Mercury MerCruiser V8 total removal & installation (How To)

hey y'all so bill and i are here we got bill's boat and we're just kind of we're getting in all kinds of trouble see what we can't break all right anyway i'll show you how to remove alpha drive gen 2 alpha drive we're going to rip it off the back of the boat here and um hopefully not actually rip it off the back of the boat we're going to try to unbolt it you know or well we'll see anyway stay tuned see what ventures lie ahead possibly go wrong toss it there's a lot to go wrong so anyway we'll break our stuff so you don't have to [Music] all right y'all so what you're gonna do these are the trim rams all right there's a little uh like a c c-clamp in here holding these on with a pen up here we've got bolts on either side all right we're going to remove this you have three on this side three on the other believe they're 5 8 okay or a 15 millimeter whatever works for you see what fits uh we're going to pop these caps off and there's the clamp we've got to get like a flathead get those off front and back so we can wedge out the trim rim got the six bolts three on either side uh we got the rams we're gonna have to wedge something in our pry bar screwdriver to get them to come apart and then we're gonna put something back there a piece of wood a pry bar to kind of wedge the uh out drive away from the transom assembly so we got the uh pin for the uh trim rams out we just put it in there we beat it with a hammer sometimes they get locked up in there but we got it out you know you can see the other side it wasn't bad it came out better than we thought um now this is all unbolted what we're gonna do is we're gonna wedge something right here and that's gonna allow us to pop it away one thing i will do though is i always shift them in forward because it allows me to to uh spin the prop to align it when i put it back in for insertion so i can line up the splines and then also why it's in forward uh it moves the shifter out of the way because the shifter will be in the way on this so it shifts it in the right direction to remove the out drive all right what we're gonna do is we're gonna put this right back here [Music] right now we're going to relieve now we're going to remove a small block chevrolet mercruiser engine inboard outboard style configuration now we remove the out drive on the back so that's the first step next what we're gonna do is we gotta remove the exhaust from the y-pipe here and here okay there's engine mounts here and there's engine mounts in the back back there there's one with two bolts here there's one there one there and another one over here with two bolts in it all right and then we have a raw water supply on this which is a little different than most alphas most alphas have the outside water supply this one has a raw water pump um down there okay so we got to remove the raw water supply from that and the the uh cool it's a closed cooling system so this one has a closed cooling reservoir we're gonna make sure remove that and then there'll be a ground power cable on the back of the bell housing usually right back there and also the power cable which will be going to the starter underneath the engine and then the shift and throttle cables right there and once we go one by one and remove all these things along with the wire harness that we already removed it should pretty much lift right out maybe you have to shim it forward a little bit but we got room here so that's good all right so we're going to get to taking this apart you got to do is the fuel line it's head right there to the fuel water separator make sure we disconnect that also all right y'all down there that's the engine mount there's one on each side under the exhaust manifold they're usually three quarter these are five eights a little hard to get to you might have to remove an exhaust manifold depending on the configuration of the engine um we're going to remove the raw water right there okay we got the throttle cable right there that's got to come off we already moved the shift cable over there you can see the bolts by bill's arm fuel lines off right there and then now he is working on the hydraulic assist uh in the back be careful with uh sam right there be careful with uh removing them don't want to mess up those threads very important that you got a good seal and then that goes up here to your hydraulic pump right here okay power steering and that's your assist back there all right there you see him right down in there right there all right so that and then like i said to shift them throttles off lane right there throttle's gonna get taken off excuse me it's right here and the wire harness has been removed so now we're gonna do the engine mounts on the side and the engine mount right there see that rusty old bolt that one has a three quarter there's one on each side of the valve housing and then that'll be that don't forget your grounds are usually grounds you can see these they're usually on the back of the bell housing in the corners then like i said there's one and three quarter bolts for the engine mount on the back and those are pretty tough you might need a breaker bar or an impact to get them off that last back one if you have air impact it does work a little bit better than the old breaker bar last back engine mounts we like to make it more challenging everybody can do it with air tools and shade we like 150 degrees and manual labor tools that's the thing we got to get to right there it's going to be fun so we got the engine out of the boat we've removed the trim senders we want to keep this helmet so we're going to change out the helmet into the transom assembly so what we're going to do is over here is a specialty tool it's like a 12 point uh fitting that goes in there it's kind of 12 point allen head looking thing that's a merc cruiser specialty tool or you can use a you get an allen headed fitter right that you won't strip it out but anyway we got to remove this one and then on this side we've got another one and then that'll remove this helmet uh from the whole gimbal ring and assembly here and then we're going to rip this off right here so this will remove this from the rest of it and then we're going to remove this and replace the transom assembly and then reinstall this helmet into the assembly so here's the specialty tool to remove that helmet all right it goes into the end of a socket anyway so the specialty tool fits into a half inch socket maybe if i can do it one-handed there we go and then it goes right in there see splines up and then we just bust it loose okay so we got the specialty tool in there and we're just gonna remove it [Music] and here we got the other side going all right so we're just gonna this is gonna be removed from the gimbal right here and the whole transom assembly once we get that uh independent of that we're going to remove the shift cable we're going to pull that out so we're going to remove this and uh we'll replace the transom assembly all right y'all so the engine's removed the helmet is released outside and then there's the engine mounts and the internal transom assembly all the nuts there's eight of them have been removed on the inside and we're gonna tap on them studs to get the transom assembly to remove from the outside of the transom we had to remove the y pipe right there that'll have to be remounted when we put it all back together all right so we're removing the transom assembly uh we just uh removed the helmet we got it loose i have to disconnect the bellows in here so there is a gasket right here and then the shifter will have to come off also we'll pull the shift cable through and then i'm gonna remove this ring the retaining ring in there and uh we'll remove this transom assembly bills on the inside uh getting ready to remove the hydraulic lines for the trim and tap on the bolts to uh push it outward just like this all right so now bill has removed the inside of the transom assembly and the studs are accessible and we're going to uh tap on the studs to remove the external part of the transom assembly now bill's going to tap on the studs to get off the outside part of the transom assembly we got the gap coming here it's coming apart slowly all right y'all we got it out now oh look there's a foot down there yeah there's definitely a hole in the boat at this point so definitely a hole we gotta get it all cleaned up and put the new transom assembly on and put it back together hey y'all so we are still working on bill's boat we just stuck the outside of the transom assembly on kind of didn't videotape that in you know i probably should have anyway let me show you a little bit about it as we put the the transform assembly on because we had to fix the steering arm in his boat and if you see there's a new seal right there see that black thing so we put a brand new seal on it and 5200 all the way around it we just kicked it into place you see the helmet is still missing all right and the seal goes all the way around it and all we've done so far is just shove it in there so seal it up and shove it in there and then bills on the inside with the inside transom plate and we are going to put it on there and tighten it up all right so bill's in here what are you doing he's putting 5200 on all the studs that we just pushed through so there's the outside of the transom assembly and if you see all the studs all have 5200 around them and now we're going to take the inside transom assembly which is right there on the floor and we're going to put it right in here and we're going to tighten it all down and compress all the seals in 5200. [Music] so [Music] so so so now you can see all the seals have cinched in on the outside all right y'all so bill has got the transom assembly in there if you noticed all the bolts are bolted up we got some block offs going there and then the steering arm was attached now this was our original problem this steering arm right here was rotted out and broken and that was the whole reason we ripped all this apart um so we got the new steering arm and the transom assembly together we just put the hydraulic assist back on to the steering arm that's a pin right here uh it's a pin and then it's got a little cotter pin on the bottom to retain it and then that'll be the hydraulic assist we'll have to uh put those hydraulic lines back in when we put the engine in currently we have these hydraulic lines here and the exhaust this y-pipe so currently we have this hydraulic lines here coming out and that's the trim hydraulics they go over here to the trim pump right there those had to be removed and we removed the transom assembly so we remove them and we put them back in and then last but not least is our y pipe right here right there and right there now these have flappers in them our flappers are burnt to help we didn't replace them on our biggest priority but what we did do is we put our tv on the seal back in here and there's four bolts two on the top and two on the bottom down there they're at twelve point three eighths and we torque the y pipe back down now that that's all done uh we're just gonna set the engine in now we're gonna get ready to put this engine in we gotta one more thing to do is we gotta bring our our shifter back through okay that hole right there there's a little boot on the outside of the transom assembly and we're going to reinstall the helmet and the shift uh sheathing for the shift cable and then we have uh the engine mounts here where the bell housing will go in it's a three quarter inch bolt there's this and a spring now we're going to glue these into place here and here and what we do is we glue them into place that they don't fall off while we're putting the engine down and then there's the engine mounts on the side here and here which we will line up the engine mounts with so there's two in the back one there and one there and then here and here and then we'll drop the engine in place but first we're gonna put the helmet on the outside and run the uh shift uh shifter cable through which is gonna come through right there all right hey y'all so we were just getting ready to put this helmet on and uh notice the shift cable had a hole in it so what we're going to do is we're going to put a new shift cable on uh to remove this on these this uh an alpha gen 2 we we have a special socket you like that as the best weld job i've ever seen anyway it's just two 916 sockets and what it is it's got to fit over this so we uh put it down in there and we're going to use it to bust this thing loose there it goes just had to get a little more leverage on it got a little coverage kind of loosened it up with the first one so we're just just a 916 a double deep socket on it that we made to uh get in there yeah it's pretty simple we just got to crack it out of there all right so we got our new cable all right and uh pulled the other one out there's a little rough way to yank it out of there pretty good and we're going to put the new one through went through there a lot easier how did you do another one came out i'll tell you what [Music] all right we got the new one installed down in there and we're going to put the helmet on the boat and put this cable up there all right all right so we got the helmet there transfer assembly there we're putting the shifter through there and then that'll go inside the boat we've got to slowly work it in and get it back inside and we're going to melt this helmet up we're gonna mount the helmet up after we get it in there another view we're just trying to show you so it goes uh right there in that little uh nipple i guess we'll call it the shifter bellows and push it up inside the boat through the transom assembly so i got the cable through actually went fairly easy considering our luck so we're happy about that now we're going to grease up the what do you call them like the gimbal mounts or something right here [Music] all right y'all so we got the shift cable through down here um we're gonna put a little tie wrap around there sometimes there's a little retaining ring i'm gonna put a little grease on the helmet here and uh we're gonna put this all back i just want to make sure i got some good lubricant in areas and that's gonna be it so there is this uh flat washer all right that goes in there and see if i can start one of them help it stick i got the washer on there and this is my uh the bolt which i need the specialty tool [Music] for just gotta line that up [Laughter] now we got one side started we're gonna start the other side we got our washer put it in there these things are like wafers everything very thin i'm gonna tighten this one down a little bit just to get make sure it's in there and then we're gonna turn the steering wheel to access the other side all right so i got the other uh the bolt and the specialty tool for here we're going to make sure we're going to line it up on this side [Music] all right we gotta start it always start it by hand and we're gonna tighten it down right here we're going to tighten both sides down that we got them in there [Music] all right we're going to turn it back the other way and we're going to torque down the other one and now we're going to tighten this one up on this side there's a specialty tool and uh our helmet is gonna be back in place we're gonna put our our trim indicator pucks back on and uh that's great we're uh ready to put the engine back in this boat all right finished up so now we just got to install the bellows and the shift cable and the insert into the shift cable all right so now we got to grease that bearing we're going to install that bellows uh the exhaust bellows and we are going to put the cable in there and run it inside the boat and then we're going to put this engine in this boat because these are all tightened down now we're ready to go all right y'all so we guys we got the specialty tool okay that thing that just fell that is the retaining ring for the main bellows all right the bearing in there and then what i did is i just there's a little groove in here and i pulled the bellows into place on that groove and now we're gonna put this retaining ring right in there and what it does is it puts pressure in there and holds that bellows into place so you just line it up straight y'all so if you can see that's nice and flush in there and that is retaining that um bellows in place so there's no water intrusion and now we just got a small o-ring that we put in front of that that helps compress and make it watertight then also on here on the outside when we install the out drive we will have another gasket all right in place and that just slides right here in front and we're just gonna set it in there that's it right there see it there it is so that's nice in place now and that'll be ready for the to receive the out drive we're just going to align that bearing back there the retaining ring is in place holding the bellows and then the o-ring to help water tight it and then we're gonna put the out drive on make sure all our gaskets and everything are in place out here and uh we gotta put our trim pucks on here and also we will use that zerk fitting right here to grease the bearing inside all right y'all we're gonna get ready to put this engine in the boat we're all pretty squared away but we got a little water damage down on this starter these bolts look how rusty that is we're gonna replace that and we're tired to pull it out but the bolts are all stripped out and rotted so going to work on getting this out first [Music] supposed got it taken care of here i'm purely administrative today here we are back again see inside where the starter goes right there before we put the engine in the boat we need well some engines are accessible this one just does happen to not be but before we put this engine in the boat we got to hook the power up to the starter and then lower the engine into the boat otherwise we have to remove the exhaust manifold to give you power it's not really accessible if you tighten this down too much it'll crack someone on it you gotta put [Music] yeah forward [Music] [Music] no it's on the bottom um go head down a little bit cliff there's a water line going through goes over here right here [Music] down right there [Music] oh you're pretty good yeah it's like just right just right we're going straight down on it go down [Music] hold it okay all right y'all so what we're doing now is we're just greasing the gimbal bearing go ahead mr bill mr bill's over here just freezing it up there's a zerk fitting you gotta put a lot of pressure on there it's all right pump hard and hold it tight i hear it you gotta go let's go [Music] there we go look at that and all that nice grease around that gimbal bearing oh yeah bump it in there mr bill all right beautiful all right now that that's done we're gonna put the gasket on here and attach this out drive all right y'all so we're gonna get this out drive on the engines in the boat we're gonna finish up tighten the stuff in there and then uh we're gonna align our gimbal bearing we have our gimbal bearing alignment tool just to make sure it's going in the back of the coupler correctly for the donkey deck on the out drive to line up correctly so anyhow there she is look at that ain't that nice and easy i love it when stuff lines up correctly although this is an alpha drive if it's a bravo drive it's much heavier come on hold it right go there all right y'all well we put the drive on we uh lined up the shifter put those six bolts on put the trim system back on the rams and these six bolts over here right there okay and then you know we had to tap that uh ram uh pin back and forth a little bit and grease it up to get everything to line up right but there we are back in business we are in the home stretch we got the engine set in the engine compartment um what we've got done now is we hook the fuel up right there that's the fuel line we got the grounds hooked up most of the time the grounds are on the back of the engine whoever redesigned this one put the ground right down there in the front bolt it in um we got the shift cable right here common that we replaced that's coming from the uh transom assembly we got the shift assembly with the shift interrupt right there we got to finish adjusting that up all right and then we have we already hooked up power to the starter down there we had to do it as we put the engine in because you can't do it on this particular configuration unless we want to remove like an exhaust manifold or something what we do have to do is secure the engine mounts so let's look at that all right guys so we got to put those on there see the engine mounts down there we got those on each side of the engine and then also see that big three-quarter inch bolt we got one there on the side of the bell housing and we got one right there we got one right there we got to tighten those down we put the exhaust together already and we tighten down the exhaust boots for the y-pipe and that's about it we're gonna finish putting this together and we'll be running it soon the moment of truth it's dark very dark we are so done with this we're it's together thank god we're we're not doing this again anytime soon um but we got it running we had a little trouble the other night had a busted ignition uh ground uh kind of killed spark on us we got together this morning everything looks good running nice and tight thanks for watching uh it's been fun it's been weird oh man this is over yes exactly [Music] nice and tight you all fired right up and that engine was cold [Music] nice [Music] don't i

Channel: Chef Outdoors

Views: 138,010

Keywords: #mechanics, #howto, #mercury, #merCruiser, Smallblockchevorlet, #v8, #5.7ltr, #350, #enginermoval, #engineinstallation, #inboardoutboard, #I/O, #Outdrive, #Mercuryoutdrive, #boatmechanics, #marinemechanics

Id: 5K---Dlz3Xw

Length: 30min 37sec (1837 seconds)

Published: Mon Nov 09 2020