Volvo Penta duoprop Outdrive - Clunks going into forward

[Split Decision]

I had a complete replacement upper and lower starboard outdrive put on our 2001 328 Four Winns earlier this summer. The drive was rebuilt by our marina and came with a one year warranty. From the first time I used the boat after replacement outdrive was installed you could clearly hear it clunked going into forward gear much louder than the original port outdrive did. The replacement starboard drive seems to run fine, shifts into reverse very similar to the original port outdrive but simply bangs louder going into forward than the port and it bugs me for it to do this being it is a rebuilt drive.

For you guys that know these drives, what would be your best guess as to the cause of this clunk going into forward? Could it be a shift cable adjustment or would it definitely be in the outdrive itself?

Thanks in advance for your thoughts.

 

[WALSHIE]

Are your RPMs the same between the port and starboard? Double check the fluid level.

 

[The Other Gary]

It could be as simple as the port outdrive cone clutches have become glazed over time and are quieter
due to their age.

 

[ddurand]

When I was in a situation with my VP duoprop drive needing to be rebuilt I did not go with the local place but had it shipped to All American Drive Service. My local place was going to be more than new a VP drive. I do not think they wanted to rebuild the drive. They had no issue putting the outdrive on a pallet for me.

Did your rebuild include replacing all the gears and bearings? Can I ask the price? I think I paid $6400 plus shipping. All gears and bearings were replaced. Two year warranty. Mine was DPX-A OXI. Now VP parts availability is a whole other issue.

The important thing when your boat is pulled and they do the outdrive service is to have the old gear oil drained into a washed/clean mayo jar so it can be evaluated. Possibly send it out for analysis. You do not want to let your warranty expire without getting to the bottom of the issue. If there is an issue.

 

[Split Decision]

Thanks gentlemen for your feedback. By the engine's tachs themselves, both port and starboard engine appear to idle very close to the same RPM. I'll see if I can verify the accuracy of both tachs this weekend. "The Other Gary's" comment about the difference in clunk vs no clunk could be due to the port outdrive cone clutches becoming glazed over time and are quieter due to their age is an interesting point of view to consider. Since the port outdrive is original and now 20 years old with about 850 hours usage. I think my replacement drive from our marina is a drive that had been disassembled and reassembled by replacing seals and gears that needed replaced and repainted. I'll bet all gears where not replaced. I'm thinking based on the feedback here and verifying both engine RPM's that I may want to consider asking our marina to pull starboard drive during our October lift out for winter storage and have them go through outdrive under warranty, unless the starboard drive does actually get quieter with further hours of use or the tachs are indeed out a bit? I appreciate all feedback..

 

[ddurand]

What was the original problem with the starboard drive? Did it involve metal bits in the gear oil? I will say that some of the gear sets on the VP outdrives are in the $1400 range. If there was any metal in the gear oil then all the bearings need to be replaced. The gear sets can be reused if not damaged. There is a screen between the upper and lower sections. But it only blocks out large pieces of metal, not fine bits that will still damage the bearings.

 

[Split Decision]

What was the original problem with the starboard drive? Did it involve metal bits in the gear oil? I will say that some of the gear sets on the VP outdrives are in the $1400 range. If there was any metal in the gear oil then all the bearings need to be replaced. The gear sets can be reused if not damaged. There is a screen between the upper and lower sections. But it only blocks out large pieces of metal, not fine bits that will still damage the bearings.

I asked my marina to check and change outdrive oils this spring before being lifted back into the water for the season. They found the drive oil was leaking and after checking drive further they advised gear damage in upper/lower to the point they felt total drive replacement was necessary. I did not get to see the gear oil before drive was replaced.

 

[ddurand]

I would get some kind of work order showing what was replaced. Every bearing needs to be replaced. Gear damage almost certainly means chunks of metal broken off. Those chunks of metal get ground down to tiny metal bits. All bearings ruined. My local shop wanted to rebuild the upper and flush out (not take apart) the lower hopefully getting all the bits of metal out. After reading and talking to knowledgeable people I decided not good enough and had the drive sent out for rebuilding.