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Tools and Parts Required to Replace the Bravo Ujoint Bellows

There are several tools required to replace the Bravo Ujoint Bellows.
It is standard practice to also replace the Gimbal Bearing, Shift Cable, water hose and somtimes the
Trim Sender Switches while the Ujoint Bellows are off.

30-803100T1 Transom Seal Kit (changes to 8M0095485)(Fits Bravo and Blackhawk) $320.00 Include Ujoint Bellows, Gimbal Bearing, Water Tube, Mounting O-Rings, Exhaust Bellows, Exhaust Tube, Shift Cable Bellows and clamps.
91-34569A1 Slide Hammer Puller Kit $ 234.00 Used to remove the gimbal bearing Only required if you are replacing the gimbal bearing
91-32325T Bearing Driver $ 52.00 Used with two other tools to drive in the new bearing. Only required if you are replacing the gimbal bearing
91-30366T1 Installer Head $ 41.00 Used with two other tools to drive in the new bearing. Only required if you are replacing the gimbal bearing
91-37323 Driver Rod $21.00 Used with two other tools to drive in the new bearing and Bellows Retainer Sleeve
91-805475A1 Alignment Tool $246.00 Used to line up the newly installed bearing and engine. This tool makes it easier to install the drive after the bearing has been replaced. Engline alignment should be checked every season.
30-862540A3 Gimbal Bearing $118.00 (changes to 879194A01) Fits R, MR, MCI, Alpha One, Alpha Gen II and Standard Bravos Included in Transom Seal Kit
92-86166Q1 Bellows Adheasive $ 10.00 Used to glue bellows and orings into place.
92-802870A1 Universal Joint and Gimbal Bearing Grease Used to grease the gimbal bearing and ujoints $15.00
16755Q1 Mounting Oring Kit $ 10.00 Included in Transom Seal Kit. Orings required to install the Bravo.
91-78310 Hinge Pin Tool $29.00 Removes hinge pins to remove bellows.
91-818169T Sleeve Removal Tool $72.00 Removes the old ujoint retainer sleeve. Not required if you don't need to reuse the retainer sleeve.
91-818162 Sleeve Installer Tool $60.00 Installs the Ujoint Retainer Sleeve. Used with driver rod and driver head.
91-45497A1 Exhaust Bellows Expansion Tool $97.00 (changes to 8M0096108) Installs the Exhaust Bellows to the Bell Housing Not required if you install the Exhaust Tube instead of the Exhaust Bellow.
91- 36569T Driver Head $18.00 Threads onto the end of the Driver Rod Used with Sleeve Installer to drive in Ujoint Retainer Sleeve.
91-43579 Tappered Insert Tool $36.00 Required to install water hose retainer inserts. The plastic Inserts lock the water hose into the bell housing and gimbal.
41674T Tappered Insert $6.00 each (requires qty 2) These plastic Inserts lock the water hose into the bell housing and gimbal.
27-44108--1 Connector Gasket $2.00 Seals the water hose connector to the inside of the gimbal. The hose connector inside the engine compartment must be removed to access the inner end of the water hose.
805320A03 Trim Sender Switch Kit $140.00 Single Station includes wires. Only required if you need to replace the sender switches.
12-41721 Side Washers $2.00 each Requires qty 2. Fits between the bell housing and gimbal ring. Plastic.
865437A02 Shift Cable Assembly $144.00 (changes to 8M0176523) Only required if you need to replace the shift cable The shift cable is typically replaced whenever replacing the bellows.

We suggest that you have a Shop Manual handy for this job.

Removing the drive unit will allow for a more complete inspection of the gimbal housing assembly.
Take the time to carefully inspect all aspects of the drive, gimbal and steering.
Plan your repair and make sure you buy all the tools and parts required to make a complete and safe repair.

Turn off your battery switch and remove the negative battery cables from the battery.

Remove the nuts from the front and rear Anchor Pins as so you can remove the Trim Cylinders from the drive.
Let the cylinders hang from their hoses out of the way.

Place the remote control into nuetral.

CAUTION: The drive unit is very heavy. Injury can result if you try to support the weight of the drive.
Support the drive with an adequate lifting mechanism when it's being removed.
Once the drive comes loose from the bell housing it will want to fall.
At the very least, have two strong people assist you while the drive is being removed.
It weighs more than 150 pounds so damage, injury or death can result if proper caution is not observed.

Lift the drive up and support it firmly in the UP position with a block of wood.
Locate the Speedometer Tube and disconnect it from the front of the drive.
This is loosened bu switching the lever of the hose connector over to one side and pulling up.

While the drive is secured in the UP position, use a slotted screw driver or a 5/16" socket and remove the rear Exhaust Bellows Clamp.
Work the rear end of the exhaust bellows free from the bell housing.

Lower the drive to the DOWN position

Remove the six drive retainer locknuts.
With the drive firmly supported, pull the drive back and off of the bell housing.

Set the drive off to the side and out of the way.

Take some time and perform a complete visual inspection of the gimbal housing assembly.
Reach into the driveshaft hole and turn the center race of the gimbal bearing.
The race must turn smooth. It must not have a loosness or free-play.
There should no water in the ujoint bellows area.
If the bearing feels bad or if there has been water getting into the ujoint bellows,
the Gimbal Bearing should be replaced.

It is easier to replace the gimbal bearing while the bell housing is removed.

You can now procede to remove the Bell Housing from the gimbal ring.

If you need to reuse the Bellows Retainer Sleeve, use the Sleeve Remover Tool along with
the Slide Hammer tool to pull out the sleeve which is locking the ujoint bellows into the bell housing.
NOTE: The Transom Seal Kit and a standard Ujoint Bellows Kit both include a new retainer sleeve.
We do not advise reusing an old sleeve unless you simply can't find a replacment.

If you don't need to save the old sleeve simply use a large screw driver and pry the old sleeve out.
Fold the bellows inward and push forward to release the bellows from the bell housing.

Next you will remove the water hose tappered insert.
Snap the Tappered Insert Tool onto the end of a long 3/8" extension.
Push the tool into the end of the exposed water hose and platic insert
Unthread (left hand) the insert from the inside of the water hose.
Push the hose forward through the bell housing to loosen it from the bell housing.

The next item to remove is the Shift Cable.
Hop up inside the boat and remove the drive shaft cable from the shift plate mechanism.
Remove the two little set screws from the black plastic guide tube on the end of the cable.
Slide the tube off the end of the cable.
Save all the parts someplace safe.

Outside the boat, pull out and remove the core of the cable.
With the core removed you can now access and remove the shift cable nut.
Once the nut is removed you can work the cable sheathing free from the front side of the bell housing.
If the brass end of the sheathing is stuck in the bell housing, wait until you have the bell housing loose from the gimbal ring.

REMOVING THE SHIFT CABLE: Once the bell housing is out of the way you can easily remove the shift cable sheathing.
BEFORE pulling the shift cable out of the gimbal you must hop up into the boat and feel down the length of the cable.
Wrapped around the cable you will find a length of spiral wrap.
You MUST remove this spral wrap before removing the cable.
You must also remove the threaded stainless tube from the end of the cable.
Loosen the brass nut and unthread the stainless tube from the end of the cable.

Turn the steering off to one side enough to gain access to one of the Trim Sender Switches.
Remove the two switch retainer screws. Pull the switch off and tie it up and above the gimbal.
Turn the steering to the other side and repeat the process with the other switch.
If you need to replace the switches you can simply cut the wires and get them out of the way.

Hinge pins are installed from the factory with locktight applyed to the threads.
If you warm the pins with a heat lamp they will be easier to remove.
With the steering still turned to one side use your Hinge Pin tool and a long breaker bar and
remove the Hinge Pin. Turn the steering to opposite side and remove the other Hinge Pin.

Now is a good time to inspect the Hinge Pins and Hinge Pin Bushings.
The plastic bushings are pressed into the side hinge pin holes in the gimbal ring.
If the hinge pins fit loosely into the bushings they should be replaced.
The new bushings are part 23-847637.
If the hinge pin threads look damaged or worn they should be replaced.
The new Hinge Pins are part 10-868014.

Now the bell housing should pull away from the gimbal and you will have access to the oil hose.
Be aware that the oil hose is still attached to the bell housing.
Use care not to pull on the oil hose as some Bravo units have a small plastic
through-gimbal hose fitting that can break off.
You CAN leave this hose attached if it is still in good condition and if you don't need to completely
remove the bell housing from the boat.
Locate the oil hose clamp where the hose attaches to the bell housing and remove the clamp.
Carefully pull the oil hose free from the bell housing and plug the end to prevent drive oil from leaking out.
Re-attaching this hose can prove to be difficult.

With the bell housing out of the way you can now completely remove the old bellows, water hose and shift cable.
Use a long 1/4" drive extension with a swival 5/16" socket and remove the forward ujoint clamp.
Also remove the front exhaust bellows clamp and the shift cable bellows clamps (if replacing the shift canle and/or shift cable bellows).

Removing the water hose requires that you hop up inside the boat and remove the water hose connector from the transom.
This Hose Connector is located just above where the driveshaft passes through the gimbal.
It is black plastic and it's held in place with two bolts.
Use a 7/16" socket on a rachett wrench and remove the two connector retainer bolts.
Some customers find it easier to first remove the engine intake water hose from the connector.
NOTE: There is a gasket between the connector and the transom which must be replaced.

With the connector remove you will be able to access the front end of the water hose and its tappered insert.
Use the Insert Tool and remove the hoses tappered insert.
Work a small screw driver between the outside of the hose and the transom to break the hose free.
Hop outsdie the boat and pull the water hose away from the gimbal and discard it.

NOTE: The hole in the gimbal where the hose resides can build up corrosion.
Inspect the hole for corrosion build up.
Use a cylinder hone tool or wire brush to remove all corrosion from the hole.
Unknown to many... this corrosion can actually collapse the hose and cause an engine overheat.
Isn't it a good thing that you decided to replace this hose?

If you havn't done so already, pull out and discard the old shift cable.
As mentioned above, you must first remove the spiral wrap and stainless tube from the cable inside the boat.

One of the last things to remove are the Trim Sender Switches (only if you plan on replacing them).
Use a 7/16" socket and remove the retainer screw from where the wires pass though the gimbal.
Disconnect the wires from inside the boat and make sure there are no retainer ties holding the wires in place.
From outside the boat, pull out the old switch wires and discard them.

Take some time and inspect all your components.
Replace any questionable parts and plan your assembly procedures.
Clean up all corrosion and grease.
Inspect the gimbal ring and steering for play and/or loosness.
Replace the gimbal ring if worn or damaged.

If you have decided to replace your Gimbal Bearing now is a good time to do so.
Follow the Replacing Gimbal Bearing Instructions.

Assembly of the gimbal is the reverse of disassembly.

Remove your new Trim Sender Switches from the package.
Notice and READ the Warning and Instruction papers that are included with the switches.
Snake the two wires in through the hole in the gimbal and position the wire-grommets into the hole.
Coat the bolt threads with Perfect seal or grease and install the retainer.
Note that the Trim Limit (TL) switch goes on the port side and
the Trim Sender (TS) switch goes on the starbord side,
Route the switches behind and up the gimbal ring on their proper sides and tie both up and above the gimbal
as so they are completly out of the way.

Inside the bilge, locate the new wires and route them neatly to where they should fasten.
The type of connectors on the ends dictate to which place they need to fasten.
Fasten the wires with tie straps as so they don;t fall onto the driveshaft.

The next item to install is the Water Hose to the gimbal.
Push the correct end of the water hose into the hole in the gimbal.
This installation is best performed with two people as the hose must be held into position.
The hose must be inserted as so the forward lip is flush the the inner gimbal.
Have an assistant hold the hose in position while you get in the boat to install the Tappered Insert.
Inside the boat, make sure the end of the hose is flush.
Apply some grease to the outside of the Tappered Insert and thread the insert into place with the Tappered Insert Tool.
Use care to make sure the hose is in the exact proper mounting position.
If there is a small bit of hose not flush it can be trimmed with a razor blade.
Install a new connector gasket and install the connector and engine water hose.

Next is the Oil Hose.
If you had disconnected or if you are replacing the oil hose, now is the time to refasten and clamp the hose.
Take the time to make sure you do this correctly.
In improperly installed hose can destroy your sterndrive unit.

Now it's time to Clamp the new Ujoint Bellows into position on the gimbal.
Coat the clean gimbal surface where the bellows clamps with Bellows Adheasive.
Coat the inside of the bellow as well.
Position the clamp on the forward end of the bellow.
Install and properly position the bellows into place before the glue has a chance to dry.
Let the glue set for 10 minutes before tightnening the clamp.
The clamp screw should be on the right side and faceing down.
Gently snug up the clamp and make sure the bellows remains in place.

You can now install either the Exhaust Bellow or the Exhaust Tube onto the gimbal.
The Exhaust Clamp Screw will be on top and facing towards the port side.
Snug up the clamp.
If you have elected to replace the Shift Cable now is the time.
Unpack the new cable and remove the core from the sheathing.
Coat the gimbal with bellows adheasive where the shift cable bellows mounts.
Coat the inside of the bellow and install the shift cable bellows onto the gimbal.
Let the glue set up for 10 minutes and then gently snug up the hose clamp.

Squirt a little grease into the small end of the new shift cable bellows.
Carefully force the end of the cable through the bellows and into the bilge.
Have an assistant up in the engine compartment with a long screw driver nudge the cable over
to the stb side of the bilge as you push the cable inward.
If you fail to nudge the cable to one side there is a chance it will enter the flywheel housing and get jammed in there.
Place the Shift Cable Gasketonto the brass end and coat with Perfect Seal.
Slip the brass end of the cable into the hole in the bell housing and install the Cable Nut.
Do not over-tighten the cable nut.
Do not install the cable core at this time.

You are now ready to get the bell housing up into place.
Smear a little grease into the gimbal ring hinge pin holes.
Move the bell housing into place while getting the rear end of the water hose into the hole.
Pull the ujoint bellows into the bell housing as so it's lip locks into place.
Turn the steering to one side enough to get one hinge pin in place.
Be sure that you have the side washer and the bushing in place.
Put a drop of locktight on the threads of the hinge pin and screw it into place.
This can be a little difficult and you have to have the bell houding properly lined up with the gimbal ring
Do not cross-thread the himge pin.
Torque the Hinge Pin to 150 ft. lbs.
Turn the steering to the opposite side and repeat the hinge pin installation.

Do not install the Trim Senders at this time.

With the bell housing mounted to the gimbal ring you can now proceed with installing the
bellows retainer sleeve, water hose, shift cable, exhaust bellows, drive and trim senders.

SECRET: Installation of the Bellows Retainer Sleeve is much easier if you coat the rubber with Mercury Power Tune.
Soapy water can also be used but we have found Power Tune to be the best.

Assemble your Sleeve Installation Tool onto the end of the driver head and driver rod.
Slip the new Retainer Sleeve onto the tool.
Using a good heavy dead blow hammer drive the sleeve into place.
Double check that you have properly installed the bellows and sleeve.
Failure to properly install the bellows and sleeve will cause the boat to sink.

Pull the water hose into the hole of the bell housing and leave a little bit (1/16") hanging out.
Grease the outside of the plastic insert and thread into the hose with the Insert Tool.

If you have decided to install an Exhaust Bellow you will need to use your Expansion Tool.
Place the rear exhaust bellows clamp into position.
You do NOT need to use bellows adheasive on the exhaust bellow although some prefer to use it anyway.
Reach the tool in through the bell housing exhaust passage and grip the inside of the first "rib" with the tool.
Expand the tool and place the clip in the end of the tools handle to keep it expanded.
Pull the tool back as so to slip the Exhaust Bellows into place on the bell housing cuff.
Slip the tools cross-pin in through the handle of the tool to hold the toll back.
Lift the bell housing and tighten the clamp.
Remove the tool.

Inspect all your work.
Do not take shortcuts.
Chances are if you feel you did something wrong... you did.
Now is the time to go back and correct the problem.

Now you have to install the shift cable core and adjust.
Slip the cable core into the sheathing.
DO NOT GREASE THE CORE.
Install the Shift Cable Core Locating Tool to the gimbal to lock the core into place.
Inside the boat, place the Cable Adjustment Tool onto the end of the cable and adjust the barrel to fit.
Assemble the cable to the shift plate mechanism and leave in nuetral.
Remove the Locating Tool from the bell housing.

Now you can install the drive unit.
Glue the new orings to the front of the drive with bellows adheasive.
Install new orings on the driveshaft.
Clean the splines of the driveshaft and grease the splines and the orings.

It is best to have the gimbal at the correct installation height as so you don;t have to lift the drive during installation.
Smear a little grease onto the mounting studs and get the drive into position.

Move the drive into place while passing the driveshaft in through the center of the gimbal bearing.
Make sure that the end of the shift cable passes correctly into the "clapper" mechanism on the drive.
Gently push the drive up into place turning the prop if need be to line up the coupler splines.
Fasten with one nut and inspect your installation to this point. Rest.

Install the remaining hardware and trim cylinders.

Check the oil in the drive and lube monitor bottle.

Test the shift before placing the boat into service.
Check for water leaks

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