Mercury MerCruiser Bravo One XR 1.26:1, 1.35:1, Standard, X, XZ, XR Bravo drive Service Manual

Bravo Drive History

Section 7A - Bravo Drive Unit History

Table of Contents

Bravo Drive Unit History

1988..........................................................................2

1989..........................................................................2

1990..........................................................................2

1991..........................................................................2

Bravo Oil Circulation System (1991 and Newer)

...............................................................................3

Bravo Driveshaft Housing/Gear Housing

Compatibility Diagrams..........................................4

1993..........................................................................4

1995..........................................................................5

1996-1/2 ...................................................................5

1997-1/2....................................................................5

Shift Changes for Bravo One/Two/Three and

BlackHawk.............................................................5

1999-1/2....................................................................7

2000..........................................................................8

Bravo 2000 Models................................................8

Driveshaft Housing Changes.................................9

Aluminum Bearing Chimney In Top Cover..........9

Drive Shaft Housing Bearing Chimney...............9

Driveshaft Housing Driven Gears.......................9

Driven Gear Needle Thrust Bearings..................9

Driven Gear Thrust Races..................................9

Needle Thrust Bearings Between The Garter

Spring And The Driven Gear...............................9

Cone Clutch........................................................9

Universal Joint Assembly..................................10

Splined Coupler Between Upper Driveshaft And

Lower Driveshaft...............................................10

Lower Unit Changes............................................10

Bravo One And Three Lower Driveshaft...........10

Water Pickups...................................................11

Hi-Performance Propeller Shaft Assembly.......11

Transom Assembly Changes for Bravo 2000

Models.................................................................11

Intermediate Shift Cable Guide Extension........11

New Gimbal Bearing.........................................12

New Universal Joint Bellows Aluminum Retention

SleevE...............................................................12

Trim Cylinder Tilt-limit Spacers.........................13

Additional Information..........................................13

Installing A Bravo X Model On An Older Transom

Assembly..........................................................13

Bravo Three Driveshaft Holding Tool Modifications

..........................................................................13

New Tools For Bravo 2000 Models...................13

Bravo One Xr Drives Gear Ratio Change.........14

Bravo 2000 Style Service Replacement Gear Sets

For All Bravo Drive Units...................................14

New Gear Sets and Gear Kits...........................14

Required New Thrust Bearing Shim Races......14

Sleeve Bearing Race Drivers............................15

Bearing Driver And Chimney For 1999 And Prior

Units With Older Bearings And Gears..............15

Bearing Driver And Chimney For The New

Designed Bravo Gears And Bearings When Used

In 1999 And Prior Units.....................................15

Bearing Driver And Chimney For Bravo 2000 And

Newer Models...................................................16

2004........................................................................16

U-joint Assembly (Standard and X models).........16

Bravo Shift Effort/Noise Reduction......................17

Revised Shift Lever Detent...............................17

Cone Clutch Change.........................................17

Shift Switch Added............................................18

Bravo Styling Change..........................................18

Increased Bravo X durability................................18

Increased Bravo XR durability.............................18

All Bravo Models will now have Shimmable

Driveshaft Housing Gears for Increased Durability

.............................................................................19

Bravo Three Changes.........................................20

Additional Corrosion Protection........................20

Improved Durability...........................................20

New Improved Propshaft Seals........................21

2005........................................................................21

Oil Leak When Using the Current Magnetic Drain

Plug in the XR or XZ Heavy-Duty (Blue Billet)

Bearing Carrier....................................................21

Water Pickups and Flushing Devices Used on Bravo

Drives..................................................................23

Bravo Driveshaft Housing Shift Shaft Bore O-ring

Replaced with a New Seal ..................................25

Bravo (and Alpha) GKN U-joint Tools..................26

Bravo Standard GKN U-joint and Cross Bearing Kit

.............................................................................26

Bravo X Series GKN U-joint and Cross Bearing Kit

.............................................................................27

Bravo Bell Housing to Gimbal Housing Alignment

Tool......................................................................27

Bravo One/Two/Three Gearcase Needle Bearing

Removal Tool......................................................28

7

A

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1988

• Bravo One introduced on Big Block Magnum and 7.4L models.

• Due to their straight-cut gears, it is a true bi-rotational drive.

• Propshaft rotation changed by changing shift cable output at remote control box and changing propeller.

• Propshaft bearing carrier was shimmed to set propshaft rolling torque.

• No gear lube monitor and no lube passages in driveshaft housing or bell housing.

• Dipstick was in the top cover. Drain plug at front of torpedo. Had to tilt drive unit approximately

45° to allow full drain.

• Fill in vertical position until oil flows out vent plug and verify with dipstick.

1989

• Bravo Two introduced.

• Designed for large, heavy boats with 45 MPH maximum speed.

• Same driveshaft housing as Bravo One, but much larger gear housing.

• Swings a 50.8 cm (20 in.) diameter propeller. Uses TR style prop mounting hardware.

• Load ring on propshaft carrier is used to maintain rolling torque instead of shims.

1990

• Bravo One received streamlined gearcase. The strut was moved forward 5 cm (2 in.).

• Bravo One drain plug is now at the rear of the propshaft carrier (C2 carrier).

• Bravo One must trim in fully to drain. Fill in vertical position until oil flows out vent plug.

• Gear lube monitor added to all driveshaft housings and transom assemblies.

• Dipstick removed from top cover.

1991

• Oil recirculation added.

• Lower gearcase pumps lubricant to the U-joint shaft bearings and it returns to the lower gearcase through cast-in passages.

• Required new driveshaft and gear housings. Service Bulletin 91-20.

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Bravo Oil Circulation System (1991 and Newer)

Oil movement starts in the gearcase, a high pressure area is created by gear rotation. Using passages cast into the housings this high pressure is directed to the U-joint bearings and seal.

Oil; cooled by water flowing past the gearcase, lowers the U-joint bearing and seal temperature.

Another passage directs oil from above the U-joint gear to the needle bearing inside the top cover.

Oil returns to the gearcase through a passage aft of the driveshaft. Oil enters this return cavity from under the driven gear. A small amount of oil will pass through the bearings under the lower driven gear and around the needle bearing on the upper driveshaft. Oil exits the driveshaft housing and reenters the gearcase through the driveshaft bore.

20452

NOTE: Gearcase and driveshaft housings with the oil circulation system will not interchange with housings from older Bravo units without oil circulation. If housings are intermixed, gear oil will drain out of the drive unit, through the interconnecting oil passage. Refer to Service Bulletin 91-20.

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Bravo Driveshaft Housing/Gear Housing Compatibility Diagrams

NOTE: All diagrams are of the mating surfaces at the driveshaft bore and forward water cavity areas. Arrows connecting diagrams mean that units are compatible.

1

2 a a b b b

3 a b

4 a a

5 b a

6 b

1993

Page 7A-4

20679

a -

Oil hole

b -

No oil hole

1 - Bravo driveshaft housing - old style

2 - Bravo gear housing - old style

3 - Bravo driveshaft housing - intermediate style

4 - Bravo gear housing - intermediate style

5 - Bravo driveshaft housing - new style

6 - Bravo gear housing - new style

NOTE: Remove and discard any oil passage plugs found in housing mating surface before assembling unit.

• Bravo Three introduced.

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• Uses two counter-rotating propellers to reduce propeller torque, improve tracking and handling.

• Used two-piece gearcase housing.

• Extension held in place with trim tab bolt.

• Negative trim must be limited by to 2.54 cm (1 in.).

• Exhaust tube must be used instead of exhaust bellows.

• Bravo One propshaft bearing carrier changed to load ring design (C3 carrier [Service Bulletin

93-10]).

1995

• Propshaft bearing carrier anode added on Bravo One models.

• Replaceable thrust wear pads added on all driveshaft housings.

1996-1/2

• Bravo Three changed to one-piece gearcase housing (anti-ventilation plate was extended aft to replace separate extension plate). Older housings will supercede to this housing.

1997-1/2

• New shift components (in driveshaft housing) to lower shift effort (Service Bulletin 97-18).

• All parts will retrofit in older driveshaft housings.

• New driveshaft housing with elongated aft trim anchor hole (Service Bulletin 98-16). Aft trim anchor pin spacer must be correctly positioned to limit negative trim on Bravo Three models.

Shift Changes for Bravo One/Two/Three and BlackHawk

1. Bravo One/Two/Three/BlackHawk New Shift Parts a.

The Cone clutch has changed. The spring ramp area is different. The yoke groove has been increased by 0.025 cm (0.010 in.) in width. The clutch is identified by a number 7 stamped down at the bottom of the spring groove on every clutch.

7

Cone Clutch (52-807375A2)

20266

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b.

The garter springs now have a smaller diameter on the Bravo One/Two/Three only and are colored orange for easy identification.

20267

Silver Color-Blackhawk (24-818829)/Orange Color-Bravo One/Two/Three (24-93505)

c.

The shift cams have a new ramp profile on them and will be identified with the casting part number molded into the top surface of the cam (as shown below on the assembly).

20268

Shift Cam Assembly (806552A1)

d.

The shift yoke has been made 0.01 cm (.004 in.) thicker. The yoke will be identified by a yellow paint stripe (illustrated on the drawing below).

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20269

Shift Yoke (806552)

2. Following is a list of the kits that are available to back fit the new shift components into every

Bravo unit from the first one built: a.

Yoke and cam assembly, for units starting with serial number 0K091000 and above.

b.

Clutch kit assembly (52-807375A1), which includes the new cone clutch and springs as well as the yoke and cam assembly and two new socket head Allen screws for use on units starting with serial number 0F345868 through 0K090999.

c.

Shift upgrade kits, for use in units with serial number 0F345867 and prior, back to the first Bravo unit built. Each kit will be preassembled and consist of the following parts:

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• (2) new driven gears

• (1) new cone clutch

• (2) new garter springs

• (1) upper drive shaft

• (2) thrust bearings

• (2) thrust bearing races

• (1) new shift yoke

• (2) shift cams

• and the miscellaneous bolts and spacers required to assemble the kits.

The Shift Upgrade kit part numbers are as follows:

32 TEETH (43-807436A1)

30 TEETH (43-807437A1)

29 TEETH (43-807438A1)

1999-1/2

• The propshaft oil seals, used in the Bravo Three and BlackHawk bearing carrier and the outer propeller shaft assembly, have been upgraded from two back-to-back seals to a new one-piece, canister type design.

• The two individual seals for the inner shaft are now housed in a canister that is inserted into the outer propeller shaft assembly.

• The two seals for the outer propshaft are also housed in a canister that is installed in the bearing carrier.

20431

Bravo Three and BlackHawk outer prop shaft oil seal

(26-861694)

20433

Bravo Three and BlackHawk inner prop shaft oil seal

(26-861695)

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The following drawings show the area and dimensions on the seal installation tools to be modified, so that they can be used to install the new one-piece canister type oil seals. Present tools can be modified in the areas shown to allow them to work with the new and old seals.

20434

Inner seal installation tool (91-805358)-modifications 0.39

x 0.22 cm (0.155 x 0.085 in.)

2000

20435

Outer seal installation tool (91-805372)-modifications

0.61 x 0.28 cm (0.240 x 0.110 in.)

There were four new Bravo 2000 drive units (S/N 0M100000 and above). These units have had many changes made to enhance durability and most of the internal parts in these drives will not backfit older Bravo product.

Use Service Manual #28 for 2000 models. Use Service Manual #11 for all older models.

Bravo 2000 Models

Versions Product Changes Models Effected

Bravo (Standard)

Bravo One (all ratios), Bravo Two

(all ratios), Bravo

Three (all ratios)

Bravo X

Improved bearings and clutch, new style cut gears, aluminum lower bearing chimney

Standard on all gasoline engines

4.3L-5.0L-5.7L-6.2L-496

Bravo One X (all ratios), Bravo Two X

(all ratios), Bravo

Three X (all ratios)

Improved bearings and clutch, larger U-joint, near-net forged gears, steel lower bearing chimney

Standard on all diesel engines and

496 H.O.

Bravo XZ

Bravo XR

Bravo One XZ (1.36

ratio), Bravo One XZ

(1.50 ratio)

Improved bearings and clutch, larger U-joint, near-net forged gears, steel lower bearing chimney,

Hi-Performance propshaft kit

Standard on all 500HP engines,

Optional on 496 H.O.

Bravo One XR

(1.26, 1.35, 1.50

ratio)

Improved bearings and clutch, larger U-joint, straight tooth net forged gears, steel lower bearing chimney, Hi-Performance propshaft kit

Standard – 575HP Hi–Performance engines, Optional – 500HP Optional on 496 H.O.

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Driveshaft Housing Changes

ALUMINUM BEARING CHIMNEY IN TOP COVER

All Bravo 2000 models

• The Aluminum bearing chimney in the top cover is machined to a shorter height to allow for the new narrower needle bearing race.

DRIVE SHAFT HOUSING BEARING CHIMNEY

Standard Bravo

• The aluminum bearing chimney in the driveshaft housing is machined to a shorter height to allow for the new narrower needle bearing races.

Bravo X, XZ, XR

• There will be a new steel lower bearing chimney that threads into the driveshaft housing, similar to the one that was used in the BlackHawk drive.

DRIVESHAFT HOUSING DRIVEN GEARS

Standard Bravo

• There will be new driven gears (spiral bevel) with the new thick web floor and narrower needle bearing.

Bravo X, XZ

• The Bravo X and XZ will have (spiral bevel) Near-Net Forged gears, including both driven gears with the new thick web floor and narrower needle bearing, as well as a new Near-Net

Forged U-joint pinion gear with an 18 tooth internal spline for all ratios.

Bravo XR

• The Bravo XR will have straight tooth, Net-Forged gears, including both driven gears with the new thick web floor and narrower needle bearing, as well as a new Net-Forged U-joint pinion gear with an 18 tooth internal spline for all ratios.

DRIVEN GEAR NEEDLE THRUST BEARINGS


• There will be new larger needle radial thrust bearings for the driven gears.

DRIVEN GEAR THRUST RACES


• Because of the change to new, larger needle radial thrust bearings; there will also be a change to the driven gear radial thrust bearing race, from the old thickness of

2.3-2.4 mm (0.091-0.094 in.) to the new thickness of 1.5-1.6 mm (0.061-0.064 in.).

NEEDLE THRUST BEARINGS BETWEEN THE GARTER SPRING AND THE DRIVEN GEAR


• There will be a new larger needle, radial thrust bearing between the garter spring and the driven gear. The bearing and race are now combined into one assembly.

CONE CLUTCH


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9


• There will be a new cone clutch identified with a shallow groove machined on the top flat surface of the cone clutch.

20436

UNIVERSAL JOINT ASSEMBLY

Standard Bravo

• The U-joint assembly will remain the same as today (L-15, 15 tooth spline input yoke) and use the present cross and bearing assemblies.

Bravo X, XZ, XR

• There will be a new, larger (L-18) U-joint assembly that will have an 18 tooth spline input (stub) yoke and use a larger cross and bearing assembly.

• There is a new retainer nut that has the stub yoke oil seal installed into it, as well as the O-ring groove in it, for installing the O-ring that seals the outside diameter of the retainer nut. The new spanner wrench is required for removal and installation of the new retainer nut.

Spanner Wrench for L-18 U-joint Bearing

Retainer

91-862219A1

• There is also a new thrust washer in the U-joint assembly, behind the oil seal in the carrier retainer nut, that is only used with the L-18 U-joint assembly.

SPLINED COUPLER BETWEEN UPPER DRIVESHAFT AND LOWER DRIVESHAFT


• There is a new splined coupler between the upper driveshaft and lower driveshaft. The only difference is that the spline has had a small radius added to the bottom root of the spline. Both the old coupler and the new coupler will work on old and new product. The reason that the radius was added to the bottom root of the spline groove was to give added strength in that area of the coupler.

20438

Old Style Spline/New Style Spline

Lower Unit Changes

BRAVO ONE AND THREE LOWER DRIVESHAFT

All 2000 Bravo One and Three lower units

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• There will be a new driveshaft only in the Bravo One and Three with induction hardened splines on both ends of the shaft. There will be a larger mid-section on the shaft as well. The Bravo

One will use the same drive shaft assembly as the Bravo Three. A screw and washer will be used to retain the pinion gear to the shaft, in place of the pinion nut and washer used on older

Bravo One product.

WATER PICKUPS

Bravo standard and X models

• The Bravo One will be offered with the new Dual Water pickup style gearcase. This unit draws water from the side water inlets and from four inlet holes in the front of the torpedo area. The front pickups provide a ram effect and will allow a slightly higher X dimension for the drive unit.

If they become plugged from beaching the boat, they will self-clean when under way again.

Bravo XZ, XR models

• The Bravo One will be offered in both the dual water pickup and the Hi-Performance low water pickup style gear housing.

20439

New Bravo One dual water pickup style gear housing

HI-PERFORMANCE PROPELLER SHAFT ASSEMBLY

Bravo One XZ, XR

• These drives are equipped with the new Hi-Performance propeller shaft assembly. The assembly includes a new heavy-duty bearing carrier, with a larger bearing and piloted gear and a larger diameter propshaft.

Transom Assembly Changes for Bravo 2000 Models

INTERMEDIATE SHIFT CABLE GUIDE EXTENSION

The Gimbal Housing for both Alpha One and all Bravo product now has a new intermediate shift cable guide extension cast into the housing. There is also a new plastic cable guide insert for the extension in the housing. This extension will help when installing a new intermediate shift cable.

It now extends out over the flange of the exhaust pipe. It will help prevent the shift cable from being pushed into the engine coupler area.

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NEW GIMBAL BEARING

There will be a new gimbal bearing installed in the gimbal housing for Bravo 2000 product only.

The new bearing and cartridge will look just like the current gimbal bearing and cartridge. The only difference will be at the center race of the bearing. If you look at the new bearing (from the side), the center race will look like it is offset towards the notched side of the bearing cartridge. The center race has been machined down on one side to provide extra clearance for the L-18 U-joint assembly. The new bearing will also be identified with a red paint dot on the aluminum cartridge of the assembly. This new gimbal bearing will be the only gimbal bearing used in all Bravo transom assemblies.

a

20440

b c a -

Current bearing (30-60794A4) - center race thickness even on both ends

b -

New bearing (30-862540A3) - center race machined down on the side that arrow is pointing towards

c -

New bearing (30-862540A3) - identifying red dot shown on side of aluminum cartridge

NEW UNIVERSAL JOINT BELLOWS ALUMINUM RETENTION SLEEVE

There will be a new U-joint bellows aluminum retention sleeve (retainer ring). The retention sleeve will have a larger inside dimension and will be narrower than the current retention sleeve. This change was required to allow clearance for the new larger (L-18) U-joint assembly. The change will be made on all Bravo transom assemblies.

Page 7A-12

20441

Original U-joint bellows retention sleeve

20442

New U-joint bellows retention sleeve

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TRIM CYLINDER TILT-LIMIT SPACERS

New trim cylinders, with the tilt-limit spacer installed by the factory, will be shipped on all Bravo

Transoms. The spacer limits the total amount of trailer limit travel by 16 mm (5/8 in.) when the unit is raised to the trailering position. The overall total travel of the trim cylinder with the tilt-limit spacer factory installed will be 672 mm (26 7/16 in.) from anchor pin hole to anchor pin hole. Current trim cylinders, without the tilt-limit spacer, have an overall total travel of 687 mm (27 1/16 in.) from anchor pin hole to anchor pin hole, +/- 3 mm (+/- 1/8 in.). The casting numbers that you now identify the cylinders with (98704 and 98703) will be changing to new casting numbers (98719 and 98718) for the cylinders with the tilt-limit spacer installed.

All diesel transoms and service parts Magnum and Hi-Performance transoms will be built with the tilt-limit spacer installed in the cylinders.

Additional Information

INSTALLING A BRAVO X MODEL ON AN OLDER TRANSOM ASSEMBLY

See MerCruiser Service Bulletin 2000-8 for information on installing a Bravo X model on an older transom assembly.

BRAVO THREE DRIVESHAFT HOLDING TOOL MODIFICATIONS

The new Bravo Three, lower driveshaft requires a larger opening in the driveshaft holding tool to accommodate the larger shaft used on Bravo 2000 models. You can order a new holding tool, or modify an older version. In order to use an older Bravo Three Driveshaft Retaining Tool on a Bravo

Three 2000 Standard, or X drive you will need to modify the tool to the

29.7-29.8 mm (1.170-1.175 in.) dimension to make it work. This modification will change the tool so that it will not work with the older Bravo Three with the smaller diameter driveshaft. Therefore you will need to retain an original tool to work with the older Bravo Three. The following artwork will illustrate the change to the lower driveshaft retaining tool.

20444 20446

Old tool for Pre-2000 Bravo Three models (91-805381) New tool for Bravo Three 2000 models (91-863738)

NEW TOOLS FOR BRAVO 2000 MODELS

91-862219A 1 - Spanner Wrench for the U-joint retainer nut on units with L18 U-joints (X series).

17-862218 - Replacement pins for spanner wrench

91-862531 - Lower bearing chimney remover/installer for units with the steel bearing chimney (X series).

91-862530 - Bearing installer for the new shorter bearing sleeve and needle bearing on all Bravo

2000 models. Used with components of the 91-90244A1 Puller/Driver Assembly.

91-862546 - U-joint bellows retention sleeve removal tool. Required to remove the new larger inside diameter sleeve without damaging it.

91-840383A 1 - If working on the gearcase housing that has the Hi-Performance propshaft kit installed (factory installed on XZ and XR models), you will need kit 91-840383A1, which includes one of each of the following:

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91-840393 - Spanner wrench

91-840385 - Seal installer

91-840388 - Seal protector

91-862064A 1 - A new tool has been released to remove the propshaft seal and bearing from the carrier on all Bravo Three models. Bearing/seal remover will press out the caged needle bearing and the propshaft seal in one step, preventing damage to the carrier.

91-863738 - Bravo Three driveshaft retaining tool. Required to accommodate new larger diameter lower driveshaft.

BRAVO ONE XR DRIVES GEAR RATIO CHANGE

New lower gear sets are now available to convert 1.50:1 Bravo One XR drives to either a 1.26:1, or 1.35:1 overall gear ratio for boats that require a gear ratio change, to improve performance. The gear sets are available from the parts department.

Gear Set

1.26

1.35

Part Number

43-840870A 1

43-840872A1

Complete Bravo One XR drive units are also now available in both low water pickup and dual water pickup gearcase versions in 1.26: and 1.35:1 gear ratios.

BRAVO 2000 STYLE SERVICE REPLACEMENT GEAR SETS FOR ALL BRAVO DRIVE UNITS

The Bravo driveshaft housing gears and kits available from Mercury Precision Parts/Quicksilver are being replaced by the current production gear sets used in the Bravo 2000 series drive units.

They will be supplied in complete installation kits that include the pinion gear, both driven gears, the cone clutch and other required parts. Some of the kits also include the Shift Upgrade Kit, depending on the drive unit serial number. All of the parts from the kits must be used to properly complete the installation of the new gear kit. New thinner thrust bearing shim races must also be ordered.

These new gears have a thicker floor for improved strength. This is where the collet on the upper driveshaft contacts the gear. They are also double shot peened for greater durability.

The bearings in the kits have increased load capacity. The thrust bearings are larger and the garter spring bearings are now incorporated into a single assembly (previous bearing was two pieces).

The following charts will show the supersession from the old gears and kits to the new gear sets and gear kits. Also listed is a cross-reference chart of the large thrust-bearing shim race that will be required to install the new gear sets and gear kits.

NEW GEAR SETS AND GEAR KITS

Gear Set

Gear Set

Gear Set

43-883473A3

43-883476A3

43-883479A3

replaces

43-807436A6 / 43-807436A7 and 43-856184A1

replaces

43-807438A5 / 43-807438A6 and 43-856186A1

replaces

43-807437A5 / 43-807437A6 and 43-856188A1

Shift Upgrade Gear Kit



43-883473A4

43-883476A4

43-883479A4

replaces Shift Upgrade Kit replaces Shift Upgrade Kit replaces Shift Upgrade Kit

43-807436A1

43-807438A1

43-807437A1

REQUIRED NEW THRUST BEARING SHIM RACES

NOTE: The number stamped on the housing will now correspond to thinner shims. Refer to the table below for specific information.

Thrust Bearing Shim Race used with Old Gear Set Thrust Bearing Shim Race Required with new Replacement Gear Set

Part Number Shim Race Size Part Number Shim Race Size

23-87560091

23-87560094

23-87560097

2.31 mm (0.091 in.)

2.39 mm (0.094 in.)

2.46 mm (0.097 in.)

23-861782051

23-861782054

23-861782057

1.30 mm (0.051 in.)

1.37 mm (0.054 in.)

1.45 mm (0.057 in.)

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SLEEVE BEARING RACE DRIVERS

The following illustrations will show the proper installation tools and positioning of the sleeve-bearing races on the bearing chimney, in the driveshaft housing and top cover, for all Bravo product.

BEARING DRIVER AND CHIMNEY FOR 1999 AND PRIOR UNITS WITH OLDER BEARINGS AND

GEARS

20450

Bearing Driver (91-90773T)

BEARING DRIVER AND CHIMNEY FOR THE NEW DESIGNED BRAVO GEARS AND BEARINGS

WHEN USED IN 1999 AND PRIOR UNITS

A new bearing driver is required to install and properly place the sleeve bearing race in all 1999 and prior Bravo drive units when installing any of these new gear sets, or shift upgrade gear kits.

The tool has a step that places the sleeve bearing race down further on the bearing chimney, in the driveshaft housing and top cover, at the correct location for this new gear set. This is to allow clearance between the gear and bearing. Sleeve placement is critical for proper operation.

Bearing Driver (91-864220)

20447

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BEARING DRIVER AND CHIMNEY FOR BRAVO 2000 AND NEWER MODELS

A different bearing driver (different from the one used for replacement gear sets used on 1999 and prior units, and the tool used on the original bravo units) is used for installing the sleeve bearing used on all Bravo 2000 series, and later drive units.

20449

Bearing Driver (91-862530)

NOTE: Information on the new gear sets, new thrust bearing shim races and sleeve bearing drivers can be found in MerCruiser Service Bulletin 2001-17.

2004

U-joint Assembly (Standard and X models)

Rockwell version is No Longer Available (NLA). GKN now makes this assembly for MerCruiser.

a b

Page 7A-16

a -

Rockwell U-joint assembly

20793

b -

GKN U-joint assembly

• The Rockwell assembly is gray in color, where as the GKN assembly is black in color.

• The Rockwell assembly has the cross and bearing end caps retained with clips at the bottom of the cap, inside of the yoke ear.

• The GKN assembly has the cross and bearing end caps retained with the clips above the cap on the outside of the yoke ear, for standard Bravo and Alpha.

• The Rockwell U-joint assembly was a greaseable assembly. The GKN is a permalube style, like the Alpha U-joint assembly and cannot be greased.

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• The GKN Bravo X assembly is black in color and has the cross and bearing end caps retained with clips at the bottom of the cap, inside of the yoke ear, as did the Rockwell style (Bachman

U-joint assembly).

Bravo Shift Effort/Noise Reduction

REVISED SHIFT LEVER DETENT

All standard Bravo drives (not on X models) received a revised shift lever detent design to reduce shift effort - in rear cover area.

• Shape change.

• Smooth detent transition when shifting for reduced effort.

20795

Standard Bravo Shift Lever (861175A03)

Used in all standard Bravo sterndrives with low-bump brass sleeves.

20796

X and XR Bravo Shift Lever (861175A2)

Used in all X and XR Bravo sterndrives with high-bump brass sleeves.

CONE CLUTCH CHANGE

Bravo cone clutch has had a change of manufacturers. They are now produced with tighter tolerances.

90-899907001 JULY 2006 Page 7A-17

17


NOTE: New part is identified by a narrow groove cut on top (shown) and bottom (not shown) of the clutch and a third groove cut near the center of the clutch, as shown. This third groove goes

down on assembly, as shown.

20797

SHIFT SWITCH ADDED

Shift switch installed on 496 models (at the shift plate). Switch signals engine controller of a shift occurring. This activates a revised engine management during shift event - ECM/PCM calibration change. These changes reduce the load on the clutch for a smoother shift (EFI models only).

Bravo Styling Change

Restyle was done to the driveshaft housing, top cover, rear cover and decals.

a b a -

Original design

20798

b -

New restyled design

Increased Bravo X durability

Ribbed upper driveshaft housing top cover with steel chimney.

• Increased strength and stability.

• Improved cooling for longer gear and bearing life.

Increased Bravo XR durability

Upper driveshaft has an improved finishing process for increased durability.

Caged needle bearing now used in driveshaft housing top cover chimney and at bottom chimney.

Page 7A-18 90-899907001 JULY 2006

18


All Bravo Models will now have Shimmable Driveshaft Housing Gears for Increased

Durability

Driveshaft housing U-joint pinion (drive) gear bearing cup has been changed to a new flanged style, which uses shims for setting clearances. Separate bearing spacer ring no longer used.

Selection of shims available.

b a

20800

a -

Eight semi-circular oil slots equally spaced on face of new bearing cup

b -

Flanged edge on bearing cup

c d

20802

a a -

Original bearing cup

b -

Bearing spacer ring

b c -

New flanged bearing cup

d -

Shim location

Driven gear thrust bearing races now available in different sizes for setting clearances.

New special tools and a shimming procedure used for setting driveshaft housing clearances (to be covered later in the course).

90-899907001 JULY 2006 Page 7A-19

19


Bravo Three Changes

ADDITIONAL CORROSION PROTECTION

A second anode has been added to the underside of the anti-ventilation plate and a propshaft anode was also added.

20803

IMPROVED DURABILITY

New outer propshaft thrust bearing design - changed for increased load-carrying capacity/ durability (increased roller diameters).

Original thrust bearing

20805

New thrust bearing

20816

Page 7A-20 90-899907001 JULY 2006

20

b


New outer propshaft (shorter - to allow clearance for new larger thrust bearing).

a

20806

a -

Older outer propshaft

b -

Newer outer propshaft

NEW IMPROVED PROPSHAFT SEALS

New lip design, material and spring tension. Greatly reduces potential for leakage.

Allows easier end play movement checking.

2005

Oil Leak When Using the Current Magnetic Drain Plug in the XR or XZ Heavy-Duty

(Blue Billet) Bearing Carrier

The current 22-67892 A05 magnetic drain plug, when installed in the XR or XZ Heavy-Duty (Blue

Billet) bearing carrier only, is making contact at the starter pilot on the end of the plug when it bottoms in the fill/drain hole of the carrier. This prevents the gasket from seating and sealing allowing the oil in the drive to leak out at that area.

To correct the problem use the old style fill/drain plug (P/N 22-67892 A1). All current production

XR/XZ drive units have been corrected using the old style fill/drain plug (22-67892 A1). This plug will be used for a short term, until a revised plug is available.

There will be a new shorter version of the 22-67892 A05 fill/drain plug, which will have a new part number (22-67892 A06).

The current 22-67892 A05 plug works with all other drive product with no interference (Alpha,

Bravo Standard, Bravo X). They will be used on these models until the stock is used up. Then they will be switched to the new shorter drain plug.

90-899907001 JULY 2006 Page 7A-21

21


Following are drawings illustrating the types of plugs, including the shortened pilot dimension

[1.65 mm (0.065 in.) less] version that will be going into production. Overall dimension of the new plug is the same as the A05 version.

a b a -

Plug version that contacts carrier (22-67892A05)

b -

New plug (22-67892A06)

c -

Original plug (22-67892A1)

c

A new, yellow colored, seal will be used with the new fill/drain plug.

20873

a b a -

Older, blue colored, fill/drain plug gasket (12-19183--1)

b -

New, yellow colored, plug seal (26-830749)

20874

Page 7A-22 90-899907001 JULY 2006

22

Bravo XR / XZ Blue Billet Aluminum Bearing Carrier

Bravo Drive Unit History a b d

20875

a -

Original plug (22-67892A1)

b -

New plug (22-67892A06)

c -

Plug version that contacts carrier (22-67892A05)

d -

Area of interference

c

Water Pickups and Flushing Devices Used on Bravo Drives

There are 3 types of water pickups available on Mercury MerCruiser sterndrives: dual-water, low-water and side pickups.

c a b c -

Side pickup

20863

a -

Dual-water pickup

b -

Low-water pickup

IMPORTANT: Bravo models equipped with closed cooling require dual-water pickups and must be equipped with a thru-hull or thru-transom pickup, in addition to the sterndrive water inlets.

90-899907001 JULY 2006 Page 7A-23

23


Flushing Devices

Dual-water pickup

Side pickup

Low-water pickup

Part Number

44357Q 2 (flushing device)

881150Q 1 (gearcase flush seal kit)

44357Q 2

84996T1

Dual-water Pick-up Gearcase Flush Seal Kit (91-881150Q1)

20872

20865

Side Pickup Flushing Device (91-44357Q2)

NOTE: Seal Kit used to block off the front water inlet holes on the dual-water inlet gear housings.

20876

Low-water Pickup Flushing Kit (91-84996T1)

Page 7A-24 90-899907001 JULY 2006

24


Bravo Driveshaft Housing Shift Shaft Bore O-ring Replaced with a New Seal

Shift Cavity Seal/Plug. Started with S/N 0W258350.

a b a -

New shift cavity seal/plug (19-865866)

b -

Original O-ring used to seal passage (25-62705)

a

20877 a -

New shift cavity seal/plug (19-865866)

20878

90-899907001 JULY 2006 Page 7A-25

25


Bravo (and Alpha) GKN U-joint Tools

Following illustrates the Bravo and Alpha GKN U-joint tool set. Individual tools are shown in full and cut away view.

c d b a

Bravo (and Alpha) GKN U-joint Tool Set (91-866107A01) a -

91-866107

b -

91-866109

c d -

25-20385

91-866108

20879

Bravo Standard GKN U-joint and Cross Bearing Kit

Cross bearing clips included in each kit will be in the sizes listed:

Qty.

1

3

4

2

1

Clip size

1.40 mm (0.055 in.)

1.45 mm (0.057 in.)

1.50 mm (0.059 in.)

1.55 mm (0.061 in.)

1.60 mm (0.063 in.)

Color Code

Light Blue

Pink

Green

Red

White

Page 7A-26

20881

90-899907001 JULY 2006

26

Bravo standard GKN U-joint repair parts

Universal joint assembly

Stub yoke gear end

Center socket

Splined yoke engine coupler end

Cross and bearing assembly

Bravo X Series GKN U-joint and Cross Bearing Kit

Cross bearing clips included in each kit will be in the sizes listed:

Qty.

3

4

2

Clip size

1.90 mm (0.075 in.)

1.95 mm (0.077 in.)

2.00 mm (0.079 in.)


Part number

864244A 2

864245T

865503T

864244A01

865496A01

Color Code

Green

Plain

Yellow

Bravo X GKN repair parts

Universal joint assembly

Stub yoke gear end

Center socket

Splined yoke engine coupler end

ITS splined yoke engine coupler


20882

Part number

865425A03

866134 (not sold separately)





Bravo Bell Housing to Gimbal Housing Alignment Tool

If there is a vibration problem when running an engine, an engine alignment procedure should be performed. If a vibration issue still exists after the alignment, then following steps need to be done.

1. Install the Engine Alignment Shaft Tool through the gimbal bearing and into the engine coupler

(similar to performing an engine alignment).

Alignment Tool Assembly 91-805475A 1

90-899907001 JULY 2006 Page 7A-27

27


2. Slide the Bell Housing to Gimbal Housing Alignment Tool over the end of the alignment shaft

(smaller tool step towards bell housing) and up to the housing. The smaller step should be inside of the bell housing case.

20883

Bell Housing Alignment Tool (91-863372)

3. Check the gap between the alignment tool larger step and the bell housing case at 90 degress and at 270 degrees. The gaps should be even.

4. If they are not, then the front engine mounts should be checked for being properly attached

(angled lag screws, etc.). They can be loosened up to see if the engine re-aligns itself side-to-side.

5. If a difference in the 90 degree and 270 degree gaps still exists, there may be a transom thickness issue that should be checked.

Bravo One/Two/Three Gearcase Needle Bearing Removal Tool

The old Bravo gearcase needle bearing (located above the pinion gear, on the driveshaft) removal tool too large in diameter at the top end for the newer gearcase bore.

There is a new tool available. Following will indicate the proper dimensions for the old and new tool. Dealers can order a new tool, or the old tool can be machined down.

a b c d

Page 7A-28

a -

Older Tool (91-63638T), 40.92-41.0 mm (1.611-1.614 in.)

b -

Tool identification mark (63638)

c -

Newer Tool (91-63638- -1), 40.39-40.46 mm (1.590-1.593 in.)

d -

Tool identification mark (63638- -1)

90-899907001 JULY 2006

28

Manual Outline

Section 8 - Bravo Drive Unit Service

A - Bravo Drive Unit Components

B - Bravo Driveshaft Housing Set Up - Earlier Models (Serial Number

0M198372 and Below)

C - Bravo Driveshaft Housing Set Up - Later Models (Serial Number

0M198373 and Above)

D - Bravo One Gear Housing Setup

E - Bravo Three Gear Housing Setup

F - Bravo Shift Cable Installation, Drive Unit Installation and Shift Setup

29

Bravo Drive Unit Components

Bravo Drive Unit Service

Section 8A - Bravo Drive Unit Components


Exploded Views.........................................................2

Driveshaft Housing and Gears for Standard and X

Series Models........................................................2

Driveshaft Housing U-Joint and Shift Components for Standard Bravo Models....................................4

Driveshaft Housing U-Joint and Shift Components for X Series Models...............................................6

Driveshaft Housing and Gears for XR Models.......8

Driveshaft Housing U-Joint and Shift Components for XR Models......................................................10

Bravo One Gear Housing - Exploded View.............12

Bravo Two Gear Housing - Exploded View.............14

Bravo Three Gear Housing.....................................16

8

A

90-899907001 JULY 2006 Page 8A-1

30


Exploded Views

Driveshaft Housing and Gears for Standard and X Series Models

31

34

32

16

12

15

14

13

17

19

26

25

20

36

33

9

35

7

8

21

23

22

23

21

20

24

5

6

19

17

18

11

10

3

4

30

28

1

2

27

29

18217

Page 8A-2 90-899907001 JULY 2006

31

1 -

Driveshaft housing

2 -

Stud (4)

3 -

Water passage seal

4 -

O-ring

5 -

Bearing race

6 -

Needle bearing

7 -

Shift shaft oil seal plug

8 -

Upper shift shaft bushing

9 -

Shift shaft seal

10 -

Vent plug

11 -

Vent plug seal

12 -

Top cover (standard)

13 -

Bearing sleeve

14 -

Needle bearing

15 -

Top cover O-ring

16 -

Top cover screws (4) (standard)

17 -

Thrust race

18 -

Ball check assembly


19 -

Thrust bearing

20 -

Upper driven gear

21 -

Garter spring thrust bearing

22 -

Clutch

23 -

Garter spring

24 -

Upper driveshaft

25 -

Thrust collar

26 -

Keepers

27 -

Washer

28 -

Plug

29 -

Nut

30 -

Trim-in insert

31 -

Top cover screws (X Series)

32 -

Top cover (X Series)

33 -

Lower shift shaft bushing

34 -

Washers

35 -

Grounding tab

36 -

Self tapping screw

90-899907001 JULY 2006 Page 8A-3

32


Driveshaft Housing U-Joint and Shift Components for Standard Bravo Models

4

5

1

31

30

29

28

27

26

39

40

7

10

49

48

2

13

8

9

11

3

13

43

15

12

41

16

17

18

14

19

20

21 22

23

24

25

24

35

34

33

42

44

45

46

47

32

37

38

36

6

18436

Page 8A-4 90-899907001 JULY 2006

33

1 -

Back cover

2 -

Back cover seal

3 -

Detent assembly

4 -

Back cover short bolt

5 -

Back cover long bolt

6 -

Wear pad

7 -

Shift shaft

8 -

Cam

9 -

Yoke

10 -

Cam screws

11 -

Spacer

12 -

Nut

13 -

Screw

14 -

Link bar

15 -

Shift lever

16 -

Washer

17 -

Cotter pin

18 -

Latch

19 -

U-joint assembly

20 -

Yoke (coupler end)

21 -

O-rings

22 -

O-ring

23 -

Socket

24 -


25 -

Yoke (gear end)


26 -

Retainer nut

27 -

O-ring

28 -

Oil seal

29 -

Preload washer

30 -

O-ring

31 -

Sealing ring

32 -

U-joint bearing assembly

33 -

Pinion gear

34 -

Washer

35 -

Nut

36 -

Anode plate

37 -

Screws

38 -

Washers

39 -


40 -


41 -

Seal

42 -

Shim

43 -


44 -

Tapered roller bearing

45 -

Flanged bearing cup

46 -

Bearing cup

47 -


48 -

Grounding tab

49 -

Self tapping screw

90-899907001 JULY 2006 Page 8A-5

34


Driveshaft Housing U-Joint and Shift Components for X Series Models

19

29

28

27

26

4

5

37

38

7

47

46

1

10

2

13

8

9

11

3

13

41

15

12

39

16

17

18

14

23

24

25

24

33

32

31

40

42

43

44

45

30

35

36

34

6

20

21

22

10808

Page 8A-6 90-899907001 JULY 2006

35

1 -

Back cover

2 -

Back cover seal

3 -

Detent assembly

4 -


5 -


6 -

Wear pad

7 -

Shift shaft

8 -

Cam

9 -

Yoke

10 -

Cam screws

11 -

Spacer

12 -

Nut

13 -

Screw

14 -

Link bar

15 -

Shift lever

16 -

Washer

17 -

Cotter pin

18 -

Latch

19 -

U-joint assembly

20 -

Yoke (coupler end)

21 -

O-rings

22 -

O-ring

23 -

Socket

24 -



25 -

Yoke (gear end)

26 -

Retainer nut and oil seal carrier

27 -

O-ring

28 -

Oil seal

29 -

Preload washer

30 -


31 -

Pinion gear

32 -

Washer

33 -

Nut

34 -

Anode plate

35 -

Screw

36 -

Washer

37 -


38 -


39 -

Seal

40 -

Shim

41 -


42 -


43 -

Flanged bearing cup

44 -

Bearing cup

45 -


46 -

Grounding tab

47 -

Self tapping screw

90-899907001 JULY 2006 Page 8A-7


Driveshaft Housing and Gears for XR Models

32

16

12

15

14

13

17

19

26

25

20

34

31

9

33

7

8

21

23

22

23

21

20

24

6

5

19

17

18

11

10

3

4

30

28

1

2

27

29

18215

Page 8A-8 90-899907001 JULY 2006

1 -

Driveshaft housing

2 -

Stud (4)

3 -

Water passage seal

4 -

O-ring

5 -

Bearing sleeve

6 -

Needle bearing

7 -


8 -


9 -

Shift shaft seal

10 -

Vent plug

11 -

Vent plug seal

12 -

Top cover (standard)

13 -

Bearing sleeve

14 -

Needle bearing

15 -

Top cover O-ring

16 -

Top cover screws (4)

17 -

Thrust race


18 -

Ball check assembly

19 -

Thrust bearing

20 -

Upper driven gear assembly

21 -

Thrust bearing

22 -

Clutch

23 -

Garter spring

24 -

Upper driveshaft

25 -

Thrust collar

26 -

Keepers

27 -

Washer

28 -

Plug

29 -

Nut

30 -

Trim-in insert

31 -


32 -

Washers

33 -

Grounding tab

34 -

Self tapping screw

90-899907001 JULY 2006 Page 8A-9


Driveshaft Housing U-Joint and Shift Components for XR Models

4

5

1

37

38

7

10

42

41

2

13

8

9

11

3

13

43

15

39

12

16

17

18

14

29

28

27

26

19

20

21 22

23

24

25

24

33

32

31

40

44

45

46

47

30

35

36

34

6

18216

Page 8A-10 90-899907001 JULY 2006

1 -

Back cover

2 -

Back cover seal

3 -

Detent assembly

4 -


5 -


6 -

Wear pad

7 -

Shift shaft

8 -

Cam

9 -

Yoke

10 -

Cam screws

11 -

Spacer

12 -

Nut

13 -

Shift shaft screw

14 -

Link bar

15 -

Shift lever

16 -

Washer

17 -

Cotter pin

18 -

Latch

19 -

U-joint assembly

20 -

Yoke (coupler end)

21 -

O-rings

22 -

O-ring

23 -

Socket

24 -



25 -

Yoke (gear end)

26 -

Retainer nut

27 -

O-ring

28 -

Oil seal

29 -

Preload washer

30 -


31 -

Pinion gear

32 -

Washer

33 -

Nut

34 -

Anode plate

35 -

Screws

36 -

Washers

37 -


38 -


39 -

Seal

40 -

Shim

41 -

Grounding tab

42 -

Self-tapping screw

43 -


44 -


45 -

Flanged bearing cup

46 -

Bearing cup

47 -


90-899907001 JULY 2006 Page 8A-11


Bravo One Gear Housing - Exploded View

20

19

18

17

16

15

14

14

12

2

13

4

3

5

48

47

11

10

8

9 1

46

8

7

21

6

22

26

23

28

45

44

43

27

31

42

49

40

39

41

37

38

36

34

35

33

32

30

29

24

25

5491

Page 8A-12 90-899907001 JULY 2006

1 -

Gear housing assembly

2 -

Stud

3 -

O-ring

4 -

Seal

5 -

Seal

6 -

Roller bearing assembly

7 -

Anodic plate assembly

8 -

Lockwasher

9 -

Screw

10 -

Shim kit

11 -

Tapered roller bearing assembly

12 -

Driveshaft assembly

13 -

Bearing race

14 -


15 -

Tab washer

16 -

Shim kit

17 -

Spacer

18 -

O-ring

19 -

Coupling assembly

20 -

Retaining ring

21 -

Gear set

22 -

Washer

23 -

Screw

24 -

Shim kit

25 -



26 -

Propeller shaft

27 -

Washer

28 -


29 -

Load ring

30 -

Thrust washer

31 -

Bearing carrier assembly

32 -

O-ring

33 -

Seal

34 -

Drain plug kit

35 -

Seal

36 -

Anode assembly

37 -

Screw

38 -

Lockwasher

39 -

Tab washer

40 -

Bearing carrier retainer

41 -

Spacer

42 -

Plastic drive sleeve

43 -

Aft propeller sleeve brass adaptor

44 -

Tab washer

45 -

Propeller nut kit

46 -

Screw

47 -

Washer

48 -

Nut

49 -

Thrust hub

90-899907001 JULY 2006 Page 8A-13


Bravo Two Gear Housing - Exploded View

46

45

43

44

42

Page 8A-14

5501

90-899907001 JULY 2006

1 -


2 -

Stud

3 -

O-ring

4 -

Seal

5 -

Seal

6 -


7 -

Drain plug kit

8 -

Seal

9 -


10 -

Lockwasher

11 -

Screw

12 -

Washer

13 -

Speedometer pickup tube

14 -

Shim kit

15 -


16 -

Driveshaft assembly

17 -

Bearing race

18 -


19 -

Tab washer

20 -

Shim kit

21 -

Spacer

22 -

O-ring

23 -

Coupling assembly


24 -

Retaining ring

25 -

Pinion gear

26 -

Pinion gear washer

27 -

Pinion gear screw

28 -

Shim assembly

29 -


30 -

Propeller shaft

31 -


32 -

Driven gear

33 -

Thrust ring

34 -

Load ring

35 -

O-ring

36 -


37 -

Roller bearing

38 -

Fish-line cutter oil seal and oil seal

39 -

Key

40 -

Tab washer

41 -

Cover

42 -

Propeller nut

43 -

Screw

44 -

Lockwasher

45 -

Washer

46 -

Nut

90-899907001 JULY 2006 Page 8A-15


Bravo Three Gear Housing

Page 8A-16

54

55

7

8

47

53

52

51

50

5504

90-899907001 JULY 2006

90-899907001 JULY 2006

1 -


2 -

Stud

3 -

O-ring

4 -

Seal

5 -

Seal

6 -

Screw

7 -

Lockwasher

8 -


9 -


10 -

Drain plug kit

11 -

Seal

12 -

Screw

13 -

Washer

14 -

Gear set

15 -

Shim kit

16 -


17 -

Driveshaft assembly

18 -

Bearing race

19 -


20 -

Tab washer

21 -

Shim kit

22 -

Spacer

23 -

O-ring

24 -

Coupling assembly

25 -

Retaining ring

26 -

Shim kit

27 -


28 -

Inner propeller shaft


29 -

Thrust bearing

30 -

Bushing

31 -

Shim assembly

32 -

Retaining ring

33 -

Shim assembly

34 -


35 -

Outer propeller shaft

36 -

Roller bearing

37 -

Oil seal

38 -

Retainer

39 -


40 -

O-ring

41 -

Roller bearing

42 -

Oil seal

43 -

Front thrust hub

44 -

Front propeller nut

45 -

Rear thrust hub

46 -

Rear propeller nut

47 -

Screw

48 -

Washer

49 -

Nut

50 -

Propeller shaft anode kit

51 -

Flat washer

52 -

Internal tooth lockwasher

53 -

Screw

54 -

Anode

55 -

Screw

Page 8A-17

Bravo Driveshaft Housing Set Up - Earlier Models (Serial Number 0M198372 and Below)


Section 8B - Bravo Driveshaft Housing Set Up - Earlier

Models (Serial Number 0M198372 and Below)


Bravo Driveshaft Housing Shimming/Setup

Procedures................................................................2

Method #1..............................................................2

Method #2..............................................................2

8

B

90-899907001 JULY 2006 Page 8B-1


Bravo Driveshaft Housing Shimming/Setup Procedures

Assemble U-joint bearings as instructed.

NOTE: Spacer between bearing cups must be free to move. Do not over press, as damage to both bearings could occur.

Secure pinion gear assembly to shaft with washer and new nut. Tighten nut to the point where washer just touches gear.

a c b

Method #1

a -

Nut

b -

Washer

c -

20276

Pinion gear assembly

Set the preload on bearing package as follows (two assembly holding methods shown):

Mount upper driveshaft housing in bench holding fixture.

Install U-joint assembly into housing and secure with retainer nut.

a b a -

Torque wrench (lb. in. – Dial

Indicator)

20277

b -

Driveshaft housing (U-joint shaft hanging straight down)

Method #2

Mount retainer nut wrench in vise to support U-joint assembly.

Page 8B-2 90-899907001 JULY 2006


Install U-joint assembly into wrench, with shaft pointing straight down.

a b a -

Torque wrench (lb-in.)

20280

b -

U-joint shaft (hanging straight down)

Set preload by tightening nut 1/16 of a turn at a time.

After each tightening check for proper preload by turning pinion gear, using an appropriate socket and torque wrench (lb-in. - with Dial Indicator), until acceptable torque is obtained.

If nut becomes over-tightened (causing excessive preload), loosen nut a number of turns and gently strike pinion end of U-joint shaft using a soft hammer. Repeat adjustment procedure.

Description New Bearings Used Bearings*

U-joint Bearing Preload 0.7-1.0 Nm (6-10 lb. in.) 0.3-0.8 Nm (3-7 lb. in.)

*Bearings are used if spun once under load.

a

90-899907001 JULY 2006

a -

Torque wrench (lb-in. - with Dial

Indicator) being used to check preload

b

20280

b -

U-joint shaft hanging straight down

Page 8B-3


6 1

a

6

4

20281

a -

Stamped number

The stamped number designates the thickness of the top and bottom thrust bearing races.

NOTE: If using the original thrust bearing race, install race so that side with original contact area faces bearing.

If the upper and lower thrust bearing races get mixed up they should be checked with a micrometer for thickness, to correspond with the housing stamped numbers.

b a -

Micrometer

a

20282

b -

Thrust bearing race

Page 8B-4 90-899907001 JULY 2006


IMPORTANT: Timing marks on clutch gears must be aligned in one of two ways. The positive (+) mark over the negative (–) or the negative (–) mark over the positive (+). Never align two positive

(+) marks or two negative (–) marks.

20283

Align clutch gear timing marks with index marks on driveshaft housing as closely as possible.

6

b a

6

b a -

Timing marks

20284 b -

Index marks

90-899907001 JULY 2006 Page 8B-5

Bravo Driveshaft Housing Set Up - Later Models (Serial Number 0M198373 and Above)


Section 8C - Bravo Driveshaft Housing Set Up - Later

Models (Serial Number 0M198373 and Above)


Bravo Driveshaft Housing Activity.............................2

Specifications............................................................2

Starting Shim Specification....................................2

Gear Tooth Count and Gear Lash.........................2

U-joint Pinion Gear Location..................................2

U-joint Pinion Gear Shim.......................................2

Driven Gear Thrust Race.......................................3

General Information...................................................3

Assembly Changes................................................3

U-Joint Shim.......................................................3

Driven Gear Shim...............................................4

Driveshaft Housing Assembly: Teardown, Inspection and Repair.................................................................6

U-joint Pinion Gear and Bearing Assembly Preload

...............................................................................6

Setting Preload Using A Vise..............................6

Setting Preload In The Driveshaft Housing.........8

Driveshaft Housing Shimming Preparation For

Assembly.................................................................10

U-joint Pinion Gear Shimming.............................10

Feeler Gauge Measurement.............................17

Measuring Driven Gear Lash...............................17

Calculation Method For Specified Gear Lash...32

Driveshaft Housing Reassembly.............................33

Reset U-joint Pinion Gear and Bearing Preload

.............................................................................33

U-joint, Pinion Gear and Bearing Assembly

Reassembly.........................................................34

U-joint Pinion Gear and Bearing Assembly Preload

.............................................................................36

Setting Preload Using A Vise............................36

Setting Preload In The Driveshaft Housing.......39

8

C

90-899907001 JULY 2006 Page 8C-1


Bravo Driveshaft Housing Activity

The object of the activity is to review and/or perform the subjects in the Service Manual #28 and the Supplement and be able to answer the related questions on the Bravo Shimmable Driveshaft

Housing activity sheet.

Specifications

Starting Shim Specification

Starting thrust race specification

Driven gear thrust race

mm

1.63

in.

0.064


U-joint pinion gear shim

Gear Tooth Count and Gear Lash

Pinion (drive) gear tooth

27

27

23

16

U-joint Pinion Gear Location

Driven gear tooth

32

29

30

19

Specification

Pinion gear location

U-joint Pinion Gear Shim

U-joint pinion gear shim

15-888927-028

15-888927-029

15-888927-030

15-888927-031

15-888927-032

15-888927-033

15-888927-034

15-888927-035

15-888927-036

15-888927-037

15-888927-038

15-888927-039

15-888927-040

mm

0.09

Driveshaft housing gear lash

0.28–0.41 mm (0.011–0.016 in.)

0.33–0.46 mm (0.013–0.018 in.)

0.28–0.41 mm (0.011–0.016 in.)

0.23–0.38 mm (0.009–0.015 in.)

mm

0.64

0.86

0.89

0.91

0.97

0.97

0.99

1.02

mm

0.71

0.74

0.76

0.79

0.81

0.83

in.

0.035

in.

0.025

0.034

0.035

0.036

0.037

0.038

0.039

0.040

in.

0.028

0.029

0.030

0.031

0.032

0.033

Page 8C-2 90-899907001 JULY 2006


Driven Gear Thrust Race

Thrust bearing race

23-864596-058

23-864596-059

23-864596-060

23-864596-061

23-864596-062

23-864596-063

23-864596-064

23-864596-065

23-864596-066

23-864596-067

Thickness

1.47 mm (0.058 in.)

1.50 mm (0.059 in.)

1.52 mm (0.060 in.)

1.55 mm (0.061 in.)

1.57 mm (0.062 in.)

1.60 mm (0.063 in.)

1.63 mm (0.064 in.)

1.65 mm (0.065 in.)

1.68 mm (0.066 in.)

1.70 mm (0.067 in.)

Color code

Brown

White

Orange

Green

Yellow

Red

Light Blue

Black

Pink

Purple

General Information

!

CAUTION

Improper gear adjustment can cause severe damage to the sterndrive. Follow the gear adjustment procedure closely.

All Bravo drives with the starting Serial Number of 0M198373 and above, must be shimmed during reassembly of the driveshaft housing.

Assembly Changes

U-JOINT SHIM

The U-joint assembly is shimmed for gear depth and location.

NOTE: The shim is between the shoulder of the U-joint snout and the flanged bearing cup.

When the driveshaft housing is assembled, the shim fits between the flanged bearing cup and the shoulder of the U-joint snout.

Adding shim thickness positions the pinion (drive) gear farther away from the driven gear and removing shim thickness positions the pinion (drive) gear closer to the driven gear.

c b a b

90-899907001 JULY 2006

c e

17570

a

Driveshaft housing cut showing shim and gear placement a -

Shims position on the flanged bearing cup

b -

Shoulder of the U-joint snout

c -

Shoulder of the flanged bearing cup

d -

U-joint retainer nut (standard Bravo)

e -

Pinion (drive) gear

Page 8C-3


The flanged bearing cup replaces the smaller outside diameter bearing cup and spacer of the pinion (drive) gear and bearing assembly.

a c

17584 b

a -

Flanged bearing cup

b -

Shoulder

c -

Shim

During reassembly of the driveshaft housing, use the original shim thickness that came out of the drive or use the shim thickness listed in the starting point specification chart below.

Starting shim specification


Shims graduate in 0.025 mm (0.001 in.) thickness.

mm

0.09

in.

0.035


15-888927-028

15-888927-029

15-888927-030

15-888927-031

15-888927-032

15-888927-033

15-888927-034

15-888927-035

15-888927-036

15-888927-037

15-888927-038

15-888927-039

15-888927-040

mm

0.71

0.74

0.76

0.79

0.81

0.83

0.86

0.89

0.91

0.94

0.97

0.99

1.02

in.

0.028

0.029

0.030

0.031

0.032

0.033

0.034

0.035

0.036

0.037

0.038

0.039

0.040

DRIVEN GEAR SHIM

The driven gears are set by measuring the gear lash of the pinion (drive) gear to each driven gear.

Driven gears in the driveshaft housing are shimmed into position by using the correct upper and lower thrust race thickness.

Therefore adding upper thrust race thickness positions the upper driven gear closer to the pinion gear thereby reducing gear lash. Consequently, removing upper thrust race thickness positions the upper driven gear farther away from the pinion gear, increasing gear lash.

Page 8C-4 90-899907001 JULY 2006


Adding lower thrust race thickness positions the lower driven gear closer to the pinion gear, reducing gear lash. Removing lower thrust race thickness positions the lower driven gear farther away from the pinion gear, increasing gear lash.

b a e c d

17585

a -

Upper thrust race

b -

Upper driven gear

c -

Lower driven gear

d e -

Lower thrust race

Pinion (drive) gear

The driveshaft housing is no longer stamped to indicate the thickness of the upper and lower thrust race.

17586

During reassembly of the driveshaft housing, use the original thrust race thickness that came out of the drive or use the thrust race thickness in the starting point specification chart.



mm

1.63

in.

0.064

Thrust race are color coded and graduate in 0.025 mm (0.001 in.) thickness.


23-864596-058

23-864596-059

23-864596-060

23-864596-061

23-864596-062

23-864596-063

23-864596-064

23-864596-065

23-864596-066

23-864596-067

Thickness

1.47 mm (0.058 in.)

1.50 mm (0.059 in.)

1.52 mm (0.060 in.)

1.55 mm (0.061 in.)

1.57 mm (0.062 in.)

1.60 mm (0.063 in.)

1.63 mm (0.064 in.)

1.65 mm (0.065 in.)

1.68 mm (0.066 in.)

1.70 mm (0.067 in.)

Color code

Brown

White

Orange

Green

Yellow

Red

Light Blue

Black

Pink

Purple

90-899907001 JULY 2006 Page 8C-5


Driveshaft Housing Assembly: Teardown, Inspection and Repair

U-joint Pinion Gear and Bearing Assembly Preload

Follow only one of the procedures: Setting Preload Using a Vise, Setting Preload In The

Driveshaft Housing.

SETTING PRELOAD USING A VISE

1. Set the preload on bearing package as follows: a.

Mount the retainer nut wrench tool in a vise to support the U-joint assembly.

b.

Position the U-joint assembly with its shaft facing down as shown.

b a c d e

Standard Bravo a -

U-joint pinion gear and bearing assembly

b -

Bearing retainer wrench

c -

U-joint shaft (facing down)

16407

d -

Vise

e -

Screwdriver

Bearing retainer wrench 91-17256

Page 8C-6

e a b d c

Bravo X series a -


b -


c -


16408

d -

Vise

e -

Screwdriver

Spanner wrench for L-18 U-joint bearing retainer c.

Apply a light coat of lubricant to bearings.

91-862219A1

90-899907001 JULY 2006

Tube Ref No.

87


Description

High Performance Gear

Lubricant

Where Used

Bearings

Part No.

92-802854A1 d.

Set preload by tightening the nut 1/16 of a turn at a time.

e.

Check for proper preload by turning the pinion gear, using an extension, appropriate socket, and a dial torque wrench lb. in. until you reach the specified torque.

!

CAUTION

Avoid premature bearing failure. Do not overtighten the U-joint pinion gear nut.

a

16409

Standard Bravo shown Bravo X series similar a -

Dial type torque wrench (lb. in.)

NOTE: Bearings are used if spun once under load.

Description

U-joint bearing preload

New

0.7–1.0 Nm (6–10 lb. in.)

Used

0.3–0.8 Nm (3–7 lb. in.)

Torque wrench, lb. in.

91-66274

2. If the nut becomes overtightened (causing excessive preload), release the pinion gear and bearing assembly preload.

a.

Remove the pinion gear and the bearing assembly from the U-joint.

b.

Place the universal puller plate under the shoulder of the flanged bearing cup.

90-899907001 JULY 2006 Page 8C-7


c.

Press end of pinion gear with a suitable mandrel just until the bearing cups rotate easily.

Failure to do this can result in premature bearing failure.

a g f d b c e a -

Universal puller plate tool

b -

Flanged bearing cup shoulder

c -

Flanged bearing cup

d -

Top roller bearing and bearing cup

16412

e -

Pinion gear

f -

Mandrel on pinion gear

g -

Press on mandrel

Universal puller plate 91-37241 d.

Reassemble the components of the U-joint and repeat the preload procedures.

SETTING PRELOAD IN THE DRIVESHAFT HOUSING

1. Set the preload on a U-joint pinion gear-and-bearing assembly as follows: a.


Tube Ref No.

87

Description


Lubricant

Where Used

Bearings b.

Install the U-joint and pinion gear assembly into the driveshaft housing.

Part No.

92-802854A1

Page 8C-8

a b

16414


U-joint and pinion gear assembly

b -

Retaining nut c.

Position the driveshaft housing so that the U-joint coupling shaft is pointing straight down.

d.

Set the preload by tightening the nut 1/16 of a turn at a time. Check for proper preload by turning the pinion gear, using an extension, appropriate socket, and dial torque wrench until you reach an acceptable torque.

90-899907001 JULY 2006


!

CAUTION

Premature bearing failure can result if U-joint pinion gear nut becomes overtightened (causing excessive preload).

a b

16415


Dial torque wrench (lb. in.)

b -

Driveshaft housing (U-joint shaft facing down)

NOTE: Bearings are used if spun once under load

Description


New

0.7–1.0 Nm (6–10 lb. in.)

Used

0.3–0.8 Nm (3–7 lb. in.)


91-66274

2. Remove U-joint and pinion gear assembly from driveshaft housing.

3. If nut becomes overtightened (causing excessive preload), release the pinion gear and bearing assembly preload: a.

Remove the pinion gear and bearing assembly from the U-joint.

b.


90-899907001 JULY 2006 Page 8C-9


c.



a g f d b c e a -


b -


c -

Flanged bearing cup

d -


16412

e -

Pinion gear

f -


g -

Press on mandrel


Reassemble components to the U-joint and repeat preload procedures.

Driveshaft Housing Shimming Preparation For Assembly

U-joint Pinion Gear Shimming

!

CAUTION

Avoid injury. Heavy sterndrive components may come apart suddenly and forcefully, possibly resulting in injury. Properly support the U-joint yoke assembly while removing the pinion gear nut.

1. Ensure that the U-joint pinion gear and bearing assembly preload is set and ready to install.

2. Disassemble U-joint from pinion gear and bearing assembly: a.


b.

Position the U-joint assembly with shaft pointing straight down.

c.

Use a long screwdriver to secure the U-joint so that it will not rotate while loosing the nut.

d.

Remove screwdriver.

Page 8C-10 90-899907001 JULY 2006

e


e.

The U-joint will fall when nut is removed. Hold the U-joint and remove the nut and washer.

a f b c b b d d a -

Retainer nut and washer

b -


c -

Bearing retainer wrench tool

d d -

U-joint shaft

e -

Vise

f -

Screwdriver

15754


3. Insert the stub shaft tool from the bottom of the the pinion gear and bearing assembly, and the remaining components.

NOTE: Do not overtighten the nut.

4. Install the washer and nut; tighten nut until the washer and nut just seat against the pinion gear and the complete assembly is firmly seated to the stub shaft tool.

d c a b

15811

Standard Bravo U-joint assembly shown a -

Tool

b -

Stub shaft tool

c d -

Pinion gear and bearing assembly

Socket on nut

Stub shaft for Standard Bravo 91-865084

Stub shaft for Bravo X Series 91-865083

5. Position the shim on the shoulder of the flanged bearing cup. Use the starting shim specification chart or the original shim thickness that came out of the drive as a starting point.

90-899907001 JULY 2006 Page 8C-11


Starting shim specification


a b mm

0.09

in.

0.035

c a -

Shim

b -

Shoulder of bearing spacer cup

15812

c -

Stub shaft tool

c

6. Carefully install the pinion gear and bearing assembly with the stub shaft tool into the driveshaft housing bore so not to damage the shim.

b a a c

15813


Driveshaft housing

b -

Stub shaft tool complete assembly

b

Bravo XR c -

Retainer nut

7. Apply lubricant to the threads of the retainer nut.

Tube Ref No.

34

Description

Special Lubricant 101

Where Used

Threads of retainer nut

16139

Part No.

92-802865A1

IMPORTANT: Ensure that the retainer nut is not cross-threaded by turning the retainer nut

COUNTERCLOCKWISE until thread engagement is felt; then, turn retainer nut clockwise.

Page 8C-12 90-899907001 JULY 2006

a


8. Install the U-joint retainer nut to driveshaft housing and torque.

b c

15814

a -

U-joint retainer nut

b -


c -

Torque wrench

9. Use the specified torque chart and torque wrench as outlined in this section under Torque

Conversion Chart For U-joint Retainer Nut Tool.

a b

16143

Typical Bravo retainer nut tool shown a -

Torque wrench length

b -

U-joint retainer nut tool measurement,

30.5 cm (12 in.)


NOTE: For Bravo X Series and Bravo XR, use the bearing retainer wrench tool to loosen and remove the retainer nut from the driveshaft housing.

Spanner wrench for L-18 U-joint bearing retainer

91-862219A1

IMPORTANT: Ensure that the number of driven gear teeth match the drive gear ratio.

NOTE: Diesel sterndrives are listed as Bravo X series.

90-899907001 JULY 2006 Page 8C-13


Sterndrive model

Standard Bravo Three and Bravo Three X series


Standard Bravo Two and Bravo Two X series

Driveshaft Housing— Gear Ratio and Gear Tooth Count

Ratio Pinion (drive) gear teeth

2.43:1

2.20:1

23

23







Standard Bravo One and Bravo One X series


2.00:1

1.81:1

1.65:1

27

27

27

23

27





1.50:1

1.36:1

27

27

Bravo One XR

Bravo Three XR

1.50:1

1.35:1

1.26:1

2.00:1

16

27

Driven gear teeth

30

30

32

29

32

30

32

29

29

19

32

Page 8C-14 90-899907001 JULY 2006


10. Insert the pinion gear shimming tool in the top of the driveshaft housing. Position the matching gear teeth count access hole to the pinion gear.

a c a -

Pinion gear shimming tool

b -

Access holes for gear tooth counts

27/32, 23/30, 16/19

b

15815

c -

Access holes for gear tooth counts

27/29

Pinion gear shimming tool 91-865114

NOTE: Refer to Feeler Gauge Measurement for further assistance.

11. Insert the feeler gauge and measure the clearance of the pinion gear shimming tool to the pinion gear teeth.

a a a c c b c b a -

Feeler gauge

b -

Access hole

d b c -

Pinion gear shimming tool

d -

Pinion gear

15816

Specification

Pinion gear location

mm

0.64

in.

0.025

12. If the pinion gear location is within specification: a.

Remove the pinion shimming tool from the driveshaft housing.

b.

Remove the the stub shaft tool complete assembly from the driveshaft housing.

c.

Proceed to Measuring Driven Gear Lash in this section.

13. If the pinion gear does not meet the specification: a.

Calculate the difference of the existing pinion gear location measurement and the specified pinion gear measurement by using the shimming charts below.

90-899907001 JULY 2006 Page 8C-15


For example, if the gear is too far away from shimming tool:

The shim assembled with the upper driven gear measures 0.89 mm (0.035 in.) thick and the existing pinion gear location measurement is 0.71 mm (0.028 in.).

NOTE: Add shim thickness to move the pinion gear away from tool. Remove shim thickness to move the pinion gear closer to tool.

The shim thickness should be decreased by 0.08 mm (0.003 in.).

Replace the shim with a 0.81 mm (0.032 in.) thick shim. Repeat the measurement process and check your work.

IMPORTANT: The shimming process must be repeated until the pinion gear location specifications are met.

Shimming Charts

Description

Existing pinion gear location (feeler gauge thickness)

Specification

Remove shim measurement (difference)

Shim thickness

0.711 mm (0.028 in.)

0.635 mm

0.076 mm

(0.025 in.)

(0.003 in.)

For example, if the gear is too close to the shimming tool: The shim assembled with the upper driven gear measures 0.89 mm (0.035 in.) thick and the existing pinion gear location measurement is 0.56 mm (0.022 in.).

NOTE: Add shim thickness to move pinion gear away from tool. Remove shim thickness to move pinion gear closer to tool.

The shim thickness should be increased by 0.08 mm (0.003 in.).

Replace the shim with a 0.81 mm (0.032 in.) thick shim. Repeat the measurement process and check your work.

IMPORTANT: The shimming process must be repeated until the pinion gear location specifications are met.

Shimming Charts

Description

Specification

Existing pinion gear location (feeler gauge thickness)

Add shim measurement (difference)

Shim thickness

0.64 mm (0.025 in.)

0.56 mm

0.08 mm

(0.022 in.)

(0.003 in.)

NOTE: A reference chart of the U-joint pinion gear shims follows:


15-888927-028

15-888927-029

15-888927-030

15-888927-031

15-888927-032

15-888927-033

15-888927-034

15-888927-035

15-888927-036

15-888927-037

15-888927-038

15-888927-039

15-888927-040

0.81

0.83

0.86

0.89

0.91

0.97

0.97

0.99

1.02

mm

0.71

0.74

0.76

0.79

in.

0.028

0.029

0.030

0.031

0.032

0.033

0.034

0.035

0.036

0.037

0.038

0.039

0.040

Page 8C-16 90-899907001 JULY 2006


FEELER GAUGE MEASUREMENT

1. To properly check gear location: a.

Position the gear with at least 2 full teeth centered on the gauging surface. One full tooth must be on each side of the gauging surface center line. Insert a 0.64 mm (0.025 in.) feeler gauge between a tooth and the gauging surface.

b.

Slightly rotate the shimming tool until one side of the gauging surface contacts the feeler gauge and a slight drag is felt on the feeler gauge.

c.

Without moving the shimming tool, remove the feeler gauge and re-insert it between the other tooth and the gauging surface.

16419

2. If the feeler gauge can be inserted with only a slight drag, the shimming is correct.

3. If the feeler gauge inserts with no drag, repeat Steps 1., a., b., and c. with progressively thicker feeler gauges until the feeler gauge can be inserted with only a slight drag.

4. If the feeler gauge cannot be inserted, repeat Steps 1., a., b., and c. with progressively thinner feeler gauges until the feeler gauge can be inserted with only a slight drag.

Measuring Driven Gear Lash

IMPORTANT: Repeat the shimming process, Measuring Driven Gear Lash, until the gear lash measurement is within specifications.

1. Ensure that the U-joint pinion gear has completed the shimming procedure and is removed from the driveshaft housing.

2. Measure the upper and lower thrust race. Record this measurement.

3. If not using the original thrust race, use a thrust race with the specified thickness as a starting point or the same thickness as the original thrust race.

a

90-899907001 JULY 2006

b a -

Micrometer

15380

b -

Thrust race

Page 8C-17




4. Lightly lubricate the lower thrust race.

Tube Ref No.

87

Description


Lubricant

Where Used

Lower thrust race

mm

1.63

in.

0.064

Part No.

92-802854A1

NOTE: If using the original thrust race, race should be installed so that the side of original contact area is in the same position as removed.

5. Position the lower thrust race in the center of the driveshaft housing.

a

Page 8C-18

15384

a -

Lower thrust race

6. Lightly lubricate the lower thrust bearing.

Tube Ref No.

87

Description


Lubricant

Where Used

Lower thrust bearing

Part No.

92-802854A1

NOTE: The thrust bearing is always positioned to the gear, and the thrust race (shim) is positioned to the driveshaft housing.

7. Position the lower thrust bearing on top of the lower thrust race in the center of the driveshaft housing.

a a -


15383

90-899907001 JULY 2006


NOTE: The clutch and gear assembly and the top cover assembly can not be properly installed if the lower thrust race and lower thrust bearing are positioned incorrectly.

a b

16444

Positioned correctly a -

Driveshaft housing

Positioned incorrectly b -


!

CAUTION

Mistiming of the clutch and gear assembly will cause the sterndrive not to shift out of gear properly and can cause damage and failure of the gear assembly. Always time the assembly as specified.

IMPORTANT: Do not align two positive (+) marks or two negative (–) marks.

NOTE: Timing marks on gears must be aligned in one of two ways. The positive (+) mark over the negative (–) or the negative (–) mark over the positive (+). Never align two positive (+) marks or two negative (–) marks.

8. Position the clutch and gear assembly timing marks on gears.

-

+ a b

18178

a -

Upper driven gear to the positive (+) mark

b -

Lower driven Gear to negative (–) mark

90-899907001 JULY 2006 Page 8C-19


9. Lightly lubricate clutch and gear assembly.

a

-

+

18179

a -

Clutch and gear assembly

Tube Ref No.

87

Description


Lubricant

Where Used


Part No.

92-802854A1

10. Install the clutch and gear assembly into the driveshaft housing so that the timing marks on gears are easily visible through the back of the driveshaft housing.

a a b a -


15793

b -

Bottom face of lower gear

11. Position the clutch and gear assembly timing marks on the gears.

Page 8C-20 90-899907001 JULY 2006


NOTE: The timing marks on the gears must be aligned in one of two ways. The positive (+) mark over the negative (–) or the negative (–) mark over the positive (+). Never align two positive (+) marks or two negative (–) marks.

a

+

_

b

16557

Clutch and gear assembly properly installed in the driveshaft housing a -

Upper gear (+) positive timing mark

b -

Lower gear (–) negative timing mark

12. Align the timing index marks of the clutch and gear assembly with the index marks on driveshaft housing as close as possible.

b a

+

a

_

b

18180

Clutch and gear assembly properly installed in the driveshaft housing a -

Index marks on driven gears

b -

Index marks on driveshaft housing

13. Ensure that the clutch and gear assembly is positioned below the top of the driveshaft housing.

90-899907001 JULY 2006 Page 8C-21


14. If the clutch and gear assembly is above the driveshaft housing, reposition the lower thrust race and lower thrust bearing.

b a a b

15794

Positioned correctly a -


15. Lightly lubricate thrust bearing.

b -

15795

Positioned incorrectly

Driveshaft housing

Tube Ref No.

87

Description


Lubricant

Where Used

Thrust bearing

Part No.

92-802854A1

NOTE: The thrust bearing is always aligned to the gear, and the thrust race (shim) is aligned to the driveshaft housing.

16. Position the upper thrust bearing on top of the clutch and gear assembly.

a

15381

a -

Thrust bearing

17. Lightly lubricate the thrust race.

Tube Ref No.

87

Description


Lubricant

Where Used

Thrust race

Part No.

92-802854A1

NOTE: If using the original thrust race, install the race so the side of original contact area is in the same position as the one removed.

Page 8C-22 90-899907001 JULY 2006


18. Position the upper thrust race on top of upper thrust bearing.

a

15379

a -

Thrust race

c

NOTE: Ensure that the shim is positioned on the shoulder of the flanged bearing cup .

19. Carefully install the stub shaft tool complete assembly into the driveshaft housing bore so not to damage the shim.

b a a c a -

Driveshaft housing

15813

b -

Stub Shaft tool complete assembly

b c -

Retainer nut

20. Apply lubricant to the threads of the retaining nut.

Tube Ref No.

34

Description

Special Lubricant 101

Where Used

Threads of retainer nut

16139

Part No.

92-802865A1

IMPORTANT: Ensure that the retainer nut is not cross-threaded by turning the retainer nut

COUNTERCLOCKWISE until you feel the threads engage and then turn the retainer nut clockwise.

90-899907001 JULY 2006 Page 8C-23


21. Install the U-joint retainer nut to driveshaft housing.

a

Standard Bravo shown a -

U-joint retainer nut

22. Torque the retainer nut.

18183

a b a -

18182

Standard Bravo shown


b -

Torque wrench

23. Use the specified torque chart and torque wrench as outlined in this section under Torque

Conversion Chart For U-joint Retainer Nut Tool.

a b

Page 8C-24

16143

Typical Bravo retainer nut tool shown a -

Torque wrench length

b -

U-joint retainer nut tool measurement, 30.5 cm (12 in.)


90-899907001 JULY 2006


NOTE: For Bravo XZ, XR and Diesel Bravo drives use the bearing retainer wrench for Bravo X series tool to loosen and remove the retainer nut from the driveshaft housing.

Spanner wrench for L-18 U-joint bearing retainer

91-862219A1

the top cover.

25. Insert the shift shaft seal into the driveshaft housing.

a

15330

a -

Shift shaft seal

NOTE: Ensure that the top cover O-ring is positioned correctly.

26. Apply lubricant to the top cover O-ring and install to the top cover.

a a

15328

a -

Top cover O-ring

Tube Ref No.

87

Description


Lubricant

27. Install the top cover and torque the screws.

a b

Where Used

Top cover O-ring

Part No.

92-802854A1

90-899907001 JULY 2006

a -

Top cover

b -

Bolts

16430

Page 8C-25


Description

Driveshaft housing top cover screws

Nm

27

lb. in.

lb. ft.

20

28. Install the adapter rod tool in the top stud hole of the driveshaft housing and tighten the nut.

b a a -

Adapter rod tool

15797

b -

Nut

Adaptor rod tool 91- 865086

29. Install the gear lash flag onto the stub shaft tool. Ensure that the drive tooth count matches the numbers on the flag.

30. Align the indicator mark of the gear lash flag toward the stub shaft tool.

b a a -

Stub shaft tool

Gear lash flag 27/32




15798

b -

Gear lash flag

91-865080

91-865081

91-865082

91-865116

Page 8C-26 90-899907001 JULY 2006


31. Install the clamp block and handle tool on the end of the stub shaft tool. Tighten just to snug up to shaft.

c a b a -

Clamp block and handle tool

b -

Stub shaft tool

15799

c -

Gear lash flag

Clamp block and handle tool 91-865085

32. Install the dial indicator holding block to the adapter rod and nut tool.

b a a -

Dial indicator holding block

15800

b -

Adapter rod and nut tool

Dial indicator holding block 91-865097

NOTE: Use the short extension tip for the dial indicator.

33. Install the dial indicator to the holding block using the correct drive gear ratio access hole.

Dial indicator 91-58222A1

34. Position the dial indicator holding block to align the dial indicator tip 90° parallel to the gear lash flag indicator mark.

90-899907001 JULY 2006 Page 8C-27


35. Final alignment can be made to ensure that the gear lash flag is positioned vertically on the stub shaft tool.

b a f b a f e c d a

15802


Gear lash flag

b -

Dial indicator tip

c -

Dial indicator

d -

Dial indicator holding block

c d g

15803

Bravo X Series e -

Adapter rod tool

f -


g -

Stub shaft tool

36. Reposition the clutch for the clamp tool installation by carefully pushing the clutch up with a screwdriver to gain access to the upper driven gear.

c a d b a -

Clutch

b -

Lower driven gear torus ring

15804

c -

Upper driven gear torus ring

d -

Screwdriver

NOTE: The clutch and gear assembly timing marks "+" and "–" must remain aligned while measuring gearlash.

NOTE: The driven gear clamping tool clamps to the torus ring.

a b

Page 8C-28

a -

Driven gear torus ring

16440

b -

Driven gear clamping tool

90-899907001 JULY 2006


37. Install the driven gear clamping tool to the upper driven gear of the clutch and gear assembly.

Position the tool so you can hold the clamping tool while reading the dial indicator.

a b c a -

Upper driven gear torus ring

b -


15805

c -

Clutch

Driven gear clamping tool 91-865115

38. Make final adjustments enabling holding the driven gear clamping tool with one hand and the handle tool with the other hand while reading the dial indicator. Tighten the clamp block and handle tool to the stub shaft tool.

39. Hold the driven gear in locked position with the driven gear clamping tool. Slightly rotate the clamp block and handle tool back and forth to move the U-joint pinion gear, to feel the gear lash.

b c a b a c c -

Dial indicator

15807

a -


b -


40. Observe the dial gauge while rotating the pinion gear back and forth to feel the gear lash.

Record this measurement as an upper driven gear measurement.

41. Remove the driven gear clamping tool from the upper driven gear.

90-899907001 JULY 2006 Page 8C-29


42. Reposition the clutch, carefully pushing the clutch down with a screwdriver to gain access to the lower driven gear.

b d a c a -

Clutch

b -

Upper driven gear

15806

c -

Lower driven gear

d -

Screwdriver

43. Install the driven gear clamping tool to the lower driven gear of the clutch and gear assembly.

NOTE: The driven gear clamping tool clamps to the lower torus ring.

c a b a -

Lower gear torus ring

b -



15817

c -

Clutch

91-865115

Page 8C-30 90-899907001 JULY 2006


44. Hold the driven gear in locked position with the driven gear clamping tool. Slightly rotate the clamp block and handle tool back and forth to move the U-joint pinion gear, to feel the gear lash.

b c a b a c c -

Dial indicator

15807

a -


b -


45. Observe the dial gauge while rotating the pinion gear back and forth to feel the gear lash.

Record measurement as a lower driven gear measurement.

NOTE: The upper driven gear and lower driven gear have the same gear lash specification.

Drive gear tooth

27

27

23

16

Driven gear tooth

32

29

30

19

Gear lash specification

0.279 mm–0.406 mm

[(0.011 in.)–(0.016 in.)]

0.330 mm–0.457 mm

[(0.013 in.)–(0.018 in.)]

0.279 mm–0.406 mm

[(0.011 in.)–(0.016 in.)]

0.229 mm–0.381 mm

[(0.009 in.)–(0.015 in.)]

46. If the gear lash measurement of the upper driven gear and the lower driven gear are within specification: a.

Carefully remove the measuring tools, stub shaft tool, and assembly. Remove the top cover from the driveshaft housing.

b.

Remove all components from the stub shaft tool.

c.

The upper thrust race and upper thrust bearing, clutch and gear assembly, and the lower thrust bearing and lower thrust race remain in the driveshaft housing for complete reassembly of the driveshaft housing.

d.

Proceed to Drive Reassembly.

NOTE: Refer to Calculation Method For Specified Gear Lash in this section.

47. If the gear lash measurement of the upper driven gear is incorrect and the lower driven gear is within the specified measurement: a.

Carefully remove the measuring tools, stub shaft tool, and assembly. Remove the top cover and the upper thrust race from the driveshaft housing.

b.

Replace only the upper thrust race.

c.

Repeat the measurement process.

48. If the gear lash measurement of the lower driven gear is incorrect and the upper driven gear is within the specified measurement: a.

Carefully remove the measuring tools, stub shaft tool, and assembly. Remove the top cover, upper thrust race and upper thrust bearing, clutch and gear assembly, and the lower thrust bearing and lower thrust race from the driveshaft housing.

90-899907001 JULY 2006 Page 8C-31


b.

Replace only the lower thrust race.

c.


49. If the gear lash measurement of the upper driven gear and the lower driven gear are incorrect: a.

Carefully remove the measuring tools, stub shaft tool, and assembly. Remove the top cover, upper thrust race and thrust bearing, clutch and gear assembly, and the lower thrust bearing and thrust race from the driveshaft housing.

b.

Replace the upper thrust race and the lower thrust race.

c.


IMPORTANT: The shimming process must be repeated until gear lash is within specifications.

CALCULATION METHOD FOR SPECIFIED GEAR LASH

!

CAUTION

Using multiple thrust races to obtain the specified gear lash can cause drive damage and failure.

Always use the correct race.

1. If the gear lash is not within specification: a.

Calculate the difference of the existing gear lash measurement and the specified gear lash measurement by using the gear lash charts below.

b.

Make the gear lash measurement changes by removing or adding thrust race thickness.

For example, if the gear lash measurement is too high:

The thrust race assembled with the driven gear measures 1.55 mm (0.061 in.) thick and the gear lash measurement is 0.43 mm (0.017 in.).

NOTE: Use the midpoint of the specified gear lash. If the specified gear lash is

0.28–0.41 mm (0.011–0.016 in.), use the midpoint of 0.36 mm ( 0.014 in.).

The thrust race thickness should be increased by 0.08 mm (0.003 in.).

Replace the thrust race with a 1.63 mm (0.064 in.) thick thrust race. Repeat the measurement process and check your work.

Gear lash chart

Description

Existing gear lash measurement

Specification

Add thrust race measurement (difference)

Thrust race thickness

0.432 mm (0.017 in.)

0.356 mm

0.076 mm

(0.014 in.)

(0.003 in.)

For example, If the gear lash measurement is too low:

The thrust race assembled with the driven gear measures 1.55 mm (0.061 in.) thick and the gear lash measurement is 0.30 mm (0.012 in.).

NOTE: NOTE: Use the midpoint of the specified gear lash; if the specified gear lash is

0.28–0.41 mm (0.011–0.016 in.), use the mid point of 0.36 mm (0.014 in.).

The thrust race thickness should be decreased by 0.05 mm (0.002 in.).

Replace the thrust race with a 1.50 mm (0.059 in.) thick thrust race. Repeat the measurement process and check your work.

Gear lash chart

Description

Specification

Existing gear lash measurement

Remove thrust race measurement (difference)

Thrust race thickness

0.356 mm (0.014 in.)

0.305 mm

0.051 mm

(0.012 in.)

(0.002 in.)

Adding thrust race thickness positions the driven gear closer to the pinion gear, reducing gear lash.

Page 8C-32 90-899907001 JULY 2006


Removing thrust race thickness positions the driven gear farther away from the pinion gear,

increasing gear lash.


23-864596-058

23-864596-059

23-864596-060

23-864596-061

23-864596-062

23-864596-063

23-864596-064

23-864596-065

23-864596-066

23-864596-067

Thickness

1.47 mm (0.058 in.)

1.50 mm (0.059 in.)

1.52 mm (0.060 in.)

1.55 mm (0.061 in.)

1.57 mm (0.062 in.)

1.60 mm (0.063 in.)

1.63 mm (0.064 in.)

1.65 mm (0.065 in.)

1.68 mm (0.066 in.)

1.70 mm (0.067 in.)

Color code

Brown

White

Orange

Green

Yellow

Red

Light Blue

Black

Pink

Purple

Driveshaft Housing Reassembly

Reset U-joint Pinion Gear and Bearing Preload

IMPORTANT: Reset the U-joint pinion gear and bearing assembly preload after the shimming procedure and before it is reinstalled into the driveshaft housing.

1. Carefully remove the shim from the pinion gear and bearing assembly.

2. Release the pinion gear and bearing assembly preload: a.

Place the universal puller plate tool under the shoulder of the flanged bearing cup.

b.



a g f d b c e a -


b -


c -

Flanged bearing cup

d -


16412

e -

Pinion gear

f -


g -

Press on mandrel

Universal puller plate 91-37241

90-899907001 JULY 2006 Page 8C-33


U-joint, Pinion Gear and Bearing Assembly Reassembly

!

CAUTION

Improper reassembly of the U-joint and pinion gear assembly can cause damage or failure of the sterndrive. Reassemble the U-joint and pinion gear as specified.

a b c d e f g h i

15755

a -

Pinion nut

b -

Washer

c -


d -

Sealing ring

e -

O-ring

Standard Bravo U-joint assembly f -

Thrust washer

g -

Oil seal and oil seal carrier

h -

Retainer nut

i -

U-joint

a b c d e f

15756

Bravo X series U-joint assembly a -

Pinion nut

b -

Washer

c -


d -

Thrust washer

e -

O-ring, oil seal, oil seal carrier, and retainer nut

f -

U-joint

Page 8C-34

a b c d e

Bravo XR U-joint assembly a -

Pinion nut

b -

Washer

c -


f

15757

d -

Thrust washer

e -

O-ring, oil seal, oil seal carrier, and retainer nut

f -

U-joint

90-899907001 JULY 2006

a


The stacking procedure below can be followed for the assembly of all Bravo U-joint assemblies.

However, the Bravo X series and the Bravo XR models must refer to specified U-joint exploded view for the parts order and orientation of U-joint reassembly.

1. Stacking procedure for reassembling a Standard Bravo U-joint, pinion gear and bearing assembly.

NOTE: Bravo X series and the Bravo XR models must refer to specified U-joint exploded view for the parts order and orientation of U-joint reassembly.

a.

Place bearing retainer wrench tool in a vise and add the retainer nut.

b.

Stack the oil seal and oil seal carrier on the retainer nut.

c.

Install the O-ring to oil seal carrier.

b c d a

Standard Bravo model shown Bravo X series and Bravo XR models are similar.

a -


b -

Retainer nut

c d -

Oil seal and oil seal carrier

O-ring

16399

Bearing retainer wrench 91-17256 d.

Stack the sealing ring on the oil seal carrier.

e.

Place the thrust washer, flat side up, on the oil seal carrier.

f.

Stack the pinion gear and bearing assembly on the thrust washer and sealing ring.

c b

16400

Standard Bravo model shown Bravo X series and Bravo XR models are similar.

a -

Sealing ring

b -

Thrust washer

c -

Pinion gear and bearing assembly g.

Apply lubricant to the washer and threads of retainer nut.

90-899907001 JULY 2006 Page 8C-35


Tube Ref No.

87

Description


Lubricant

Where Used

U-joint pinion gear washer and retainer nut h.

Install the U-joint from the bottom of the stacked assembly.

i.

Place the washer over the U-joint stub and hand-start the pinion nut.

Part No.

92-802854A1

b c a

16401

a -

U-joint

b -

Washer

c -

Pinion nut j.

Use a screwdriver to secure the U-joint.

k.

Tighten the pinion nut until the washer contacts the gear. Do not overtighten the nut before setting the preload.

b a a -

Screwdriver

b -

Ratchet and socket

16402

NOTE: Complete the U-joint and pinion gear preload procedure before installing the assembly to the driveshaft housing.

U-joint Pinion Gear and Bearing Assembly Preload

Follow only one of the procedures: Setting Preload Using a Vise, Setting Preload In The

Driveshaft Housing.

SETTING PRELOAD USING A VISE

1. Set the preload on bearing package as follows: a.


Page 8C-36 90-899907001 JULY 2006


b.

Position the U-joint assembly with its shaft facing down as shown.

b a c d e



b -


c -


16407

d -

Vise

e -

Screwdriver


e a b d c

Bravo X series a -


b -


c -


16408

d -

Vise

e -

Screwdriver

Spanner wrench for L-18 U-joint bearing retainer c.


91-862219A1

Tube Ref No.

87

Description


Lubricant

Where Used

Bearings

Part No.

92-802854A1 d.

Set preload by tightening the nut 1/16 of a turn at a time.

e.

Check for proper preload by turning the pinion gear, using an extension, appropriate socket, and a dial torque wrench lb. in. until you reach the specified torque.

90-899907001 JULY 2006 Page 8C-37


!

CAUTION

Avoid premature bearing failure. Do not overtighten the U-joint pinion gear nut.

a

16409


Dial type torque wrench (lb. in.)

NOTE: Bearings are used if spun once under load.

Description


New

0.7–1.0 Nm (6–10 lb. in.)

Used

0.3–0.8 Nm (3–7 lb. in.)


91-66274

2. If the nut becomes overtightened (causing excessive preload), release the pinion gear and bearing assembly preload.

a.

Remove the pinion gear and the bearing assembly from the U-joint.

b.


c.



a g f d

Page 8C-38

b c e a -


b -


c -

Flanged bearing cup

d -


16412

e -

Pinion gear

f -


g -

Press on mandrel


Reassemble the components of the U-joint and repeat the preload procedures.

90-899907001 JULY 2006


SETTING PRELOAD IN THE DRIVESHAFT HOUSING

1. Set the preload on a U-joint pinion gear-and-bearing assembly as follows: a.


Tube Ref No.

87

Description


Lubricant

Where Used

Bearings b.

Install the U-joint and pinion gear assembly into the driveshaft housing.

Part No.

92-802854A1

a b

16414


U-joint and pinion gear assembly

b -

Retaining nut c.

Position the driveshaft housing so that the U-joint coupling shaft is pointing straight down.

d.

Set the preload by tightening the nut 1/16 of a turn at a time. Check for proper preload by turning the pinion gear, using an extension, appropriate socket, and dial torque wrench until you reach an acceptable torque.

!

CAUTION

Premature bearing failure can result if U-joint pinion gear nut becomes overtightened (causing excessive preload).

a b

90-899907001 JULY 2006

16415


Dial torque wrench (lb. in.)

b -

Driveshaft housing (U-joint shaft facing down)

Page 8C-39


NOTE: Bearings are used if spun once under load

Description


New

0.7–1.0 Nm (6–10 lb. in.)

Used

0.3–0.8 Nm (3–7 lb. in.)


91-66274

2. Remove U-joint and pinion gear assembly from driveshaft housing.

3. If nut becomes overtightened (causing excessive preload), release the pinion gear and bearing assembly preload: a.

Remove the pinion gear and bearing assembly from the U-joint.

b.


c.



a g f d b c e a -


b -


c -

Flanged bearing cup

d -


16412

e -

Pinion gear

f -


g -

Press on mandrel


Reassemble components to the U-joint and repeat preload procedures.

Page 8C-40 90-899907001 JULY 2006

Bravo One Gear Housing Setup


Section 8D - Bravo One Gear Housing Setup


Driveshaft Bearing Preload Shimming/Setup

Procedure..................................................................2

Pinion Gear Location Shimming/Setup Procedure

..................................................................................5

Driven Gear Lash Shimming/Setup Procedure.........6

Checking/Adjusting Final Propeller Shaft and Overall

Gear Housing Bearing Preload (Rolling Torque).......9

Major Differences Between The Bravo One And Bravo

Two Gear Housing..................................................11

8

D

90-899907001 JULY 2006 Page 8D-1


Driveshaft Bearing Preload Shimming/Setup Procedure

1. Remove clamp plate.

NOTE: Clamp plate was installed after drive shaft housing and gear housing were split.

a

20288

a -

Clamp plate

2. Remove O-ring, spacer, and shims.

NOTE: There should not be any shims between the tab washer and the bearing.

a b c d a -

O-ring

b -

Spacer

20290

c d -

Shims

Tab washer (above bearing)

3. Determine shim thickness required for drive shaft bearing preload.

Page 8D-2 90-899907001 JULY 2006


a.

Measure distance between top of gear housing and tab washer, at three locations.

a

19835

a -

0-to-1 in. Depth Micrometer b.

Measure thickness of spacer from top machined surface to bottom machined surface.

b a

20291 a -

Outside Micrometer

b -

Spacer c.

Calculate shim thickness as shown:

Measurement found in Step "a" minus measurement found in Step "b"

+ .001 in. = Shim thickness required.

(a – b) + .001 = Shim(s) required

c c -

Location of measurement

90-899907001 JULY 2006 Page 8D-3


4. Install calculated amount of shims, spacer, and new O-ring.

a b c d a -

New O-ring

b -

Spacer

20290

c -

Shims

d -

Tab washer (above bearing)

5. Reinstall clamp plate on gear housing.

6. Tighten nuts to specification.

Description

Clamp plate nuts

Nm

47.5

lb. in.

lb. ft.

35

NOTE: Use two washers on each stud (under nuts) so that nut does not run out of threads when torquing it down.

a a -

Clamp plate

20288

Page 8D-4 90-899907001 JULY 2006


7. Using a dial-type (lb. in.) torque wrench, check the rolling preload -0.3-0.6 Nm (3-5 lb. in.).

Adjust preload, as necessary, to attain proper reading. Add shims to increase rolling torque.

Subtract shims to decrease rolling torque. After correct rolling torque is achieved, then check pinion gear location.

b a a -

Dial-type (lb. in.) torque wrench

20292

b -

Drive shaft adaptor

Pinion Gear Location Shimming/Setup Procedure

IMPORTANT: Drive shaft bearing preload must be to specification before checking the pinion gear location (height).

1. Check pinion height.

a.

Insert shimming tool into gear housing.

b.

Measure clearance between shimming tool and gear with feeler gauge. Clearance must be set to specification. Take measurement at 3 locations on gear (120 degrees apart).

b a a -

Driveshaft Pinion Gear Shimming Tool

b -

Feeler gauge


20293

91-42840T

90-899907001 JULY 2006 Page 8D-5


2. If clearance is less than specified: Add appropriate thickness of shim(s) under lower tapered roller bearing cup. Any thickness added here must be subtracted from shim thickness

at upper bearing. If clearance is more than specified: Remove appropriate thickness of shim

(s) from under lower tapered roller bearing cup. Any thickness subtracted here must be

added to shim thickness at upper bearing.

a b c d e f a -

O-ring

b -

Spacer

c -

Shims, upper

20392

d e f -

Tab washer

Bearing cup, lower

Shims, lower

3. Recheck clearance after changing shim(s) in previous step.

b a

20293

a -


b -

Feeler gauge

4. Recheck rolling torque (preload) before proceeding to setting propeller shaft preload. Adjust, if necessary, to attain proper reading.

Driven Gear Lash Shimming/Setup Procedure

NOTE: Models with shims in front of the bearing carrier can be upgraded to a load ring per Service

Bulletin 93-10.

Page 8D-6 90-899907001 JULY 2006


NOTE: When switching to a load ring, in an older gear housing that was using shims, some housings will cause the tab on the tab washer to bend as the bearing carrier retainer nut is tightened to get the proper rolling torque (preload). The round tab hole in the older cases may not have enough clearance to allow some forward movement of the tab as the bearing carrier retainer nut is tightened.

Newer cases have an elongated tab hole to permit this forward movement without bending the tab. If you find that excess torque is required to get the proper rolling torque preload (more than

339 Nm (250 lb. ft.)), or if there are signs of the tab being deformed, then order a Tabless Spacer

Washer (14-863195) and place it under the tab washer. This spacer washer may also be required on some early load ring gearcases.

1. Install the original load ring, thrust ring, and O-ring into the gear housing.

d b c a a -

Load ring

b -

Thrust ring (.105 in. thickness)

20295

c -

O-ring

d -

Propeller shaft

2. Install the bearing carrier and tab washer in the gear housing.

3. Lubricate threads on bearing carrier retainer with Special Lubricant 101 and then install and tighten bearing carrier retaining nut until no more end-play can be felt (to preload bearings).

Then tighten bearing carrier retainer nut enough to make propshaft hard to turn - to assist when making gear lash check. Do not over-torque.

a a -

Bearing Carrier Retainer Nut Wrench


4. Driven gear shimming.

90-899907001 JULY 2006

20296

91-61069T

Page 8D-7


a.

Install the following special tools: Dial Indicator Adapter, Backlash Indicator Rod, and

Dial Indicator, as shown. Ensure dial rod is aligned with "II" on indicator rod and that dial rod and indicator rod are at exactly 90 degrees to each other.

b c a

20297

a -

Dial Indicator Adapter

b -

Dial Indicator (positioned at 90 degrees to indicator rod)

c -

Backlash Indicator Rod

Dial Indicator Adapter 91-83155

Backlash Indicator Rod 91-53459

Dial Indicator 91-58222A1 b.

Check gear backlash by lightly rotating drive shaft back and forth. Do not allow propeller shaft to turn. Observe dial indicator and record the reading.

NOTE: For a more definite feel of the gear lash, channel-lock pliers can be used to grip the drive shaft splines while rotating shaft to determine amount of play.

c.

If backlash is not correct, disassemble and proceed as follows. If backlash is more than specified: Add shim(s) under driven gear bearing cup. If backlash is less than specified:

Subtract shim(s) under driven gear bearing cup.

5. When lash is correct, perform final prop shaft rolling torque (preload) adjustment.

Page 8D-8 90-899907001 JULY 2006


Checking/Adjusting Final Propeller Shaft and Overall Gear Housing

Bearing Preload (Rolling Torque)

1. Remove bearing carrier and items shown.

a b c a -

O-ring

b -

Thrust ring

20298

c -

Load ring

IMPORTANT: Always use a new load ring when reassembling.

2. Install new load ring, original thrust ring and new O-ring.

3. Install bearing carrier and tab washer in gear housing (and Tabless Spacer Washer,

14-863195, if required).

4. Lubricate threads on bearing carrier retaining nut with Special Lubricant 101. Install, and tighten bearing carrier retainer until resistance to propeller shaft rotation can be felt (to preload bearings).

5. Tighten the retainer nut to achieve the proper overall gearcase preload. To determine overall gearcase preload, add prop shaft bearing preload to drive shaft preload as outlined in the following example.

Setting Overall Gear Housing Preload

IMPORTANT: The overall preload includes both the driveshaft preload and the propshaft preload.

Preloads

Propshaft new bearings

Propshaft used bearings*

.9 - 1.4 Nm (8 - 12 lb. in.)**

.6 - .9 Nm (5 - 8 lb. in.)**

Driveshaft .3 - .6 Nm (3 - 5 lb. in.)

* Bearing is considered used if spun under load (with power applied).

** Plus driveshaft preload [.3-6 Nm (3-5 lb. in.)]

Example:

Driveshaft preload

Propshaft (new bearing) preload

Over-all preload

.45 Nm (4 lb. in.)

+

1.1 Nm (10 lb. in.)

1.6 Nm (14 lb. in.)

90-899907001 JULY 2006 Page 8D-9


Propeller shaft preload

OVERALL GEARCASE PRELOAD TABLE

Driveshaft preload

.6 Nm (5 lb. in.)

.68 Nm (6 lb. in.)

.3 Nm ( 3 lb. in.)

.9 Nm (8 lb. in.)

1 Nm (9 lb. in.)

1.1 Nm (10 lb. in.)

.45 Nm (4 lb. in.)

1 Nm (9 lb. in.)

1.1 Nm (10 lb. in.)

1.2 Nm (11 lb. in.)

.8 Nm (7 lb. in.)

.9 Nm (8 lb. in.)

1 Nm (9 lb. in.)

1.1 Nm (10 lb. in.)

1.2 Nm (11 lb. in.)

1.4 Nm (12 lb. in.)

1.5 Nm (13 lb. in.)

1.4 Nm (12 lb. in.)

1.5 Nm (13 lb. in.)

1.6 Nm (14 lb. in.)

1.2 Nm (11 lb. in.)

1.4 Nm (12 lb. in.)

1.6 Nm ( 14 lb. in.)

1.7 Nm ( 15 lb. in.)

1.7 Nm (15 lb. in.)

1.8 Nm (16 lb. in.)

.6 Nm (5 lb. in.)

1.1 Nm (10 lb. in.)

1.2 Nm (11 lb. in.)

1.4 Nm (12 lb. in.)

1.5 Nm (13 lb. in.)

1.6 Nm (14 lb. in.)

1.7 Nm (15 lb. in.)

1.8 Nm (16 lb. in.)

1.9 Nm (17 lb. in.)

6. Tighten the retainer nut to achieve the proper preload using the following procedure.

a.

Tighten the retainer nut in small increments.

a a -



20296

91-61069T

Page 8D-10 90-899907001 JULY 2006


b.

After tightening retainer nut in small increments, check overall gear housing bearing preload at propeller shaft, each time, until correct specification is reached.

a b c a -

Dial-type (lb. in.) Torque Wrench

20302

b -

Propeller nut (under socket)

c -

Rotate shaft in direction of normal rotation using a smooth, steady motion c.

If you tighten the retainer past the overall preload, replace the load ring and start again at Step 2.

7. When proper overall preload is reached, bend the tab washer up into the retainer nut to secure it.

Major Differences Between The Bravo One And Bravo Two Gear

Housing

• A larger bearing carrier retainer wrench tool is used (91-17257).

• The propshaft bearing carrier uses a locating key, like the older Alpha drives.

• The propshaft bearing carrier has a tapered roller bearing race (like a Bravo One) and a caged needle bearing (like the Alpha series). The bearings are serviced separately, but the roller bearing race is used to set the propshaft bearing preload and the caged needle bearing absorbs axial thrust loads. A Driver (91-55919) is used to press the needle bearing from the carrier (like an Alpha) and a different Driver (91-55918) is used to install the bearing. The tapered roller bearing race is removed with a slide hammer and installed with a Driver (91–

63626), which is the same tool used to install the driven gear race.

• All Bravo Two units use a load ring. There are no shimmed bearing carriers. Propshaft rolling torque is still measured at the propshaft and must be .9-1.4 Nm (8-12 lb. in.) (new bearings) or .6-.9 Nm (5-8 lb. in.) (used bearings) above the driveshaft rolling torque of .3-.6 Nm (3-5 lb. in.), just like a Bravo One.

• A larger seal installer (91-55916) is used and the seals are pressed in from the outside (rear of the carrier).

• A larger bearing installer (91-63626) is used to press in the driven gear race. The shims under the cup are still used to set backlash.

• The vertical shaft and the pinion bearing are serviced in the same manner (and with the same tools) as the Bravo One, with the exception that on earlier units there are two different bearing part numbers, depending on the gearcase casting number (See Service Manual #11,

90-17431--4 [3/98], page 3C–15) .

• A larger Shimming Tool (91-96512) is used to set pinion height, but the specification is still

0.64 mm (0.025 in.).

90-899907001 JULY 2006 Page 8D-11


• Backlash specification is 0.23-0.38 mm (0.009-0.015 in.), which is a little more forgiving than the Bravo One.

Bearing Carrier Retainer Tool 91-17257

Bearing Driver

Bearing Driver

Bearing Cup Driver

Oil Seal Driver

Gearcase Pinion Shimming Tool

91-55919

91-55918

91-63626

91-55916

91-96512

Page 8D-12 90-899907001 JULY 2006

Bravo Three Gear Housing Setup


Section 8E - Bravo Three Gear Housing Setup


Bravo Three Gear Housing Activity...........................2

Propeller Shaft Spline Lash Check (Bravo Three Only)

..................................................................................2

Bravo Three Backlash Shimming/Setup Procedure

..................................................................................3

8

E

90-899907001 JULY 2006 Page 8E-1


Bravo Three Gear Housing Activity

The object of the activity is to review and/or perform the subjects titled in Service Manual # 28 and answer the related questions on the activity sheet.

Propeller Shaft Spline Lash Check (Bravo Three Only)

1. Check inner propeller shaft spline lash as follows: a.

Place inner propeller shaft on two V-blocks.

a b a -


20304

b -

V-blocks b.

Install Spline Backlash Tool on inner propeller shaft, just behind shaft spline.

a

Page 8E-2

b a -

Spline Backlash Tool

20305

b -


Spline Backlash Tool 91-806192 c.

Slide front driven gear assembly onto spline of inner propeller shaft.

d.

Mount Dial Indicator to gear and position so that indicator probe aligns with mark on

Indicator Rod.

b c a -

Dial Indicator

b -



Dial Indicator

a

20311

c -

Mark stamped on Indicator Rod

91-806192

91-58222A1

90-899907001 JULY 2006


e.

Rotate gear back and forth, while observing dial indicator. Record spline lash reading

(for use later in this section). This reading is required to determine true backlash between pinion and driven gear.

2. Check outer propeller shaft spline lash following the same procedures as for the inner propeller shaft listed in Steps "a" through "e" above using Spline Backlash tool.

Bravo Three Backlash Shimming/Setup Procedure

1. Front driven gear shimming. a.

Remove clamp plate, O-ring, spacer and shim(s), and place drive shaft retaining tool on tab washer as shown. Do not tighten locking bolt at this time.

a b c

20312

a -

Driveshaft Retaining Tool (1999 and prior, 91-805381 / 2000 and Newer,

91-863738)

b -

Locking bolt

c -

Tab washer

Driveshaft Retaining Tool 91-805381

Driveshaft Retaining Tool 91-863738 b.

Position gear housing so that propeller shafts are facing up in the vertical position. Rotate propeller shafts several times to seat bearings prior to making checks.

c.

Lightly press down on Driveshaft Retaining Tool, while simultaneously turning shaft, to ensure bearings are seated in bearing cups, then tighten locking bolt to retain drive shaft.

90-899907001 JULY 2006 Page 8E-3


d.

Install Backlash Indicator Rod to inner propeller shaft as shown. Mount Dial Indicator to bearing carrier and position probe on mark stamped in Indicator Rod.

c b a

Page 8E-4

a -

Dial Indicator

b -


20313

c -


NOTE: Dial Indicator Rod and Backlash Indicator Rod should be at exactly 90 degrees to each other.

Dial Indicator 91-58222A1

Spline Backlash Tool 91-806192

NOTE: For a more definite feel of the gear lash, channel-lock pliers can be used to grip the drive shaft splines while rotating shaft to determine amount of play.

e.

Check total backlash by lightly rotating inner propeller shaft back and forth. Observe dial indicator and record reading.

f.

Subtract the gear/shaft spline lash reading (obtained from Propeller Shaft Spline Lash

Check performed earlier) from total backlash reading. Actual gear backlash should be between 0.3-0.4 mm (.012-.016 in.).

Example:

Total backlash reading: 0.75 mm (.030 in.)

Minus –

Gear/Shaft spline lash (from propeller shaft spline lash check): 0.4 mm (.016 in.)

Equals

Actual gear backlash:

=

0.35 mm (.014 in.) g.

If backlash is not correct, disassemble and proceed as follows: If backlash is more than specified, add shims behind front driven gear bearing cup. If backlash is less than specified, remove shims from behind front driven gear bearing cup.

h.

Recheck backlash reading after reassembly.

2. Rear driven gear shimming. a.

Position gear housing so that propeller shafts are facing down in the vertical position.

Loosen locking bolt on drive shaft retaining tool and rotate propeller shafts several times to seat bearings prior to making checks. Lightly press down on drive shaft retaining tool to ensure bearings are seated in bearing cups, then tighten locking bolt to retain drive shaft.

90-899907001 JULY 2006


b.

Install Spline Backlash Tool to outer propeller shaft as shown. Mount Dial Indicator to bearing carrier and position probe on mark stamped in Indicator Rod.

a c b

19342

a -


b -

Dial Indicator

c -

Outer propeller shaft

Spline Backlash Tool 91-806192

Dial Indicator 91-58222A1 c.

Check total lash by lightly rotating outer propeller shaft back and forth. Observe dial indicator and record reading.

d.

Subtract the gear/shaft spline lash reading (obtained from Propeller Shaft Spline Lash

Check, performed earlier) from total backlash reading. Actual gear backlash should be between 0.3-0.4 mm (.012-.016 in.).

Example:

Total backlash reading:

Minus

0.75 mm (.030 in.)

–

Gear/Shaft spline lash (from propeller shaft spline lash check): 0.4 mm (.016 in.)

Equals =

Actual gear backlash: 0.35 mm (.014 in.) e.

If backlash is not correct, disassemble and proceed as follows: If backlash is more than specified, remove shims from in front of rear driven gear bearing cup. If backlash is less than specified, add shims in front of rear driven gear bearing cup.

f.

Recheck backlash reading after reassembly.

3. Check propshaft end play.

90-899907001 JULY 2006 Page 8E-5


a.

Install Dial Indicator on propshaft as illustrated below. Move inner shaft up and down while reading Dial Indicator (ensure outer shaft is also being lifted by inner shaft). If reading is outside of range, the outer propeller shaft thrust race shims must be increased or decreased to bring the end-play reading within range of specifications.

b a a -


20315

b -

Dial Indicator

Specification Range

End-Play Range 0.03-0.30 mm (.001-.012 in.)

Dial Indicator 91-58222A1

4. Remove Driveshaft Retaining Tool and reinstall shim(s), spacer and O-ring.

Page 8E-6 90-899907001 JULY 2006

Bravo Shift Cable Installation, Drive Unit Installation and Shift Setup


Section 8F - Bravo Shift Cable Installation, Drive Unit

Installation and Shift Setup


Replacing Earlier Model Bravo Shift Cables with Later

Model Shift Cables....................................................2

Bravo Drive Unit Shift Cable Installation...................4

Bravo Sterndrive Unit Installation..............................8

Bravo Drive Unit Remote Control and Drive Unit Shift

Cable Adjustment....................................................15

Changes to Shift Plate Assembly - 2003.................19

8

F

90-899907001 JULY 2006 Page 8F-1


Replacing Earlier Model Bravo Shift Cables with Later Model Shift

Cables

Models with earlier style shift cable – identified by small nut which will not pass over cable anchor - core wire must be pulled from shift cable to remove cable assembly from bell housing.

21258

Models with later style shift cable – identified by larger nut which fits over core wire anchor; it is unnecessary to remove core wire to remove shift cable assembly.

b a c

Page 8F-2

a -

Shift cable retaining nut

b -

Washer

c -

21261

Inside nut

To install the later model shift cable on all Bravo transom assemblies with serial number OD542204 and lower you must enlarge the bell housing shift cable retainer hole from 9.53 mm (3/8 in.) to

11.11 mm (7/16 in.) . Use the Bravo Shift Cable Replacement Kit (815471A3).

All Bravo Transom Assemblies, serial number OD542205 and above, already have the latest style shift cable.

Shift Cable Inspection and Upgrade

1. Remove the sterndrive unit.

2. Compare the shift cable that was removed from the unit with the replacement shift cable.

a.

If cable diameter a is equal on both the removed cable and the replacement cable, then both cables are the later model. Install the replacement cable (skip Steps 3-8 and go to

Bravo Drive Unit Shift Cable Installation).

90-899907001 JULY 2006


b.

If cable diameter a is larger on the replacement shift cable than on the removed shift cable, proceed with the following instructions.

a a

21263

a -

Cable diameter

3. Slide the slotted hole of the Drill Bushing Tool over the lowest stud closest to the bell housing shift cable bore.

4. Install the alignment rod through the round 11.11 mm (7/16 in.) hole of the bushing tool and into the bell housing shift cable bore. Make sure that it is seated fully into the bore.

5. Clamp the drill bushing tool into place using one of the nuts and washers that hold the sterndrive unit to the bell housing.

f a e b a -

Alignment rod

b -

Nut

c -

Washer

c d

21264

d -

Drill Bushing Tool

e -

Bell housing stud

f -

Bell housing shift cable bore

!

CAUTION

Water leakage could cause premature shift component failure. Using the wrong drill may create a rough surface in the shift cable bore, allowing water leakage. Use a sharp, straight drill with a

118° point and without nicks.

90-899907001 JULY 2006 Page 8F-3


6. Drill through the 11.11 mm (7/16 in.) hole in the Drill Bushing Tool and through the bell housing shift cable bore. Use the 11.11 mm (7/16 in.) drill provided in Service Tool Kit 91-818836A-1.

a e f d c b a -

Drill

b -

Nut

c -

Washer

21266

d -

Drill Bushing Tool

e -

Bell housing stud

f -

Bell housing shift cable bore

7. Remove the drill bushing tool and clean the debris out of the bell housing. Apply 2-4-C Marine

Lubricant with Teflon to the newly drilled hole.

8. Install the new shift cable.

Bravo Drive Unit Shift Cable Installation

1. Insert shift cable end into and through shift cable bellows.

a -

Shift cable end

a b

21267

b -

Shift cable bellows

Page 8F-4 90-899907001 JULY 2006


2. Apply Perfect Seal to shift cable retaining nut threads. Secure shift cable to bell housing. Hold inner nut with wrench and torque outer retaining nut to specifications.

e c f d a -

Shift cable

b -

Inner nut

c -

Seal washer (hidden by nut)

Description

Outer retaining nut

3. Install shift cable wrapping.

b a

21268

d -

Outer retaining nut

e -

Later style cable - washer

f -

Core wire is in later model cable, only

(at this step of reinstallation)

Nm

7

lb. in.

65

lb. ft.

a

21270

a -

Shift cable wrapping

!

CAUTION

Water leakage into the bilge may result if the shift cable bellows crimp clamp is not installed properly. Check that bellows end is not flattened out when crimping. Installation tool information is found in drive unit service manual.

90-899907001 JULY 2006 Page 8F-5


4. Install and compress shift cable bellows crimp clamp, maintaining a 12.7 mm (1/2 in.) diameter

round O.D. Ensure that clamp is crimped evenly so that a good seal is maintained between bellows and shift cable. (Do not allow bellows to flatten.)

a

21272

a -

Crimp clamp

5. Models with earlier shift cable - install inner core wire.

Page 8F-6

a

19918

a -

Inner core wire

6. Install Core Wire Locating Tool on face of bell housing.

a b a -

Bell housing

Shift Cable Anchor Adjustment Tool

19917

b -

Core Wire Locating Tool

91-17262A1

90-899907001 JULY 2006


7. Install threaded tube until it bottoms out. Tighten finger tight. Tighten jam nut securely.

b a -

Threaded tube

a

21275

b -

Jam nut

8. Earlier shift cables with support tubes - discard support tube; do not reinstall.

9. Install cable end guide over core wire, and insert core wire through cable anchor. Tighten anchor screws evenly and torque to specification.

c b a a -

Core wire

b -

Anchor screws

c -

Cable end guide

b

Earlier Models

Description

Anchor screws

a d

19919

c

Nm

2.3

lb. in.

20

lb. ft.

c b d

19920

Later Models a -

Cable end guide

b -

Core wire

c -

Anchor screws

d -

Sight port - bottom-out core wire (present on all later style and some earlier style cables)

90-899907001 JULY 2006 Page 8F-7


10. Place Shift Cable Anchor Adjustment Tool on end of shift cable as shown.

c a b

19444

a -

Shift Cable Anchor Adjustment Tool

b -

Stud - placed through hole in end guide

c -

Hole - barrel placed here

Shift Cable Anchor Adjustment Tool 91-17262A1

11. Ensure that bell housing end of core wire is positioned tightly against Core Wire Locating Tool.

a c b

19445

a -

Bell housing

b -

Core Wire Locating Tool

c -

Core wire

12. Adjust cable barrel to align with hole in tool. Remove tools and install cable on shift plate assembly, being careful not to lose adjustment.

a a -

Barrel

b

21276

b -

Hole in tool

Bravo Sterndrive Unit Installation

1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)

Page 8F-8 90-899907001 JULY 2006


2. Remove monitor cap and fill gear lube monitor.

a b

5497

a -

Gear lube monitor cap

3. Push in on dribble valve until gear lube appears.

b -

Fluid level full mark

a a -

Dribble valve

4. Once gear lube appears, release dribble valve.

5. Fill monitor to "FULL" mark.

6. Replace monitor cap.

7334

90-899907001 JULY 2006 Page 8F-9


7. Apply 2-4-C Marine Lubricant with Teflon to studs.

a

42

42 a

7335

a -

Studs

Tube Ref No.

42

Description

U-joint and Gimbal Bearing

Grease

Where Used

Studs

Part No.

92-802870A1

8. Lubricate U-joint shaft splines and U-joint shaft O-rings with Quicksilver Engine Coupler Spline

Grease.

42 b

42 a a -

Splines

Tube Ref No.

42

Description

U-joint and Gimbal Bearing

Grease

7336

b -

O-rings

Where Used

Shaft splines and O-rings

Part No.

92-802870A1

Page 8F-10 90-899907001 JULY 2006


9. Check drive shaft bellows for cleanliness and absence of debris.

a

7337

a -

Driveshaft bellows

10. Lubricate O-ring seals with 2-4-C Marine Lubricant with Teflon.

95 a -

O-ring seals

Tube Ref No.

95

Description

2-4-C with Teflon

a

7338

Where Used

O-ring seals

Part No.

92-802859A1

90-899907001 JULY 2006 Page 8F-11


11. Pull out shift linkage as far as it moves. Jaws will open, as shown.

a

21421

a -

Shift linkage

IMPORTANT: As sterndrive is inserted into drive unit, entry of the bell housing shift cable must be closely checked to make sure cable enters the jaws of shift linkage assembly in the sterndrive.

12. Place remote control in neutral position.

NOTE: As bell housing shift cable enters the shift linkage assembly, it pushes the assembly back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps "A", "B" and

"C".

21407

Page 8F-12 90-899907001 JULY 2006


IMPORTANT: If bell housing shift cable "b" does not line up to properly enter jaws of shift linkage assembly "a", cable will have to be aligned manually.

b a a -

Shift linkage assembly

21406

b -

Shift cable

13. Place driveshaft housing in position on bell housing and install drive unit, as follows: a.

Position trim cylinders so they point straight backwards.

b.

Position drive unit so that U-joint shaft aligns with bell housing bore.

c.

Guide U-joint shaft through bearing in gimbal housing and into engine coupler. Make sure that shift linkage jaws engage the bell housing shift cable assembly.

d.

If necessary, rotate propeller shaft counter-clockwise slightly (using a propeller) to align

U-joint shaft splines with splines in engine coupling, then slide drive unit all the way into bell housing.

14. Secure drive unit to bell housing with 5 flat washers and 6 locknuts. Torque to specification.

a b

7342

a -

Do not install flat washer here

b -

Elastic stop nuts (6) and flat washers (5)

Description

Locknuts

Nm

68

lb. in.

lb. ft.

50

IMPORTANT: On Bravo One, Two and Three models, the Trim-In Limit Pin (if equipped) must be properly positioned before installing the trim cylinder anchor pin in the following steps.

90-899907001 JULY 2006 Page 8F-13


15. Ensure that the Trim-In Limit Pin is positioned as shown for the appropriate Bravo model.

a b a -

Trim-In Limit Pin for Bravo One and Two (positioned forward)

b -

Trim-In Limit Pin for Bravo Three (positioned aft)

7343

IMPORTANT: The position of the Trim-In Limit Pin on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested.

IMPORTANT: To aid in installing rubber bushings, use a water and soap solution. Do not use oil or grease.

16. Install trim cylinders on aft end of drive unit with hardware as shown. Lubricate anchor pin threads with 2-4-C Marine Lubricant with Teflon and tighten nuts until they bottom. Install plastic caps and tighten hand tight only.

c b c d f a

140 c e a -

Aft anchor pin

b -

Large l.D. flat washers (2)

c -

Rubber bushings (4)

7344

d -

Small l.D. flat washers (2)

e -

Locknuts (2)

f -

Plastic caps (2)

Tube Ref No.

95

Description

2-4-C with Teflon

Where Used

Anchor pin threads

Part No.

92-802859A1

17. Raise drive to gain access to area between gimbal housing and sterndrive, and locate the opening in the forward end of the anti-ventilation plate.

Page 8F-14 90-899907001 JULY 2006


18. Insert speedometer tube fitting into opening on topside of anti-ventilation plate, in position shown.

a b a -

Speedometer hose fitting

b -

7345

Opening

19. With fitting fully seated, turn handle clockwise to a tightly seated position, as shown.

a a -

Fitting installed (handle pointing forward)

7346

Bravo Drive Unit Remote Control and Drive Unit Shift Cable

Adjustment

NOTE: Bravo Models only: Using Shift Cable Adjustment Tool , shift cables can be adjusted without or with the sterndrive installed, using the following procedure.

Shift Cable Adjustment Tool 91-12427

IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control.

• Bravo One/Two - If shift cable end guide moves in direction "A" when control lever is placed in forward, remote control is set up for right-hand (RH) propeller rotation.

90-899907001 JULY 2006 Page 8F-15


• Bravo One/Two - If shift cable end guide moves in direction "B" when control lever is placed in forward, remote control is set up for left-hand (LH) propeller rotation.

A

B

6614

Arrow indicates direction of motion

• Bravo Three - Front propeller on sterndrive unit is always LH rotation and rear propeller is always RH rotation. Shift cable end guide must move in direction "A," when control lever is placed in forward gear position.

A

8519

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.

1. Loosen the adjustable stud and move it to dimension, as shown. Retighten stud.

a b

8587

Typical Bravo shift bracket shown without switch a -

Adjustable stud

b -

76 mm (3 in.) (center of pivot bolt to center of stud)

2. Install sterndrive unit shift cable.

3. Install cotter pin.

4. Insert cotter pin from top and spread ends fully.

b

Page 8F-16 a c

8523

a -

Typical Bravo shift bracket shown without switch

Washers (2)

b -

Long cotter pin

c -

Short cotter pin

90-899907001 JULY 2006


5. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place using a piece of tape over the barrel retainer.

8522

Typical Bravo shift bracket shown without switch

6. Locate center of remote control and control cable play (backlash).

IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making the following adjustment.

a.

Shift remote control to neutral.

b.

Push in on control cable end with enough pressure to remove play and mark position "a" on tube.

c.

Pull out on control cable end with enough pressure to remove play and mark position "b" on tube.

d.

Measure distance between marks "a" and "b" and mark position "c" half-way between marks "a" and "b."

c a

7815

b

7. Temporarily install control cable end guide into shift lever and insert anchor (clevis) pin.

8. Adjust control cable barrel so that hole in barrel centers with vertical center line of stud. Ensure that backlash center mark is aligned with edge of control cable end guide.

!

CAUTION

Do not attempt to install or remove control cable barrel from stud without first removing end guide anchor pin from shift lever and removing cable. Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur.

90-899907001 JULY 2006 Page 8F-17


9. Remove control cable end guide from shift lever by removing anchor (clevis) pin.

b a c d e

8593

Typical Bravo shift bracket shown without switch a -

Control cable end guide

b -

Clevis pin (Anchor pin)

c -

Backlash center

d -

Control cable barrel

e -

Stud

10. Install the control cable.

11. Install the washer and cotter pin to secure the barrel.

12. Install the clevis pin.

13. Install the cotter pin into the clevis pin from the top and spread the ends.

14. Remove the adjustment tool.

15. Shift remote control lever into forward position. Place end of adjustment tool in barrel retainer.

If slot does not fit over stud, loosen shift lever stud and slide stud up or down until slot in tool fits over stud. When adjustment is correct, retighten stud.

16. Lift the adjustment tool so that the slot is above the stud.

17. Shift the remote control into reverse and repeat the adjustment process.

a

8525

b a -

RH rotation Bravo One, Two, Three forward, LH rotation Bravo One and Two

reverse slot

b -

LH rotation Bravo One and Two forward, RH rotation Bravo One, Two and Three

reverse slot

18. Remove adjustment tool.

19. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180 degrees.

20. Lubricate shift cable pivot points with 30W oil.

Page 8F-18 90-899907001 JULY 2006


Changes to Shift Plate Assembly - 2003

Switch guide bosses added to hold switches in place when tightening mounting screws, switches have elongated screw slots for moving them to make the adjustment, studs and cotter pins replace threaded studs and nuts and shift levers modified.

d c b f e a b g b

21494 a b c d -

Alpha shift plate assembly (Bravo similar)

Clevis pin

Cotter pin

Shift lever with dual detents

Cast-in switch guide bosses

e -

Shift interrupt switch (Alpha only)

f -

Gear indicator switch (Alpha and

Bravo)

g -

Shift assist assembly (Alpha only)

Dual gear indicator switch detents added so that lever can be moved from run position to set position for adjusting switch (lever moves out of the way of the adjusting screws and switch plunger can also be viewed). "ALPHA" and "BRAVO" stamped on individual levers for identification.

90-899907001 JULY 2006

New shift levers for Alpha and Bravo

21499

Page 8F-19

Mercury MerCruiser Bravo One XR 1.26:1, 1.35:1, Standard, X, XZ, XR Bravo drive Service Manual

Assistant Bot

Bravo Drive History

Section 7A - Bravo Drive Unit History

Table of Contents

1988

1989

1990

1991

Bravo Oil Circulation System (1991 and Newer)

Bravo Driveshaft Housing/Gear Housing Compatibility Diagrams

1993

1995

1996-1/2

1997-1/2

Shift Changes for Bravo One/Two/Three and BlackHawk

7

1999-1/2

2000

Bravo 2000 Models

Driveshaft Housing Changes

ALUMINUM BEARING CHIMNEY IN TOP COVER

DRIVE SHAFT HOUSING BEARING CHIMNEY

DRIVESHAFT HOUSING DRIVEN GEARS

DRIVEN GEAR NEEDLE THRUST BEARINGS

DRIVEN GEAR THRUST RACES

NEEDLE THRUST BEARINGS BETWEEN THE GARTER SPRING AND THE DRIVEN GEAR

CONE CLUTCH

UNIVERSAL JOINT ASSEMBLY

SPLINED COUPLER BETWEEN UPPER DRIVESHAFT AND LOWER DRIVESHAFT

Lower Unit Changes

BRAVO ONE AND THREE LOWER DRIVESHAFT

WATER PICKUPS

HI-PERFORMANCE PROPELLER SHAFT ASSEMBLY

Transom Assembly Changes for Bravo 2000 Models

INTERMEDIATE SHIFT CABLE GUIDE EXTENSION

NEW GIMBAL BEARING

NEW UNIVERSAL JOINT BELLOWS ALUMINUM RETENTION SLEEVE

TRIM CYLINDER TILT-LIMIT SPACERS

Additional Information

INSTALLING A BRAVO X MODEL ON AN OLDER TRANSOM ASSEMBLY

BRAVO THREE DRIVESHAFT HOLDING TOOL MODIFICATIONS

NEW TOOLS FOR BRAVO 2000 MODELS

BRAVO ONE XR DRIVES GEAR RATIO CHANGE

BRAVO 2000 STYLE SERVICE REPLACEMENT GEAR SETS FOR ALL BRAVO DRIVE UNITS

NEW GEAR SETS AND GEAR KITS

REQUIRED NEW THRUST BEARING SHIM RACES

SLEEVE BEARING RACE DRIVERS

BEARING DRIVER AND CHIMNEY FOR 1999 AND PRIOR UNITS WITH OLDER BEARINGS AND

GEARS

BEARING DRIVER AND CHIMNEY FOR THE NEW DESIGNED BRAVO GEARS AND BEARINGS

WHEN USED IN 1999 AND PRIOR UNITS

BEARING DRIVER AND CHIMNEY FOR BRAVO 2000 AND NEWER MODELS

2004

U-joint Assembly (Standard and X models)

Bravo Shift Effort/Noise Reduction

REVISED SHIFT LEVER DETENT

CONE CLUTCH CHANGE

SHIFT SWITCH ADDED

Bravo Styling Change

Increased Bravo X durability

Increased Bravo XR durability

All Bravo Models will now have Shimmable Driveshaft Housing Gears for Increased

Durability

Bravo Three Changes

ADDITIONAL CORROSION PROTECTION

IMPROVED DURABILITY

NEW IMPROVED PROPSHAFT SEALS

2005

Oil Leak When Using the Current Magnetic Drain Plug in the XR or XZ Heavy-Duty

(Blue Billet) Bearing Carrier

Water Pickups and Flushing Devices Used on Bravo Drives

Bravo Driveshaft Housing Shift Shaft Bore O-ring Replaced with a New Seal

Bravo (and Alpha) GKN U-joint Tools

Bravo Standard GKN U-joint and Cross Bearing Kit

Bravo X Series GKN U-joint and Cross Bearing Kit

Bravo Bell Housing to Gimbal Housing Alignment Tool

Bravo One/Two/Three Gearcase Needle Bearing Removal Tool

Manual Outline

Section 8 - Bravo Drive Unit Service