First Outdrive Pump Change- Alpha1Gen2

[stopher]

My first change of my newly acquired 1991 Alpha1Gen2 IO Drive.

ITEM 1: upper and lower don't separate after removing 2port, 2 starboard, 1 rear, and 1 skegged annode. is there another hidden bolt after removing annode ?
....if i did get all of the bolts, is there a trick to force bonded units apart without hurting the forged aluminum ?

ITEM 2: joining lower and upper units.
mixed information on web...do I need a gasket for the circumference of the upper, lower units ?
I have the waterpump kit. it doesn't seem to have a gasket with a unit-sized circumference...gasket with waterpump kit is about size of waterpump

ITEM 3: grease tips of water pump for gentle dry breakin before pump prime. is this a good idea ? what is a good initial lube for neoprine rubber ?

 

[avpro91]

I would like those questions myself. Try posting this in ask the captain.

 

[j-d]

Actually, Engines/Electrical would be the best forum to ask in.

 

[stopher]

ANSWER:
1. use a rope to tie the lower to the upper, with 6" slack.
2. 2port,2starboard,1 rear, 1 skeg, 1 hidden bolt inside skeg hole. the hidden bolt differs across different outdrives...even alpha1G2s.
3. after disconnecting, pull to left 2 ft. and hang from tiedown. the lower unit hammocks between upper and port tiedown hook. we just made a simple "stand" for the lower without risking dropping it, or pulling our backs out.
4. "ITEM2" joinery is contained in the secondary section inside of unit. the units have raw water, but have a greased cavity that goes from lower gears, into lower unit, o-ringed off below pump. the rest of lower is wet. the upper continues that cavity through an oring connector between upper and lower.
5. neoprine pump: i use a plastic tie to give it its initial form before inserting it into the housing. then i cut the tie, pull out the tie, place the housing back on the lower unit, and am done without a need to grease the neoprine. i think the grease might not be beneficial to the neoprine life anyway. Be very sure you put the neoprine pump it in the correct orientation in the housing.
6. replace the requisite gaskets and pump everytime. also replace the orings. i made a pressure tester, but think it is probably an overkill step due to the excitement of a beginner.