Cup 1.781 in. Diameter(S/N OF680000 and Above)

Top Cover Bearing Cup Drivers

Use the appropriate driver for installation of the bear-ing cup.

70701a

b

c

d

e

a - Shims

b - Bearing Cup

c - Bearing Cup Driver (91-38918) used with 31-61100 A1

Bearing OR Bearing Cup Driver (91-808053) used with31-32575 A1 Bearing

d - Driver Rod (91-37323)

e - Top Cover

INDEX



Standard Rotation GearHousing Specifications



TORQUElb. in. lb. ft. Nm

Water Pump BodyScrews

60 6.8

Pinion Gear Nut 70 95

Gear Housing to DriveShaft Housing Screws

28 38

Gear Housing to DriveShaft Housing Nuts

35 47

Trim Tab Screw 23 31

Shift Shaft BushingScrews

60 6.8

Drive Shaft Retainer 100 136

Bear Carrier Retainer 210 285

Oil Fill/Drain Screw30-50

3.4-5.6



Shimming Specifications

GEAR LOCATION

inches millimeters

Pinion Gear Height .025 0.64

Forward Gear Backlash .017-.028 0.43-0.71

Reverse Gear Backlash .034-.054 0.86-1.37



Quicksilver 2-4-C MarineLubricant with Teflon

92-825407A3

3M Brand Adhesive 92-25234-1


92-86166

Quicksilver Needle BearingAssembly Lubricant

92-825265A1



Obtain Locally


92-13872A1

Loctite 8831 92-823089-1

Quicksilver HighPerformance Gear Lube

92-816026A4

INDEX



Special Tools

DESCRIPTIONPART

NUMBER

Backlash Indicator Rod 91-53459

Bearing Carrier RetainerWrench

91-61069

Bearing Preload Tool 91-14311A2

Belleville Washer 12-54048

Dial Indicator 91-58222A1

Dial Indicator Holding Tool 91-89897

Drive Shaft Nut Wrench 91-56775

Cup Driver 91-36577

Drive Shaft Bearing Wrench 91-43506

Needle Bearing Driver 91-15755




Pinion Gear Shimming Tool 91-56048

Pinion Nut Adapter 91-61067A3

Drive Shaft Adapter 91-61077

Puller Bolt 91-85716

Puller Jaws 91-46086A1


Torque Wrench (Inch Pound) 91-66274

Water Pump Alignment Pins 91-821571A1Universal Bearing Removal andInstallation (Includes theFollowing Items)

91-31229A5

Bearing Adapter 91-37263

Bearing Installation Tool 91-38628

DESCRIPTIONPART

NUMBER

Collar 91-30366

Driver Head 91-32366





Driver Head Rod 91-37323

Nut 11-24156

Pilot Washer 91-36571



Puller Plate 91-29310

Puller Head 91-36379



Puller Rod 91-52394

Puller Shaft 91-31229

Roller Bearing Removal andInstallation Tool

91-37292

Washer 12-34961

*The 91-14311A2 Bearing Preload Tool is also used

on Mercury and Mariner V-6 gear cases. Check yourinventory before buying.

NOTE:Water Pump Face Seal Tool is not availableseparately, 26-816575A2 is a kit part number whichincludes the tool and the face seal.

INDEX



THIS PAGE IS INTENTIONALLY BLANK

INDEX



Standard Rotation Gear Housing Exploded Parts ViewDrive Shaft Components

74242

28

7

30

25

26

29

31

a

f

a

b

A

D

A

A

A

(ID)

C

A

B

D

A

hE

18

21

19

20

13

11

10

32

34

3

9

38

37

33

7

5

4

1

2

16

15

14

8

23

17

24

22

6

27

36

12

38

INDEX



1 - Gear Housing2 - Pin3 - Stud4 - Oil Fill/Drain Screw5 - O-ring6 - Seal7 - Dowel Pin8 - Roller Bearing9 - Speedometer Fitting10- Drive Shaft11- Shim

12- Bearing and Cup13- Nut14- Gear Drive15- Washer16- Nut17- Face Plate18- Carrier19- Oil Seal20- Oil Seal21- O-ring22- Water Pump23- Gasket24- Gasket25- Face Seal26- Screw27- Impeller28- Key29- Coupling30- O-rings31- Sleeve32- Shift Shaft33- Retaining Ring34- Sleeve35- Bushing Assembly36- Oil Seal37- O-rings38- Screw



B - 3M Brand Adhesive 92-25234. . . . . . .

C - Loctite 8831 92-823089. . . . . . . . . . . . .

D - Quicksilver HighPerformance Gear Lube 92-816026A.

E - Quicksilver Needle BearingAssembly Lubricant 92-825265A. . . . .


a 60 lb. in. (6.8 Nm)

b 70 lb. ft. (95 Nm)

c 28 lb. ft. (38 Nm)

d 35 lb. ft. (47 Nm)

e 23 lb. ft. (31 Nm)

f 100 lb. ft. (136 Nm)

g 210 lb. ft. (285 Nm)

h 30-50 lb. in. (3.4-5.6 Nm)

INDEX



Propeller Shaft Components

73601

c

d

g

F

(OD)

A(ID)

C

C

B

CE

D

2223

e

35

25 24

2627

282930

12

14

15

1617

18

2

4

5

6

10

8

11

3

9

7

31

33

34

1

20

21

13

19

32

INDEX



1 - Gear Housing2 - Shift Crank3 - Shift Spool Assembly4 - Shim, Bearing Outer Race5 - Bearing and Cup6 - Forward Gear7 - Roller Bearing8 - Sliding Clutch9 - Cross Pin10- Spring11- Propeller Shaft

12- Reverse Gear13- Thrust Washer14- Thrust Hub15- Ball Bearing16- O-ring17- Roller Bearing18- Bearing Carrier Assembly19- Anode20- Screw21- Star Washer22- Oil Seal (Inside)23- Oil Seal (Outside)24- Tab Washer25- Retainer26- Thrust Hub27- Continuity Washer28- Spline Washer29- Tab Washer30- Locknut - Propeller31- Anodic Trim Tab (Anodic Plate - Some Models)32- Screw33- Star Washer34- Screw35- Nut


A - Quicksilver 2-4-C MarineLubricant with Teflon 92-825407A1. . . .

B - Loctite 8831 92-823089. . . . . . . . . . . . .

C - Quicksilver HighPerformance Gear Lube 92-16026A. .

D - Quicksilver Perfect Seal 92-34277. . . .

E - Permatex Ultra BlueSilicone Sealant Obtain Loca. . . . . . .

F - Quicksilver SpecialLubricant 101 92-13872A. . . . . . . . . . . .


a 60 lb. in. (6.8 Nm)

b 70 lb. ft. (95 Nm)

c28 lb. ft. (38 Nm)

d 35 lb. ft. (47 Nm)

e 23 lb. ft. (31 Nm)

f 100 lb. ft. (136 Nm)

g 210 lb. ft. (285 Nm)

INDEX



Special Information For StandardRotation Gear Housing

! CAUTION

Avoid damage to stern drive unit. Drive unit dam-

age will occur if Later Style parts are intermixedwith Earlier Style parts.

SHIFT SPOOL ASSEMBLY

The later style shift spool assembly has a larger gapthan the earlier style. This later style shift spoolbeginning with serial number 0K041000 is sold as awhole assembly and can be used when replacing theearlier style (Prior to S/N 0K041000). The end playfor the spool will remain the same as the earliermodels (.002-.010 in. .051-.254 mm).

75219c

b

a

74877

c

a - Earlier Style Shift Spool Assembly (Prior to S/N 0K041000)

b - Later Style Shift Spool Assembly (S/N 0K041000 andAbove)

c - Measure End Play Here at Gap

FORWARD GEAR BEARING BORE

The later style forward gear bearing bore is smaller(3.2635 to 3.2650 in.) than the earlier style (3.4985to 3.5000 in.) This slightly smaller bearing bore forthe forward gear bearing adapter is approximately1/4 in. (6.3 mm) smaller.

3.4985to

3.5000

75241

Earlier Style Forward Gear Bore (Prior to S/NOF680000)

75248

3.2635to

3.2650

Later Style Forward Gear Bore (S/N OF680000and Above)

The later style bearing cup is thinner and has asmaller diameter than the earlier style.

75256

a

b

a - Earlier Style Gear Bearing Cup 3.500 in. diameter(Prior to S/N OF680000)

b - Later Style Gear Bearing Cup 3.265 in. diameter(S/N OF680000 and Above)

INDEX



Standard Rotation GearHousing AssemblySpecifications

Pre-Disassembly Inspection

Action Reading

Move propeller shaftfrom one side toanother

Less than .003 in.(0.08 mm)

Rotate propeller shaft .005 in. (.127 mm) orless

22086

Pinion Gear Height

Check pinion height at four locations.Average pinion gear height: .025 in. (0.64 mm).

26410

Shift Spool End Play

NOTE: The later style shift spool assembly has larger gap than the earlier style. This later style shspool beginning with serial number OK041000 is soas a whole assembly and can be used whereplacing the earlier style (Prior to S/N OK041000The end play for the spool will remain the same as thearlier models (.002-.010 in. .051-.254 mm).

75219c

b

a

74877

c

a - Earlier Style Shift Spool Assembly (Prior to S/N 0K04100

b - Later Style Shift Spool Assembly (S/N 0K041000 andAbove)

c - Measure End Play Here at Gap

INDEX



Forward Gear Backlash

Apply forward pressure to the propeller shaft withpuller jaws. Torque the puller bolt to 45 lb. in.(5 Nm ).

70719

a - Puller Jawsb - Puller Bolt

Take readings at four different locations, 90_ apart,and average them for the backlash reading.Backlash reading: .017-.028 in. (0.43-0.71 mm)

70717

fed

a

a

cb

a - Nuts (4)b - Threaded Rodc - Dial Indicator Holding Toold - Dial indicatore - Indicator Pointer-Set at I on Backlash Indicator Rodf - Backlash Indicator Rod

Reverse Gear Backlash

Use the pinion nut adaptor to apply backward pres-sure on the propeller shaft. Torque Propeller nut to45 lb. in. (5 Nm).

23355

abc

a - Pinion Nut Adaptorb - Washerc - Propeller Nut

Backlash reading: .034-.054 in. (0.86-1.37 mm).

70717

fed

a

a

cb

a - Nuts (4)b - Threaded Rodc - Dial Indicator Holding Toold - Dial indicatore - Indicator Pointer-Set at I on Backlash Indicator Rodf - Backlash Indicator Rod

INDEX



Counter-Rotation GearHousing SpecificationsTorque Specifications


TORQUE

lb. in. lb. ft. Nm

Water Pump BodyScrews

60 6.8

Pinion Gear Nut 70 95

Gear Housing to DriveShaft Housing Screws

28 38

Gear Housing to DriveShaft Housing Nuts

35 47

Trim Tab Screw 23 31

Shift Shaft BushingScrews 60 6.8

Drive Shaft Retainer 100 136

Bear Carrier Retainer 210 285

Oil Fill/Drain Screw30-50

3.4-5.6



Shimming Specifications

GEAR LOCATIONinches millimeters

Pinion Gear Height .025 0.64

Forward GearBacklash

.017-.028 0.43-0.71

Reverse GearBacklash

.040-.050 1.02-1.27



Quicksilver 2-4-CMarine Lubricant with Teflon

92-825407A3

3m Brand Adhesive 92-25234-1


92-86166

Quicksilver Needle BearingAssembly Lubricant

92-825265A1



Obtain Locally


92-13872A1

Loctite 8831 92-823089-1

Quicksilver HighPerformance Gear Lube

92-816026A1

INDEX



Special Tools

Description Tool Part Number

Backlash Indicator Rod 91-53459

Bearing AdaptorInstallation Tool

91-18605 A1

Bearing CarrierRetainer Wrench

91-61069

Bearing Driver 91-816244

Bearing Preload Tool 91-14311 A2

Bearing Removal Tool 91-816245

Belleville Washer 12-54048

Dial Indicator 91-58222 A1

Dial Indicator HoldingTool

91-89897


Drive Shaft Bearing

Retainer Wrench91-43506

Guide Plate 91-816243




Pinion GearShimming Tool

91-56048

Pinion Nut Adaptor 91-61067 A3

Special Tools (continued)

Description Tool Part Number

Drive Shaft Adaptor 91-61077

Puller Bolt 91-85716


Puller Jaws 91-46086 A1

Puller Jaws 91-816242

Slide Hammer Puller 91-34569 A1

Forward GearInstallation Tool

91-815850

Torque Wrench(Inch Pound)

91-66274

Universal Puller Plate 91-37241

Water PumpAlignment Pins

91-821571 A1

Universal Bearing

Removal andInstallation Tool

91-31229 A5


Driver Head Rod 91-37323

Nut 11-24156


Puller Plate 91-29310

Puller/Driver Head 91-38628

*The 91-14311A2 Bearing Preload Tool is also usedon Mercury and Mariner V-6 gear cases. Check yourinventory before buying.

NOTE:Water Pump Face Seal Tool is not availableseparately, 26-816575A2 is a kit part number whichincludes the tool and the face seal.

INDEX




INDEX


28/43

74242

18

21

19

20

11

28 32

34

3

9

38

33

7

4

1

2

16

15

14

8

7

23

17

24

30

25

26

29

31

a

f

a

b

A

D

A

A

A

(ID)

C

A

B

D

A

6

hE

5

37

36

10

13

12

27

22

39


Counter-Rotation Gear Housing Exploded Parts View

Drive Shaft Components

INDEX



1 -Gear Housing2 -Pin3 -Stud4 -Screw5 -Oil Fill/Drain Screw

O-ring6 -Seal7 -Dowel Pin8 -Roller Bearing9 -Speedometer Fitting10-Drive Shaft

11 -Shim12-Bearing and Cup13-Nut14-Gear Drive15-Washer16-Nut17-Face Plate18-Carrier19-Oil Seal20-Oil Seal21-O-ring22-Water Pump23-Gasket24-Gasket25-Face Seal26-Screw27-Impeller28-Key29-Coupling30-O-rings31-Sleeve32-Shift Shaft33-Retaining Ring34-Sleeve35-Bushing Assembly36-Oil Seal37-O-rings38-Screw39-Stuffer Plug



B - 3M Brand Adhesive 9225234. . . . . .

C - Loctite 8831 92-823089. . . . . . . . . . . . .

D - Quicksilver HighPerformance Gear Lube 92-816026A.

E - Quicksilver Needle BearingAssembly Lubricant 92-825265A. . . . .


a 60 lb. in. (6.8 Nm)

b 70 lb. ft. (95 Nm)

c 28 lb. ft. (38 Nm)

d 35 lb. ft. (47 Nm)

e 23 lb. ft. (31 Nm)

f 100 lb. ft. (136 Nm)

g 210 lb. ft. (285 Nm)

h 30-50 lb. in. (3.4-5.6 Nm)

INDEX


30/43



1 - Gear Housing2 - Screw - Trim Plate or Tab3 - Nut4 - Screw5 - Lockwasher6 - Anodic Plate or Tab7 - Shift Crank8 - Shift Spool Assembly9 - Shims

10- Bearing Adapter - Reverse Gear11- Roller Bearing12- Thrust Washer13- Thrust Bearing14- Roller Bearing15- Reverse Gear16- Retainer Spring - Cross Pin17- Clutch18- Cross Pin19- Propeller Shaft20- Forward Gear21- Shim Spacer22- Thrust Bearing23- Roller Bearing24- Bearing Adapter - Forward Gear

25- Thrust Washer26- Thrust Bearing27- Thrust Race28- Keepers29- O-ring30- Needle Bearing31- Bearing Carrier32- Propeller Anode and Screws33- Seals34- Tab Washer35- Retaining Nut36- Thrust Hub37- Continuity Washer38- Spline Washer39- Tab Washer40- Locknut


A - Quicksilver 2-4-CMarine Lubricantwith Teflon 92-825407A. . . . . . . . . . . . .

B - 3M Brand Adhesive 9225234. . . . . .

C - Quicksilver BellowsAdhesive 92-8616. . . . . . . . . . . . . . . . . .

D - Quicksilver Needle BearingAssembly Lubricant 92-825265A. . . . .

E - Quicksilver Perfect Seal 92-34227. . . .

F - Permatex Ultra BlueSilicone Sealant Obtain Loca. . . . . . .

G - Quicksilver SpecialLubricant 101 92-13872A. . . . . . . . . . . .

H - Loctite 8831 92-823089. . . . . . . . . . . . .

I - Quicksilver HighPerformance Gear Lube 92-816026A.


a 60 lb. in. (6.8 Nm)

b 70 lb. ft. (95 Nm)

c 28 lb. ft. (38 Nm)

d 35 lb. ft. (47 Nm)

e 23 lb. ft. (31 Nm)

f 100 lb. ft. (136 Nm)

g 210 lb. ft. (285 Nm)

INDEX



Special Information ForCounter-Rotation GearHousing

! CAUTION

Avoid damage to stern drive unit. Drive unit dam-

age will occur if Later Style parts are intermixedwith Earlier Style parts.

SHIFT SPOOL ASSEMBLY

The later style shift spool assembly for the counterrotation has a larger gap than the earlier style. Thislater style shift spool beginning with serial numberOF726586 is sold as a whole assembly and must beused when replacing the earlier style (Prior to S/NOF726586).

75219c

b

a

c

74877

d - Earlier Style Shift Spool Assembly(Prior to S/N OF726586)

e - Later Style Shift Spool Assembly(S/N OF726586 and Above)

f - Measure End Play Here at Gap.

PROPELLER SHAFT

The later style propeller shaft has a groove on theshaft where the clutch slides onto the shaft. Thekeeper slot is also moved toward the forward end ofthe shaft.

75223

a

b

a - Earlier Style Propeller Shaft (Prior to S/N OF680000)

b - Later Style Propeller Shaft (S/N OF680000 and Above)

FORWARD GEAR BEARING BORE

The later style forward gear bearing bore is smaller(3.2635 to 3.2650 in.) than the earlier style (3.4985to 3.5000 in.)This slightly smaller bearing bore for theforward gear bearing adaptor is approximately 1/4 in.(6.3 mm) smaller.

3.4985to

3.5000

75241

Earlier Style Forward Gear Bore(Prior to S/N OF680000)

75248

3.2635to

3.2650

Later Style Forward Gear Bore(S/N OF680000 and Above)

INDEX



BEARING CARRIER

The later style bearing carrier is somewhat slimmerand about an 1/8 of an inch taller than the earlier stylebearing carrier.

75231a

b

a - Earlier Style Bearing Carrier (Prior to S/N OF680000)

b - Later Style Bearing Carrier (S/N OF680000 and Above)

THRUST COLLAR

The later style thrust collar is thinner than the earlier

style, but still maintains the same diameter.

75220

b

a

a - Earlier Style Thrust Collar (Prior to S/N OF680000)

b - Later Style Thrust Collar (S/N OF680000 and after)

REVERSE GEAR BEARING ADAPTOR

The later style reverse gear bearing adaptor has asmaller diameter than the earlier style adaptor and isdesigned to fit into the smaller bore gear housing.

74719 74718

ab

a - Earlier Style Reverse Gear Bearing Adaptor(Prior to S/N OF680000)

b - Later Style Reverse Gear Bearing Adaptor(S/N OF680000 and Above)

FORWARD GEAR BEARING ADAPTOR

The forward gear bearing adaptor has the needbearing pressed into the adaptor. For future refeence, the needle bearing inside the bearing adaptdoes not require a special driver. The needle bearinis pressed into the adaptor until the bearing is fluswith the edge of the adaptor bore.

74720 74721a

b

74888

c

74886

d

a - Earlier Style Forward Gear Bearing Adaptor(Prior to S/N OF680000)

b - Later Style Forward Gear Bearing Adaptor(S/N OF680000 and Above)

c - Later Style Forward Gear Bearing Adaptor Needle Bearin

d - Earlier Style Thrust Washer

INDEX



Counter-Rotation GearHousing AssemblySpecifications

Pre-Disassembly Inspection

ACTION READINGMove propeller shaftfrom one side toanother

Less than .003 in.(0.08 mm)

Rotate propeller shaft .005 in. (.127 mm) orless

22086

Forward and Reverse GearIdentification

IMPORTANT: The forward and reverse gears lookalmost identical. There are two ways to distin-guish between the reverse and forward gears.The reverse gear has a shorter hub and it has agroove cut into the back of the gear just insidethe thrust bearing race.

5088

REVERSE FORWARD

ab

a - Shorter Hubb - Groove

Pinion Gear Height

Take readings in three locations, 120_ apart.Readings: .025 in. (0.64 mm).

26410

.

Shift Spool End Play

74877

e a f g

d

b c

h

a - Washers (2)b - Springc - Retainerd - Spoole - Shift Shaftf - Castle Nutg - Cotter Pinh - End Play Measurement: .002 in. (.05mm) to

.010 in. (.25mm)

INDEX



Forward Gear Backlash

Apply a slight preload on forward gear using tools asshown.

50880

a b

c

d

a - Torque Wrench (91-66274)b - Propeller Nut [Torque to 45 lb. in. (5 Nm)]c - Washer (91-54048)d - Pinion Nut Adaptor (91-61067A3)

Check Backlash in four places. Rotate the drive shaft90_ after each check.

Backlash Reading: .017-.028 in (0.43-0.71mm).

70717

a

a

b c

d

e f

a - Nuts (4) (obtain locally)b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]c - Dial Indicator Holding Tool (91-89897)d - Dial Indicator (91-58222A1)e - Indicator Pointer-set indicator pointer at I on

backlash indicator rodf - Backlash Indicator Rod (91-53459)

Reverse Gear Backlash

Apply a slight preload on reverse gear using tools ashown.

709

b

c

d

a

a - Torque Wrench (91-66274)b - Driver Bolt [Torque to 45 lb. in. (5Nm)]c - Bearing Adaptor Installation Tool

(91-18605A1)d - Reverse Gear

Check Backlash in four places. Rotate the drive sha90_ after each check.

Backlash Reading:.050-.060 in. (1.27-1.52 mm).

a - Nuts (4) (obtain locally)b - Threaded Rod [3/8 in. (9.5 mm) obtain locally]c - Dial Indicator Holding Tool (91-89897)d - Dial Indicator (91-58222A1)e - Indicator Pointer-set indicator pointer at I on

backlash indicator rodf - Backlash Indicator Rod (91-53459)

707

a

b c

d

e f

a

INDEX




INDEX



Transom AssemblySpecifications



TORQUElb. in. lb. ft. Nm

Shift Cable Core WireAnchor Screws

20 2.3

Bellows Hose Clamps 35 4

Gimbal Ring to BellHousing Hinge Pins

102 143

Gimbal Ring Screws 55 74

Steering Screw and Nut 60 81

Transom Assembly

Attaching Screws, Nut

20-

25

27-

34

90_Fitting Nut10-14

14-19

90_Fitting70-90

8-10

Oil Fill/Drain Screw 23 30

Special Tools


Bearing Removal andInstallation Tool 91-31229A5

Bellows Expander Tool 91-45497A1


Shift Cable Removaland Installation Tool

91-12037

Driver 91-33492

Driver 91-33491

Driver 91-33489


Driver Rod 91-37323


Alignment ToolAssembly

91-805475A1

Expander Tool 91-45497A1

Hinge Pin Tool 91-78310

Mandrel 91-30366

Nut 11-24156

Special Tools (continued)


Plate (2) 91-29310

Puller 91-63616



Washer 12-34961

Bushing InstallationTool

91-806928T

Sleeve Installation Tool 91-818169

Sleeve Removal Tool 91-818162




92-86166


92-825407A12

Quicksilver U-Joint andGimbal Bearing Grease

92-828052A2

Perfect Seal 92-34227-1

Anti-Corrosion Grease 92-78376-12

Locquic Primer T 92-59327-1

Loctite 8831 92-823089-1Quicksilver SpecialLubricant 101

92-13872A1

INDEX


38/43

6

16

a

A

A

73316

17

18

3

13

22

24

10

12

23

7

A

b

20

11

36

38

5

35

37

33

34

2

14

15

14

14

3130

2928

32

26

25

4

9

18

a21

B

A

27

1

C

E

CB

F

B

(O.D.)

c


Alpha One Transom Assembly Exploded ViewBell Housing Components

INDEX



1 - Bell Housing Assembly2 - Gasket3 - Connector4 - Pipe Plug5 - Bushing6 - Bushing7 - Gasket (Rubber)8 - O-ring9 - Washer (Synthane)10-Stud11- Washer

12-Nut13- Universal Joint Bellows14-Ground Clip15-Clamp16-Sleeve17-Hose18-Clamp19-Exhaust Bellows20-Seals21-Clamp22-Lever Assembly23-Washer24-Screw25- Shift Shaft (Upper)26-Coupling Assembly27-Tubing28-Clip29-Clamp30- Fitting Assembly31-Connector32-Clamp33-Hose34-Clamp35-Connector36-O-ring37- Valve Assembly38-O-ring


A - Quicksilver BellowsAdhesive 92-8616. . . . . . . . . . . . . . . . . . . . . . . . . . .

B - Loctite 8831 92-823089. . . . . . . . . . . . .

C - Perfect Seal 92-34227. . . . . . . . . . . . . .

D - Special Lubricant 101 92-13872A. . . . .

E - Quicksilver High PerformanceGear Lube 92-816026A. . . . . . . . . . . . . . . . . . . . . .

F - 3M Brand Adhesive 92-25234. . . . . . .


a Tighten SecurelyApproximately 35 lb. in. (4 Nm)

b 50 lb. ft. (68 Nm)

c 8 lb. ft. (11 Nm)

INDEX


40/43



1 - Gimbal Housing2 - Stud3 - Lower Bushing4 - Oil Seal5 - Upper Bushing6 - Grease Fitting7 - Lubricap8 - Grease Seal9 - Bearing Assembly10- Tolerance Ring11- O-Ring12-Stud13-Seal14-Pipe Plug15- Water Tube16-Bushing17-Cover18-Screw19-Lower Swivel Pin20-Cotter Pin21-Washer22-Bolt23-Washer

24-Washer25-Nut26-Bolt27-Clamp28-Clamp29-Washer30-Nut31-Gasket32-Connector33-Lockwasher34-Nut35-Anodic Plate36-Seal37-Gasket38-Screw

39-Lockwasher40-Hose41-Clamp42- 90_ Fitting43-Nut44-Washer45-O-ring46-Connector47- Continuity Wire48- Continuity Wire

Connection49-Hose Clamp


A - Quicksilver BellowsAdhesive 92-8616. . . . . . . . . . . . . . . . . .

B - Quicksilver Perfect Seal 92-34227. . . .

C - Loctite 8831 92-823089. . . . . . . . . . . . .

D - Quicksilver U-Joint andGimbal Bearing Grease 92-828052A. .


a 70-90 lb. in. (8-10 Nm)

b 10-14 lb. ft. (14-19 Nm)

c 35-42 lb. in. (3.96-4.75 Nm)

d 25 lb. ft. (34 Nm)

INDEX



Inner Transom Plate Components

c 4

9

2

3

1

74850

10

a11

b

5

6

7

8

74865

13

12

19

20

17

18

16

14

15

1 - Transom Plate Assembly2 - Pivot Bolts3 - Tab Washers4 - Screw Engine Mounting

5 - Washer6 - Spacer7 - Washer - Fiber8 - Lockwasher - Double Wound9 - Locknut10- Washer11- Locknut12- Shift Cable Outer Casing13- End Guide14- Core Wire Anchor

15- Anchor Screws16- Core Wire17- Shift Slide18- Screw - Core Wire Cavity

19- Gimbal Housing Eyelet20- Cable Wrapping


a 25 lb. ft. (34 Nm)

b 23 lb. ft. (30 Nm)

c 37 lb. ft. (50 Nm)

INDEX


43/43

Gimbal Ring and Steering Lever Components

24

25

13

19

23

22

5

109

8

2

34

20

6

21

18

7

16

15

17

1

73

c

a

b

26

A

14

11

12

8

9

10

d

1 - Gimbal Ring2 - Bushing3 - Grease Fitting4 - Lubricap5 - Hinge Pin6 - Trim Limit Switch7 - Washer8 - Screw9 - Lockwasher10- Retainer11- Trim Wire Clamp

12- Screw13- Steering Lever14- Swivel Shaft15- Washer16- Washer17- Nut18- Screw19- Nut

22- Washer23- Locknut24- Clevis Pin25- Cotter Pin26- Trim Position Sender


A - Resiweld Sealer 92-65150. . . . . . . . . .


a 60 lb. ft. (81 Nm)

b 55 lb. ft. (74 Nm)

c 110 lb. ft. (148 Nm)

Documents

ALPHA ONE gen.2