  

 

 
 DP-E, SP-E

Contents

Introduc
ntroducti
tio
on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Removal
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
.7

Upper Gear
Gear Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Universal
Universal Joint
oint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
. 12

Shift
hift Mecha
Mechani
nism
sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
. 23

Intermediate
Intermediate Housi
Housing
ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
. 25

SP-E Lo
Lower
wer Uni
Unitt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
. 29

DP Lo
Lower
wer Unit
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
. 39

Sterndrive Install
Installatio
ation
n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
. 57

Transom
ransom Shi
Shiel
eld
d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
. 63

Trim
rim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Electrical
lectrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
. 73

Weldi
Welding
ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
. 75

Painti
ainting
ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
. 77

Technical
echnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Too
oolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
. 81

INTRODUCTION
This
This Workshop
W orkshop Manual
Manual contains
c ontains technical specifications,
specif ications,
Check that the warning or information labels on
INTRODUCTION
This
This Workshop
W orkshop Manual
Manual contains
c ontains technical specifications,
specif ications,
descriptions, and instruct ions for the
t he repair of the
t he Volvo
Volvo Penta
Penta Check that the warning or information labels on
products or product types described in the Table of Con- the product are always clearly visible. Replace
tents. Check that
t hat you have
have the correct Workshop Manual
Manual for labels which have been damaged or painted
the product you are servicing.
servicing. over.
Before starting work on the engine be sure to read, Engines
Engines equipped with turbocharger: Never
Never start
follow and underst and the “S
understand afety Precautions,” “Gen-
“Safety the engine without installing the air cleaner fil-
eral Information,” and “Repair Instructions” sections of ter. The rotating
rotating compre
c ompressor
ssor in the turbo
t urbo can
this W orkshop Manual.
Workshop cause serious personal injury. Foreign objects
In this book and on the product you will find the following entering the intake ducts can also cause me-
special warning symbols: chanical damage.

Never use ether spray or similar starting fluid

Special instruct ions to aid assembly.
assembly.
when starting the engine. They may cause an
explosion in the inlet manifold. There is a real
Indicates an potentially hazardous
situation which, if not avoided, may result in minor or moderate danger of personal injury.
injury. It may also be used to alert against unsafe practices.
Avoid opening the filler cap for engine coolant
Indicates a potentially hazardous situation systems (freshwater cooled engines) when the
which, if not avoided, could result in death or serious injury. engine is still hot. Steam or hot coolant can
spray out. Open the filler cap slowly and release
the pressure on the system. Take great care if a
Indicates an immediately hazardous cock, plug, or engine coolant line must be re-
situation which, if not avoided, will result in death or
moved from a hot engine. Steam or hot coolant
serious injury. This is a signal word is used in only the
most extreme situations. can spray out in any direction.

Below is a summary of the risks involved and safety precau- Hot oil can cause burns. Avoid getting hot oil on
tions you should always observe or carry out when operating the skin. Ensure that the lubrication system is
or servicing the engine. not under pressure before carrying out any work.
Never start or operate the engine with the oil
Immobilize the engine by turning off the power
cap removed;
removed; otherwise, oil could
c ould be ejected.
eject ed.
supply to the engine at the main switches and
lock it (them) in the OFF position or by discon- Stop the engine and close the sea cock before
necting the battery negative (-) lead. carrying
carrying out operations on the engine cooling
system.
As a general rule, all service operations must be
carried out with the engine stopped. However, Only start the engine in a well-ventilated area. If
some operations, such as certain engine adjust- operating the engine in an enclosed area, en-
ments, will require the engine to be running. sure that there is exhaust ventilation leading out
Approaching an engine that is operating is a of the engine compartment or workshop area to
safety risk. Loose clothing or long hair may be remove exhaust gasses and crankcase ventila-
caught in rotating parts and cause serious injury. tion emissions.
If working in the proximity of an engine when it is
operating, careless movements, or a dropped
tool can result in personal injury or damaged Always use protective glasses or goggles
gogg les when
carrying out work where there is a risk of splin-
equipment. Take care to avoid contact with hot
surfaces; e.g., exhaust pipes, turbocharger, air ters, grinding sparks, acid splashes, or where
intake pipe, start element, etc.; and hot liquid other chemicals are used. The eyes are ex-
lines and hoses on an engine which is running tremely sensitive: an injury could result in blind-
or which has just been stopped.
stopp ed. Reinstall
Reinstall all ness!
protective parts removed during service opera-
tions before starting the engine.

Avoid getting oil on the skin! Repeated exposure Never expose a battery to open flame or sparks.
 Avoid getting oil on the skin! Repeated exposure Never expose a battery to open flame or sparks.
to oil or exposure over a long period can result Never smoke in the proximity of batteries. The
in the skin becoming dry. Irritation, dryness, and batteries give off hydrogen gas during charging
eczema and other skin problems may occur. which, when mixed with air, can form an explo-
From a health perspective, used oil is more dan- sive gas - oxyhydrogen. This gas is easily ignited
gerous than fresh oil. Use protective gloves and and highly volatile. Incorrect connection of the
avoid oil soaked clothes and shop rags. Wash battery can cause an explosion with resulting
regularly, especially before eating. There are damage. Do not shift the connections when
special skin creams which counteract drying out attempting to start the engine (spark risk) and do
of the skin and make it easier to clean off dirt not lean over any of the batteries.
after work is completed.
Always ensure that the Plus (positive) and Minus
Many chemicals used on the product (for ex- (negative) battery leads are correctly installed
ample, engine and transmission oils, glycol, on the corresponding terminal posts on the bat-
gasoline and diesel oil), or chemicals used in the teries. Incorrect installation can result in serious
workshop (for example, de-greasing agents and damage to the electrical equipment. Refer to
solvents) are dangerous to health. Read the wiring diagrams.
instructions on the product packaging carefully!
Always follow the safety precautions for the Always use protective goggles when charging
product (for example, use protective mask, the batteries. Battery electrolyte contains sulfu-
glasses, gloves etc.). Make sure that other per- ric acid, which is highly corrosive. If the battery
sonnel are not exposed to hazardous chemicals electrolyte comes into contact with unprotected
(for example, in the air). Ensure good ventilation skin, wash immediately with plenty of water and
in the work place. Follow the instructions pro- soap. If battery acid comes in contact with the
vided when disposing of used or leftover chemi- eyes, immediately flush with p lenty of water
cals. and obtain medical assistance at once.

Exercise extreme care when leak detecting on Turn off the engine and turn off power at the
the fuel system and testing the fuel injector jets. main switch, or disconnect the battery negative
Use eye protection. The jet from a fuel injector (-) lead, before carrying out work on the electri-
nozzle is under extremely high pressure and has cal system.
a great penetrative energy, so the fuel can pen- Clutch adjustments must be carried out with the
etrate deep into the body tissue and cause seri- engine stopped.
ous personal injury. There is a real danger of
blood poisoning. Use the lifting eyes fitted on the engine/reverse
gear when lifting the drive unit. Always check
All fuels and many chemical substances are that the lifting equipment used is in good condi-
flammable. Do not allow open flame or sparks in tion and has the load capacity to lift the engine
the vicinity. Fuel, certain thinner products, and (engine weight including reverse gear and any
hydrogen from batteries can be extremely flam- extra equipment installed)
mable and explosive when mixed with air. Smok-
ing is p
prohibited
rohibited in tthe
he vicinity!
vicinity! Ensure the work Use an adjustable lifting beam or lifting beam
area is well ventilated and take the necessary specifically for the engine to raise the engine to
safety precautions before starting welding or ensure safe handling and to avoid damaging
grinding operations. Always ensure that there engine parts installed on the top of the engine.
are fire extinguishers on hand when work is be- All chains and cables should run parallel to each
ing performed. other and as perpendicular as possible in rela-
tion to the top of the engine.
Ensure that rags soaked in oil or fuel and used
fuel or oil filters are stored safely. Rags soaked If extra equipment is installed on the engine,
in oil can spontaneously ignite under certain which alters its center of gravity, a special lifting
circumstances. Used fuel and oil filters are envi- device is required to obtain the correct balance
ronmentally dangerous waste and must be dis- for safe handling.
posed at an approved site for disposal together
with used lubricating oil, contaminated fuel, Never carry out work on an engine suspended
paint remnants, solvents, de-greasing agents, on a hoist without other supporting equipment
and waste from washing parts. attached.

About this Workshop Manual

Manual
Never work alone when removing heavy engine
 About this Workshop Manual
Manual
Never work alone when removing heavy engine
components, even when using lifting devices This Workshop Manual contains technical specifications,
such as locking tackle lifts. When a lifting de- descriptions and instructions for the repair of the SP-E, and
DP-E Sterndrive. As a result, the illustrations and pictures in
vice is in use, two people are usually required to
the manual that show certain parts on the sterndrive do not, in
do the work: one to take care of the lifting de-
some cases, apply to the variations of the specific models of
vice and the other to ensure that components the SP-E, and DP-E Sterndrive. However, the repair and
are lifted clear and are not damaged during the service operations described are essentially the same. Where
lifting operations. If working onboard a boat, the difference is considerable the operations are described
check before starting work to make sure there is separately. The SP-E, and DP-E model designation and serial
enough room to carry out removal work without number can be found on the product plate located on the
risking personal injury or damage to the engine upper gear housing. Always include the model designation
or parts. and the serial number in all correspondence.

The components in the electrical system, in the The Workshop Manual is produced primarily for the use of
ignition system (gasoline engines), and in the Volvo Penta workshops and service technicians. For this
fuel system on Volvo Penta products are de- reason the manual assumes a basic knowledge of marine
propulsion systems and that the user can carry out the work
signed and manufactured to minimize the risk of
described to a general standard of engineering competence.
fire and explosion. The engine must not be run in
areas where there are explosive materials. Volvo Penta products are under a continual process of
development and we therefore reserve all rights concerning
Always use the fuel and lubricating oil recom- changes and modifications. All the information in this manual is
mended by Volvo Penta. Refer to the appropri- based on product specifications available at the time of
ate Owner’s Manual. Use of fuel and lubricating printing. Any changes or modifications introduced into
oil that are of a lower quality can damage the production or updated or revised service methods introduced
engine or sterndrive. On a diesel engine, poor after the date of publication will be provided in the form of
quality fuel can cause the actuating rod to seize Service Bulletins.
and the engine to over-rev with resulting risk of ReplacementParts
damage to the engine and personal injury. On
gasoline engines, poor quality fuel can lead to Replacement parts for the sterndrive are subject to various
national safety requirements, for example the United States
detonation on server engine damage and short-
Coast Guard Safety Regulations. Volvo Penta original spare
ened engine life. Poor fuel and lubricating oil parts meet these specifications. Any type of damage which is
quality can also lead to higher maintenance the result of using replacement parts that are not original
costs. Volvo Penta spare parts for the product being serviced, will
not be covered under any warranty or guarantee provided by
Volvo Penta.

The working methods described in the Workshop Manual degreasing agents for all cleaning of components unless
 The working methods described in the Workshop Manual degreasing agents for all cleaning of components unless
apply to work carried out in a workshop. otherwise stated in the Workshop Manual. When working on-
board a boat, make a special point of preventing oil waste
Carefully observe the safety alert symbols shown for dangers,
water from washing components entering the bilge; instead,
warnings, and cautions as shown below. They warn you of
remove all such waste for safe disposal at an approved site.
possible dangers or important information contained in this
manual. TighteningTorques
These instructions are not in any way comprehensive, since it The correct tightening torques for critical joints which must be
is impossible to predict every circumstance under which tightened using a torque wrench are listed under “Technical
service work or repairs may be carried out. Volvo Penta can Specifications - Tightening Torques” and st ated in the method
only indicate the risks considered likely to occ ur as a result of descriptions in the Workshop Manual. All tightening torques
incorrect working methods in well equipped workshops using apply to cleaned threads, bolt heads, and mating surfaces.
approved methods and tools tested by Volvo Penta. Tightening torques stated are for lightly oiled treads. Where
grease, locking, or sealing agents are required for screwed
All operations described in the Workshop Manual for which
joints, it is so stated in both the operation description and in
there are Volvo Penta special tools available assume that
“Tightening Torques.” Where no tightening t orque is stated
these tools are used by the service technician or person
for a joint use, refer to Volvo Penta’s General Information
carrying out the repair. Volvo Penta special tools have been
manual (P/N 773107 3-8) for information on tightening
specifically developed to ensure as safe and rational working
torques. The tightening torques stated are a guide and the
methods as possible. It is, therefore the responsibility of the
joint does not have to be tightened using a torque wrench.
person or persons using tools other than Volvo Penta special
tools or approved Volvo Penta working methods (as de- Lock Nuts
scribed in a Workshop Manual or Service Bulletin), to acquaint
Do not reuse lock nuts that have been removed during
themselves of the risk of personal injury or actual mechanical
disassembly operations, since they have reduced service life
damage or malfunction that can result from failing to use the
when reused. Use new nuts during assembly or reinstallation.
prescribed tools or working method.
For a lock nut with a plastic insert (such as Nylock® nut) that
In some cases, special safety precautions and user instruc- has the same head height as a standard hexagonal nut
tions may be required to use the tools and chemicals men- without plastic insert, reduce the tightening torque by 25%
tioned in the Workshop Manual. Always follow these precau- for bolt size 8mm or larger. Where Nylock® nuts are higher, or
tions as there are no specific instruct ions given in the Work- of the same height as standard hexagonal nut, the tightening
shop Manual. torques given in Volvo Penta’s General Information manual
apply.
By following these basic recommendations and using com-
mon sense, it is possible to avoid most of the risks involved in StrengthClasses
the work. A clean work place and a clean engine will eliminate
Bolts and nuts are divided into different classes of strength;
many risks of personal injury and engine malfunction.
the class is indicated by the number on the bolt head. A high
Above all, when working on the fuel system, engine lubrication number indicates stronger material; for example, a bolt marked
system, air intake system, turbocharger unit, or bearing seals 10-9 indicates a higher strength than one marked 8-8. It is
it is extremely important to observe the highest standards of important, then, that bolts removed during t he disassembly of
cleanliness and avoid dirt or foreign objects entering the parts a bolted joint must be reinstalled in their original position when
or systems, since this can result in reduced service life or you reassemble the joint. If a bolt must be replaced, check in
malfunctions. the replacement parts catalog to make sure the correct bolt is
used.
Bear in mind that most of the chemicals used around boats
are harmful to the environment if used incorrectly. Volvo Penta
recommends the use of biodegradable

Sealant Room Temperature Vulcanizing (RTV) agents. These agents

 Sealant Room Temperature Vulcanizing (RTV) agents. These agents
are used for gaskets, sealing gaskets joints, or c oating
A number of sealants and locking liquids are used on the
gaskets. RTV is visible when a part has been disassembled;
engines. The agents have varying properties and are used for
old RTV must be removed before re-sealing the joint.
different types of jointing strengths, operating temperature
ranges, resistance to oil and other chemicals, and for different The following agents are mentioned in the Service Manual:
materials and gap sizes in the engines.
• Locktite® 574 1
To ensure service work is c orrectly carried out, it is important • Volvo Penta P/ N 840879-1
that the correct sealant and locking fluid type is used on the • Volvo Penta P/ N 1161099-5
joint where the agents are required. • Volvo Penta P/N 1141570-0 Sealant
Wherever appropriate, your Volvo Penta Workshop Manual • Permatex® No. 31
will indicate the proper sealants and locking liquids. • Permatex® No. 771
During service operations use the same agent or an alternative In all cases, old sealants may be removed by using methylated
from a different manufacturer. spirits.

Make sure that mating surfaces are dry and free from oil, Anaerobic agents. These agents cure in an absence of air.
grease, paint, and anti-corrosion agents before you apply They are used when two solid parts, (for example, cast
sealant or locking fluid. Always follow the manufacturer's components) are installed face-to-face without a gasket. They
instructions for use regarding temperature range, curing time are also commonly used to secure plugs, threads in stud
and any other instructions for the product. bolts, cocks, oil pressure switches, and so on. The cured
material is glasslike and is therefore colored to make it visible.
Two different basic types of agents are used on the engine: Cured anaerobic agents are extremely resistant to solvents
room temperature vulcanizing agents and anaerobic agents. and the old agent cannot be removed. When reinstalling, the
part is carefully de-greased, then new sealant is applied.
The following anaerobic agents are mentioned in the Work-
shop Manual:
Loctite® 572 (white)1
Volvo Penta P/N 1161053-2 Thread Lock (Blue)
1
Loctite® is the registered trademark of Loctite corporation, Perma-
tex® is the registered trademark of the Permatex Corporation.

REMOVAL
 REMOVAL

Disconnect power to prevent accidental starting.

Remove the shift linkage cover.

VO
VOL
TA
PEN

Move control to reverse.

Remove the cotter pin and washer from the shift cable end.
Remove the end pivot pin from the cable.

Loosen propeller cone lock bolt.

Remove the aft propeller cone.

Move control to forward gear.

Loosen screw holding the shift cable clamp and release shift
cable.

Remove the aft line cutter, forward propeller nut, and forward
propeller. Return the shift control to neutral.

7
 1
3
2

Remove the two screws (1) holding the steering pin to the
upper gear head. Using two M6 screws 30mm or longer,
install into the threaded holes of the steering pin. As the
screws are turned in, the steering pin will be forced out of the
steering pin socket and steering helmet bushing. Remove the clamp on the raw water hose. Remove the raw
water hose. Remove special tool 88514 3-8 and carefully
lower the drive.

Remove the hook-up fork pin lock bolt. Using Pin removal tool
P/N 885148-7, pull the pin half way out of the transom shield.
Using special tool P/N 884573-7, remove the clamp around
the u-joint bellows.
Do not remove the pins completely, the
sterndrive will fall off the boat.

Remove the cotter pin on the trim cylinder pin. Remove the
trim cylinder pin. Raise the drive manually and insert special
tool 885143-8.
Install special tool 885146-1 and remove the sterndrive from
Only use special tool 885143-8 to secure the transom shield.
outdrive. Serious injury may result if sterndrive is not properly
blocked. See Installation found elsewhere in this manual.

Using special tool 884573-7, disconnect the exhaust bellows.

UPPER GEAR HEAD

Removal Disassembly
 UPPER GEAR HEAD
Removal Disassembly

GR970385
Place a 4 quart drain pan under the sterndrive. Remove the
drain plug and drain oil from drive. Reinstall the drain plug after
the oil has drained.

GR970034
1. Install the upper gear housing on special tool P/N 883830.

GR990976
Remove cotter pin and washer from gear shift linkage, and
remove the linkage.

GR970035
2. Remove the 4 screws holding the shift mechanism and
remove the mechanism.

Be sure to remove the shift shoe with the shift

mechanism.
GR990975
Remove two retaining nuts from upper gear head studs.

GR990974
Remove two allen head retaining bolts. Remove the gear GR970083
head. 3. Loosen and remove the 4 allen head bolts holding the
double bearing box.

9
 GR970038
7. Remove the LE FT HAN
LEFT HAND D TH
THR READ nut on the vertical
GR970036 shaft. Use special tool P/N 884 830 and the spline shaft as a
4. Pull out the double bearing box by pulling and turning counter-hold while removing the nut.
simultaneously. Use strap wrench P/ N 999917 9-6 to rotate
the double bearing box.

Do not damage or lose the shims.

GR970039
8. Lift out the upper bearing assembly along with the sliding
GR970086 sleeve and the spring.
5. Remove the 4 screws holding the gear housing cover.

1
2

GR970040
9. Lift out the upper gear housing from the special tool.
Disassemble the bearing assembly and shaft by lifting the
shaft enough to remove the split locking ring (1), then the
thrust washer (2).

Do not scratch the sliding sleeve or the gear cups

while removing them.

GR970037
6. Remove the cover.

The front right hand screw is a hollow screw with an

O-ring. Do not damage or lose the shims for the cover.

10
 GR970045
13. Use special tool P/N 3850608 to remove the locking ring,
remove the shoulder washer.
GR970041
10. Remove the needle bearings from the upper and lower The seal ring can be removed at a later time.
gear cup assemblies.

Do not mix upper and lower needle bearings.

GR970042
11. Press out the upper and lower gear wheels from the
bearings. Mount the bearing and gear assembly in holding GR970046
fixture P/N 8849 38, use special tools P/N 884259 with 14. Press out the input gear. Use special tool P/N 884938 and
handle 9991801. 884266. Remove the crush sleeve and discard.

GR970044
GR970047
12. Brace the universal joint in a vice. Use soft jaws to protect
15. Turn over the double bearing box and press out the seal
the universal joint. Use special tool 8850 43 to remove the ring along with the roller bearing. Use special tool P/ N
TX50 torx head screw and the tapered washer; discard the
884263.
screw. Remove the double bearing box from the universal
joint.

11

Recondition Universal Joint

 Recondition Universal Joint

GR970048

GR980766
The bearing will be damaged if removed, only 1. Remove the locking rings (1) holding the needle bearing in
remove if a new bearing will be installed. the yoke.
16. Use a “knife puller” to remove the roller bearing from the
gear (if necessary). Also use special tool P/N 884266. To avoid having the locking rings “jump out” and
getting lost, hold a rag over the universal joint when removing
the locking rings.

GR980767
2. Hold the universal joint in your hand and strike with a
hammer until the bearing emerge from the yoke.

Do not strike the splines or sealing surfaces.

GR970049 The universal joint will be damaged and must be replaced.
17. When replacing the outer bearing races, the bearing
races must be pressed
pressed out. Use special tool P/N 9991801
handle with 88 4938 and 884933 holding fixture. If neces-
sary, recondition the universal joint.

GR980768
3. Try to ease out the bearing using a pair of pliers or Channel
Lock® pliers. If this is unsuccessful the bearing can be driven
out by using a hammer and a drift punch. Once the bearings
are removed, remove the spider from the yoke.

12

24
 24
27

29
25

31

32
26
30 28
GR980769
4. Inspect the spider (29) and needle bearings for play in the
yokes (25, 27, and 24) and possible wear marks in the
bearing races (30). If faulty, the spider (29) and needle
bearing caps (30) must be replaced as a complete unit.DO DO
NOT
NOT install new bearings and caps onto a used spider or
vice-versa. If the bearing caps (30) are found to have play in
the yokes (25, 27, and 24), the yokes must also be replaced.
5. Install new seal washers (31) on t he spider. Feed the
spider in t he yoke.

GR980771
6. Use a small amount of water resistant EP bearing grease
to retain the needle bearings in the cap. Push the spider
through the yoke in one directions to allow the needle bearing
to align with the spider. Push the needle bearing cap into the
yoke with the spider inside the needle bearing cap to keep the
needle bearings in place. Press the needle bearing cap into
the yoke far enough to allow the lock ring t o be installed.
Install the remaining needle bearing caps in the same manner.
Be extremely careful when pressing the
needle bearing caps into place.The needle bearings may
come loose and fall to the bottom of the bearing cap. DO
NOT
NOT force the needle bearing caps onto the spider. If the
locking grooves for the needle bearings caps do not readily
align, a bearing may have come loose and fallen to the bottom
of the cap.

13

Assembly
 Assembly
When assembling the upper gear housing it is very important
that the drive gears and shift gears are installed in the correct
positions relative to each other. This applies not only to the
backlash between the teeth, but also to the gear teeth
contact. Correct gear teeth contact spreads the load over a
larger area of the gear tooth. This prevents gear break down
and abnormal wear and, at the same time, provides quiet
operation.

GR970052
3. Install the input gear in the double bearing box and press
on the smaller roller bearing, leaving approximately 1mm
clearance. Use special tool P/N 884 263 and 88 4259 to
protect the gear wheel.

GR970053
1. Install the outer bearing race. Use special tool P/N 8849 32
and handle 9991801 .

Make sure that the double bearing box is positioned

horizontally. Turn the special tool over to use the small
diameter when installing the other bearing race.

GR970053
4. Press the seal ring until seated against t he shoulder. Use
special tool 884938 with handle 9991801 and 884932. Use
special tool P/N 3850608 to install the lock ring.

GR970051
2. Install the larger roller bearing on the input gear by pressing
it on. Use special tool P/N 88 4263. Inst all a new crush
Install
sleeve.

Protect the gear teeth while pressing on the

bearing.

14

Forward and Reverse Gears

 Forward and Reverse Gears

GR970054
5. Coat the shoulder washer O-ring with petroleum jelly, then
install it on the spline shaft of the universal joint.

The O-ring must face the universal joint.

GR970057
1. Lubricate the bearings with synthetic gear lube API GL-5.
Press the bearing onto their respective gears. Use special
tool P/N 884168.

Protect the gear cups during pressing operations.

GR970055
6. Install the clamp ring and the double bearing box on the
universal joint. Install the tapered washer and new torx head
screw
screw. Coat the screw thread with Volvo Penta P/N A
1161053 thread locking compound. Always use a new screw
during final assembly. Tighten the screw with special tool P/ N
885043. NOTE! If the screw is tightened too much and
preload becomes too high, the double bearing box must be
disassembled and a new crush sleeve must be installed.

GR970058
2. Always start by adjusting the forward gear (A). If the
previously dismantled gears are to be used, it is important not
to mix forward and reverse gears with each other when
assembling.

GR970056
7. Check the bearing preload between tightening intervals
with spring scale Volvo Penta P/N 9985494. Preload new
bearings to at least 500 grams minimum and 1000 grams
maximum. Preload used bearings to 500 grams minimum and
800 grams maximum.

15

Shimming
 Shimming
Method 1

GR970061
3. Only the decimal values of the “B” and “C” dimensions are
stamped into the upper gear housing. The nominal value for
both “B” and “C” is 61.00mm. Add this value to the value
stamped into the gear to calculate shims for the forward and
reverse gears.
A The shim calculations can be seen in the example below:
Measurement A 62.05mm (Fixed Dimension)
+ 0.05mm (Gear Etching)
62.10mm
“C” Stamping – 61.78mm
0.32mm (0.013 in.)
The shim thickness for the forward gear is 0.32mm (0.013 in.)
The shim thickness for the reverse gear is calculated the same
way, only using the “B” stamping.
GR970059
1. Measurement “A” is a fixed distance at 62.05mm for W hen calculating the shim thickness for the forward
calculating shims. and reverse gears, remember:
The upper gear housing nominal dimension has two
values
values.
If the stamped number is 50 or more,
more, use the lower
lower nominal
value, 61.00mm.
If the stamped number is 49 or less,
less, use the higher
higher nominal
value, 62.00mm.
Example: Stamping 50 or more
“C” stamping: 78 = 00.78mm
+5 Use Nominal Dimension = 61.0 0mm
61.78mm

Example: Stamping 49 or less

+.05mm
05mm “C” stamping: 43 = 00.43mm
GR970060 Use Nominal Dimension = 62.00mm
2. Add or subtract the value marked on t he gear.
62.43mm

All markings are in hundreds of millimeters (e.g., +5

= 0.05mm.)

16

Method 2
Method 2
1. Insert a 0.2mm shim under both forward and reverse gears
as a starting point. The shim value is a number derived from
experience. Then follow the procedure in points 2 through 10
below.

Backlash and Contact Pattern

GR970066
5. Install the pre-assembled double bearing box with 0.4mm
shim. Make sure not to squeeze the shims in the O-ring
groove. Tighten the 4 Allen head screws.

GR970063
2. Install the forward gear with t he calculated shims into the
gear housing. Insert the needle bearings and the vertical shaft.
Install the reverse gear into the gear housing, using the needle
bearings as a guide.

Split Lock
Ring
GR970084
Locking
Washer 6. Use sufficient number of shims to create 0 .1mm clearance
between the top cover and the upper gear housing. Install the
cover and tighten the cover screws.

GR970064
3. Insert the washer and the split lock ring and tighten the
“Left Hand nut” at the opposite end of the vertical shaft. Use
0
90 10
80 20

70 30

special tool 3850598.

60 40
50

GR970069
7. Install a dial indicator to measure backlash. The correct
backlash should be 0.15 – 0.25mm. If the backlash is too
tight, shims must be added between the double bearing box
and the gear housing. If the backlash is too loose, shims must
be removed from the double bearing box. A shim thickness of
0.10mm is a safe adjustment step.

GR970065
4. Brace the special tool P/N 885 152 plate and ring in a vise
and install the gear housing in the tool.

17

and positioned halfway on the gear tooth. It should be slightly

 and positioned halfway on the gear tooth. It should be slightly
toward the gear cup but not running off the end of the gear
tooth.

B
GR970070
8. Install the double bearing box when the correct backlash
has been obtained.
To gain a clearer picture of the contact pattern, coat the gear 11. If the dye pattern shows cont act, as shown in picture “B,”
teeth with a thin coating of marking dye. Then install the the shim thickness for the double bearing box must be
double bearing box again. reduced. The input gear moves toward the forward and
reverse gears. The forward and reverse gears must be
shimmed the same amount to maintain the correct backlash.

GR970071
9. Rotate the gears in the normal direction of rotation while 12. If the dye pattern shows contact as shown in picture “C,”
wedging a wooden brace against the gear cups. The marking the shim thickness underneath the double bearing box
dye will be pressed away from the point of contact on the
gear tooth face, which will show a picture of the contact
pattern.

GR970072
10. Dismantle the gear set and compare the contact patterns
to that of picture “A.” This picture shows the desired contact
pattern for the drive side of the forward and reverse gears.
The drive side is the convex side of the gear. The dye pattern
should be oval in shape

18

Assembling the Upper Gear

Assembling the Upper Gear

GR970077
GR970075
Install the needle bearings and the spacer ring between the
Install the lower gear unit along wit h the calculated number of
bearings in the lower gear and insert the shaft in the gear.
shims.

The needle bearings are matched in pairs and must

not be mixed up.

GR970076
Install the washer (1), the locking ring (2), the spring (3) and
the engagement sleeve (4) onto the shaft (5).

The end of the engagement sleeve marked “TOP”

must be facing upwards on the shaft. On earlier models there
is a drilled recess, which must be turned upwards. The
engagement sleeve must rest lightly on the spring. Feel by
hand to make certain.

GR970078
Install the washer and the split locking ring. Then place the
gear housing in the splines sleeve P/N 884 830.

Carefully inspect the condition of the brass washer

and replace if necessary.

19
 GR970081
Measure the clearance between the nut and the bearing. The
axial clearance should be 0 .1-0.5mm. If it is not possible to
obtain the correct clearance with any of the nuts, most
probably the bearing is defective.

GR970079
Place the upper gear wheel with the calculated shims in the
gear housing. Install the needle bearings along with the
spacer ring between the bearings.

1 GR970082

Install the shims and the new O-ring on the double bearing
box.

GR970080
In order to obtain the correct axial clearance, there are three
left hand threaded nuts with shoulders of different thicknesses
(1). Select a nut and tighten it with a tightening torque of 120
N•m (88.3 ft. lb.).

Lubricate the threads with gear lube to prevent the

nut from galling.

GR970083
Coat the surfaces between the double bearing box and the
gear housing with Volvo Penta White Sealing Compound for
Drives P/N 1141570-0 or its equivalent. Install the double
bearing box with the universal joint in the gear housing. Coat
the screws with Loctite locking fluid or its equivalent and
tighten them with a torque of 35 N•m (25.8 ft. lb.).

20

Shimming Upper Gear to Intermediate

 Shimming Upper Gear to Intermediate
Housing

A
GR970084
Install a sufficient number of shims underneath the cover to
obtain a clearance of max 0.1mm between the cover and the
gear housing. Locate the cover and push it lightly into position
and measure the clearance all around with a feeler gauge.

GR970374
Measure the distance from the bottom of the upper gear
housing to the top of the outer bearing race (A). Record the
measurements in the table below.

The shift mechanism must be in neutral (if installed)

to achieve and accurate measurement.

1
B
GR970085
Coat the cover with Volvo Penta White Sealing Compound for
Drives P/N 1141570-0 and install the sealing ring (1) so that
the sealing for the front, right hand screw ends up in the
recess of the cover, provided for it.

GR970373
Measure the distance from the top of the intermediate
housing and the upper gear head lower bearing outer race
seat. (B). Record the measurement in the table below.

B mm
- A mm
Clearence mm
+ 0.06 mm
Shims Required mm
UPPER SHIM TABLE
GR970086 Subtract the upper gear head bearing thickness (A) from the
Insert the calculated shims and tighten the cover. intermediate housing measurement to find the bearing
clearance. Add enough shims to take up the clearance plus
The front, right hand screw is a hollow screw, to be 0.06mm shim to preload the upper gear head bearing.
installed with an O-ring underneath the head of the screw.
Tighten the screws with a torque of 15 N•m (11.4 ft. lb.) in
diagonal sequence.

21

Apply a light coating of Volvo Pent a W hite Sealing Com-

 Apply a light coating of Volvo Pent a W hite Sealing Com-
pound for Drives P/N 1141570 to the mating surfaces of
the intermediate housing and the upper gear head. Install the
upper gear head on the intermediate housing with the
calculated shims in place.

GR990975
Install the two nuts onto the upper gear head studs. Do not
tighten the nuts.

GR990974
Install the two allen head bolts into the upper gear head.
Alternately tighten the allen head bolts and nuts in a crossing
pattern.

GR990976
Install the shift linkage rod, washer and cotter pin.
Always use a new cotter pin. Never reuse a
cotter pin that has been removed.

22

SHIFT MECHANISM
 SHIFT MECHANISM

The upper gear head does not have to be removed

from the intermediate housing, nor the sterndrive from the
transom shield, to replace the shift mechanism.

GR970093
4. Pull the pin out.

GR970035
1. Remove the shifter assembly from the upper gear head.

GR970094
5. Remove the eccentric piston from the shift housing.

GR970091

2. Remove the shift shoe, spring, and O-ring.

GR970095
6. Tap the eccentric piston lightly on a wooden surface to
remove the spring pin. Inspect the eccentric piston for
scoring, distortion, or damage that may cause it to leak or
bind in the housing.

GR97009
3. Knock out the spring pin as far as necessary to free the
locating pin. GR970096
7. Using a screwdriver, pry out the eccentric piston seal.
Clean all surfaces and check for damage that may cause leaks.
Replace parts as necessary.

23
 GR970097
8. Oil all parts prior to assembly. Install a new eccentric piston
seal with the steel edge facing inward, as shown. Use special
tool 884793.

12. Install special tool 3856802 under the two starboard side
retaining screws, as shown.

GR970098
9. Install the eccentric piston in the housing (do not damage
the seal). Push in the locating pin; align the hole with the
housing. Lock it in place with a new spring pin.

GR970100
This will position the shift locating pin on a “high” spot of the
ramp.

Do not attempt to mount the special tool on any

GR970091 raised portion or raised lettering on the shift housing.
10. Install a new O-ring, then insert the spring and shift shoe.
13. With the special tool installed, add one shim to the
Coat the contact surface with Volvo Penta white sealing
shimming screw and install finger tight while rotating the
compound P/N 1141570-0.
propeller shaft by hand. If propeller shaft binds, repeat t his
step, adding one shim at a time, until no resistance is felt
through 360° of rotation.

Do not attempt to rotate the propeller shaft with any

leverage devices (e.g., propellers or pliers). This will damage the
sliding sleeve and/or the shift shoe.
14. After the proper amount of shims have been established:
For DP-D
DP-D add one more shim to the shimming screw.
For DP-D1 and DP-E add three more shims to the shimming
screw.
GR970099
15. Coat the shimming screw threads with Teflon pipe sealing
11. Remove the shim screw and install the assembly in the
compound and install. Tighten the shimming screw to 14 - 16
upper gear head. Make sure the long edge of the shift shoe is
N•m (10 - 12 ft. lb.).
toward the right side of the housing as viewed from the top.
16. Remove the special tool and install the shift linkage.

24

INTERMEDIATE HOUSING
 INTERMEDIATE HOUSING

GR970354
Remove the 2 screws holding the hose connection. Remove
the hose connection and the gasket. GR970356
Press out the lower steering spindle bushing. Use special tool
P/N 884259 -3 and 999180 1-3.

GR970355
Remove the hook up fork by driving out the steering spindle.
Use special tool P/N 884311-2 and 9991801-3.
GR970357
Press out the upper steering spindle bushing using special
tool 884259-3 and 9991801-3.

25
 3
1

GR980499
Should the shift fork require replacement, remove the cot ter
pin (1). Remove the shaft (2) and remove the shift yoke (3). To
install reverse procedure. GR970360
Grease the lower hook up fork bushing with Volvo Penta P/N
Always use a new cotter pin when reinstalling. 828250-1 water resistant grease. Using special tool
8842 59-3 and 9991801 -2, press in the bushing.

GR970359
Remove the bearing race of the axial bearing. Use special tool
P/N 8 8414 0-5 and 884143-9. Also replace the O-rings (1). GR970362
One on each side of the oil tube. Press the bushing into the hook up fork. Use special tool P/N
884259-3 with handle 9991801-2.

26
 2
1

GR970363 GR970365
Place the wear washer (1) on the intermediate housing and Insert the plastic wear washer (1) between the intermediate
push the steering spindle (2) in f ar enough to hold the wear housing and the hook up fork. Push the steering spindle in
washer. until the collar bottoms.

2
1

GR970364 GR970354
Push the steering spindle (1) through the intermediate Install the O-ring and the hose connection on the yoke. Use a
housing exhaust port (2) stopping short of the upper hook up small amount of Volvo Penta P/N 828250-1 water resistant
fork bushing. grease to hold the O-ring in place while installing the hose
connection.

27
 3
1

GR980499
Install the shift yoke (3). Align the shift yoke with the shaft hole
in the intermediate housing. Push the shaft (2 ) through and
lock it with a new cotter pin (1).

28

SP LOWER UNIT
Reconditioning the Lower Gear
 SP LOWER UNIT
Reconditioning the Lower Gear
The Propeller Shaft
Disassembly

203129
4. Remove the 6 nuts holding the washer (1) and knock the
203126
1. Remove the oil strainer (1). propeller shaft out of the bearing housing. Use a copper
mallet or its equivalent in order not to damage the threads.

1 2
883830

203127
2. Use special tool P/N 883830 and install the lower gear 203130
upside down in this tool. 5. Fold down the locking washer (1) remove the round nut
(2).

884168

203128
3. Remove the 2 screws holding the propeller bearing 203131
housing. Remove the propeller shaft and the propeller bearing 6. Press off the gear wheel and the bearing from the propeller
housing. Use special tool P/ N 884161. Remove the special shaft simultaneously. Use special tool P/ N 884168.
tool once the propeller bearing housing is free and pull out the
bearing housing by hand.

29
 2
3 3
1
1 2 3
203135
2. Fold down the tab of the locking washer (1) and remove
0203132 the round nut (2 ). Remove the locking washer and the spacer
7. Remove the locking ring (1) and the oil deflector (2) from ring (3).
the gear wheel.

In order not to damage the oil deflector during the

dismantling, apply the bending tool close to the 2 carrier pins
(3). (This is valid for sterndrives of earlier manufacture). On
sterndrives of later manufacture the carrier pins have been
replaced by a load pin.

884267
884830
203136
3 Use special tool P/N’s 8 84267 and 884830 to remove the
pinion.
1
203133
8. Knock out the 2 sealing rings (1) off the propeller bearing
housing.

2 3
1 203137
4. Lift out the pinion (1) and the needle bearing washer (2).

The needle bearing is a full needle type of bearing

203134 with loose needles (3). Remove all 27 needles.
The vertical shaft
1. Fold down the tab on the locking washer (1) and remove
the nut holding the pinion to the vertical drive shaft.

30
 884316
1

203141
203138 8. Should the needle bearing of the propeller shaft be da-
5. Carefully lift off the lower gear housing from the vertical
maged, use special tool P/N 884316 to remove it. Insert the
drive shaft.
puller into the needle bearing in a way that the barbs of the
puller end up at t he backside of the needles. Then tighten the
Take care of the shims (1).
puller forcing the barbs apart and pull out the bearing.

884143

203142
9. Remove the bearing race on the propeller shaft by cracking
it. Clean all parts and check them for wear. Replace parts if
necessary.
203139
6. Press (knock) off t he outer ring of the needle bearing. Use The gear wheels are sold in matched pairs in order
special tool P/N’s 884381 and 884143. Insert the tool from to obtain the correct contact pattern.
underneath and the shaft from above.

203140
7. Press off the ball and roller bearings from the vertical shaft
(against the frame of the press).

There are spacer pads between the bearings.

31

Assembly
 Assembly
884266
Oil all moving parts and the screws prior to assembly.

203146

The vertical shaft

203143
1. Fill up with grease between the two sealing rings (1) and 1. Press on the ball bearing on the vertical shaft. Use special
press them home in the propeller bearing housing. Use special tool P/N 884266.
tool P/ N’s 884283 and 9991801.
Turn the ball bearing in a way that the balls become
Turn the sealing rings correctly. They are to seal visible (1).
against the oil in the gear housing as well as against water.
884266
884283
9991801

203147
2. Install the spacer pad (1) on the ball bearing and press on
203144
the roller bearing. Use special tool P/N 884266.
2. Install the needle bearings for the propeller shaft. The side
of the needle bearing carrying the description must be t urned
facing aft. Use special tool P/N’s 8 84283 and 9991801.

3
1
2
1

203148
203145 3. Install the spacer ring (1), t he locking washer (2) and the
3. Grease abundantly the outer race (1) with grease and round nut (3) on the vertical shaft. Tighten the nut.
insert the 27 needles, well cleaned, into the ring letting the
grease hold them. Insert special tool P/N 884385 in the Don’t lock the nut with the washer just yet.
bearing and insert the bearing from underneath into the gear
housing. Then install the special tool P/N 884241 from above
and pull the bearing into its seat in the gear housing.

32

884143
 884143

8
8
4
1
4
0

1
203152
7. Remove the conical roller bearing race in the intermediate
2 3 housing (if the old bearing can still be used). Use special tools
203149 P/N’s 884140 and 884143.
4. Insert the pinion (1) along with the washer (2) for the
needle bearing (3) into the gear housing.
8
8
4
3
4
8

1 203153
8. Insert the bearing race on the roller bearing on the lower
203150 gear housing and install the spanner tool P/N 884348. Insert
5. Install the vertical shaft with a 0.35 mm (0.14") thick shims if necessary shims between the bearing race and the tool to
package (1) consisting of a paper shim 0.25 mm (0.01") prevent the vertical shaft from moving axially. Tighten the
between two metal shims 0.05 mm (0.002") each. spanner tool with two screws and nuts.

3
203154
203151
6. Install the washer and the nut. Tighten the nut with a torque The Propeller Shaft
of 160 Nm (16 kpm--118 lbs ft). Use special tool P/N 884830 1. Install the oil deflector (1) and the locking ring (2) on the
on the splined end as a counter hold. gear wheel (3).

Don’t lock just yet. Make sure that the two holes on the oil deflector
coincide with the carrier pins (on sterndrive of earlier manufac-
ture). On sterndrives of later manufacture a load pin acts as
carrier of the oil deflector.

33
 1
3

2
1
203158
203155
2. Press on the bearing race (1) on the propeller shaft (in 5. Install the locking washer (1) and t he round nut (2). Tighten
case it has been dismantled). the nut and lock it wit h the locking washer (3).

Shimming
884263

B
884265
C

203156
3. Press on the gear wheel on the propeller shaft. Use special
tools P/ N’s 884265 and 884263.

884168

884265
F

2
1 G

203157
4. Install the locking washer (1) and press on the ball bearing
(2). Use special tools P/ N’s 884265 and 88 4168 . NOTE! 203159

Install the bearing in a way that the recess in the bearing races
(for the insertion of the balls) is turned facing the propeller.
Method 1

1. The lower gear housing is stamped with a ‘F’-measurement

(center vertical shaft- contact surface of the propeller bearing
box), the propeller bearing box is stamped with a
‘G’-measurement (shoulder of the propeller bearing - contact
surface of the propeller bearing box). Add these together.

34
 F 496

10
3
G=

203160
2. The gear length is fixed at 5.85 mm (0.230"). Add or
subtract the plus or minus
minus marking
marking of the gear wheel. Sub-
tract from this sum the sum of the ‘F’ and ‘G’ measurements. 203162
The sum
sum thus obtained denotes thet he thickness of t he shim.
shim. 4. Install the propeller shaft along with bearings in the gear
g ear
housing. Be careful so that the bearing does not end up
On some geargear housings for instance the figures
fig ures 03 obliquely in the bearing housing or that t he sealing
sealing rings are
can be stamped or some other figure.fig ure. In these cases add add t he damaged. Make sure that the six holes in the washer coincide
number
number 5.00
5.0 0 to
t o that of the ‘F’-measure
‘F’-measureme mentnt and the figure
f igure with the screws. Insert the nuts before the bearing is pushed
1.00 to that of the ‘G’-measurement. Then the ’F’ measure- home completely in the bearing box. Tighten the six nuts.
ment
ment ends up being for instance 5.03 5 .03 or some other measu
measure- re-
ment above 5 mm and the ’G’-measurement for instance 1.03
or some other measurement above 1.0 mm.
If the sum obtained does not coincide with
w ith available
available shims
select the closest five - or ten - number. How to calculate the
shim tthickness
hickness
hic kness can
c an be seen
seen in the following exam
example:
ple:
1
Measurement ‘F’ stamped 4 .97 (0 .1 9 5” )
Measurement ‘G
‘G’ st
stamped + 0.
0.98 (0 .0 3 9” )
5 .95 (0 .23 4” )
Gear wheel
fixed measurement 5 .85 (0 .23 0” )
Gear wh
wheel ma
marking et
etched* + 0.
0.04 (0 .0 0
02
2” )
5 .89 (0 .23 1” ) 203163
5. Install the propeller shaft wit h its bearin
b earing
g box in the gear
5 .95 (0 .23 4” ) housing. Tighten the screws with a torque of 40 Nm (4.0
—5 .8 9 (0 .2 3 1” ) kpm-29.5 Ibs ft).
Cal
Calcula
culate
ted
d su
sum alway
ways po
posi
siti
tiv
ve! +0.06
+0.06 (0.
(0.002”)
The two O-rings (1) on the bearing housing should
As per this
t his exam
example
ple a 0.06
0.0 6 mm (0.002 ") shim is inserted not be installed.
between the propeller
prop eller bearing box and
and the propeller
p ropeller thrust
bearing. Carry on according to points 4-12 below!
* Only the figure 4 is etched on t he gear wheel.
wheel.

Method 2

203164
6. Check
C heck the gear backlash and measure
measure it directly against the
203161
3. Insert the 0.2 mm (0.008") shim (1) in the propeller bearing vertical splines shaft.
shaft. The clearance
clearance should be 0.06-0.10
0 .06-0.10 mm
housing. This is a value of experience. (0.002-0.004") resulting in a gear backlash of 0.15-0.25 mm
(0.0000.020").

35
 1

203167
9. Install special tool P/N 884830 onto the splines end and
turn the gear in the set direction of rotation, clockwise for left
handed propeller. At the same time brake the movement on
the propeller shaft, as forcefully as possible.
2

203165
7. If the backlash is found not to be correct, adjust as follows:

If the method
method 11 hashas been
been used:
used:If the backlash is too
small, increase the shim thickness underneath the ball bearing

A
(1 ) and if t he backlash
backlash is too big,
big , decrease the shim thick-
ness.

If method
method 22 has
has been
beenused:
used:If the backlash is too small
decrease the shim thickness in the t he propeller bearing housing
203168
and if the backla
b acklash
sh is too big, increase the shim thickness.
10. Check that the contact pattern on the teeth surfaces of
the drive side coincide with that of the picture
pict ure A, which is
correct. The contact pattern should be positioned in the
middle of the tooth but displaced towards the small end.

B
203166
8. Remove
Remove the screws and pull out the t he propeller. Coat the
gear teeth of the gear wheel and the pinion gear wit h marking
marking
203169
dye. Then
Then install the propeller shaft with t he bearing box in the 11. Should the contact pattern correspond to that of picture
gear housing. Tighten the screws with a torque of 40Nm (4.0 B, reduce the
t he shim thickness
thickness for the
t he vertical shaft
shaft and the
kpm--29.5 lbs ft). propeller shaft.

36

Final Assembly
 Final Assembly

884830

203170
12. Should the contact pattern correspond to that of picture
C, increase the shim thickness for the vertical shaft and the
propeller shaft.
203171
13. Dismantle pinion and gear and clean parts from marking
If the pinion is moved the gear wheel must be moved dye and then assemble with the calculated shims. Then install
correspondingly in order not to alter the gear backlash. the spacer ring, the locking ring and the nut on t he vertical
vertical
shaft. Tighten the nut and lock with t he locking washer. UsUsee
special tool P/N 884830 as a counter hold.

203172
14. Tighten the pinion nut with a torque of 160 Nm (16.0
kpm-118 Ibs ft). Then lock the nut with the locking washer (1).
Use special tool P/N 884830 applied at the splines shaft end
as a counter hold.

203173
15. Install the O -rings (1) in the propeller
prop eller bearing
bearing housing.
Coat the contact surfaces and the screws with Permatex.
Install the propeller bearing housing in the gear housing and
tighten the 2 Allen-head screws. NOTE! Turn the vertical shaft
somewhat
somewhat to t o allow the
t he gears to engage. Tightening torque
40 Nm (4.0 kpm-29.5 kpm).

37

NOTES
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38

DP LOWER UNIT
Disassembly
 DP LOWER UNIT
Disassembly
Clean the sterndrive externally.

GR970385
1. Drain the oil by removing the screw (1), if not already
drained in previous steps.
GR980765
4. Remove the spline sleeve (1) and the O-rings (2 and 3).
Place a 4-quart drain pan under the sterndrive. Tilt Remove the spacer sleeve along with the O-ring (4) and
the sterndrive all the way down to allow all the oil to drain.
the oil strainer (5).

GR970345
GR970394 Remove the two screws holding the anode to the lower unit.
2. Remove the shift mechanism cover and remove the 5 bolts
holding the lower unit on the intermediate housing. (Two bolts
are inside the shift mechanism cover.)

GR970346
Remove the two propeller shaft housing bolts.

3. Install the suspension fixture 885192-5 in stand

99922520-8 and brace the lower unit in the stand.
34 7
Install special tool 884789 on the outer propeller shaft. Using
special tool 884161 with a slide hammer, remove the outer
propeller shaft and bearing housing.

39
 1

38 1
6. Remove the 2 O-rings (1) from the propeller shaft housing.
Discard the O-rings. Remove the nut from the pinion gear. Use a 23mm wrench.

Do not discard the nut. Put it aside for use in the

shimming procedure later.
34 8
8. Install special tool 885192-4 on the inner propeller shaft.

11. Lift the gear housing off the special tool and place it b ack
in the work stand. Remove the nylock® nut with a hook
GR970379 spanner wrench 885127-1
9. Install special tool 884802 over the inner propeller shaft.
Add the washer and nut. The slot in the end of the tool should
face the pinion gear. Tighten the nut until the shaft is extracted
from the forward gear. Use a 30mm wrench.

Install special tool 884267-6 on the vertical shaft. Attach

special tool 884830-1, and turn counter clockwise until the
shaft can be lifted out of the lower unit gear housing. Remove
the tool from the shaft. Remove the shims from under the
449a vertical shaft bearing. Be sure not to damage the shims!
10. Brace special tool 884830 in a vise and place the lower Save them for use later in the assembly process.
unit upside down in the tool.

40
 GR970370
12. Remove the pinion gear and the front gear from the lower
unit housing. The forward gear should be free to remove from
the housing with the forward bearing attached to the gear. GR980462
15. Press off the roller bearing from the propeller shaft, using
special tool 884797-2.
OuterPropeller Shaft

GR970371
13. Remove the forward gear bearing outer race from the
lower unit, using special tool 884794 -9 and slide hammer
884161. Remove the shims from the housing. Be careful not
to damage
damage thethe shims!
shims!Save them for use later.

GR980377
16. Insert the shaft in special tool 884831-9. Install puller
halves between the shaft and the special tool. Install special
tool 884789-9 on the shaft t o protect the shaft during
pressing operations. Press off the bearing race.
GR970372
14. Use special tool 884791 -1 with drift 884 143-9. Drive the Do not use a knife puller or other, similar tool
needle bearing from the lower unit gear housing. to remove this bearing race. Such tools may scratch the
sealing surfaces of the shaft and result in water leaking into
Inner Propeller Shaft the sterndrive.

41

Propeller Shaft Bearing Box

 Propeller Shaft Bearing Box

GR970351
20. Remove the O-rings from the propeller shaft bearing
GR970350 housing and discard. Using special tool 884797-2 to press
17. Install special tool 8847 89-9 to protect the propeller out the seals and needle bearings.
shaft. Install a knife puller on the outer propeller shaft roller
bearing. Using a press, remove the roller bearing. Center the tool carefully. Locate a pair of
wooden blocks underneath the bearing box to protect the
Make sure the sealing surfaces of the bearing box. Always use new seals and O-rings during final
shaft are not damaged during the process! assembly.

GR970376
18. Install special tool 884832-7 under the intermediate
bearing outer race. Insert handle 884143-9 to expand the
bearing tool. Press out the intermediate bearing outer race
from the rear propeller shaft gear.

GR970352
21. Remove the outer bearing race using special tools
884796-4 and handle 9991801-3.

Center the tool carefully. Locate a pair of

wooden blocks underneath the bearing box to protect the
bearing box while pressing out t he bearing race.

GR980463
19. Remove the inner needle bearing and seals using special
tools 884803 and 884143. Install special tool 884789-9 to
protect the propeller shaft threads.
NOTE! If you only want to replace the seals, it is still easier to
remove the seals along with the bearings.

42

ForwardGear
 ForwardGear

GR970369
23. Use a knife puller to press off t he front roller bearing from
the gear. GR980466
27. Remove the ball bearings (use a knife puller).
The Vertical Shaft

25. Use a knife puller to remove the bearings one by one or

together. GR980467
28. Check the bearing race. Replace as necessary, using a
Use spline socket 38505 98-8 to protect the knife puller. Clean and check all parts for wear.
spline when pressing off the bearings

There is a shim ring (944970-3) located between

the roller bearing and the ball bearing. This one, however, is
smaller.

GR980465
26. Remove the spacer washer located between the bear-
ings.

43

Assembly 20.85 mm
 Assembly 20.85 mm

Shimming the Front Bearing 0,821 in.

3. The nominal height of the bearing is 2 0.85mm.

The front and rear roller bearings are different and

must not be mixed.
G=85
F=91
G=85
H=37

GR980
1. Find the G-marking on the parting plane of the lower gear
housing.
2. Only the decimals of t he G-marking are stamped into the
gear housing. In this case, the G-stamping is 85. The nominal
value of the G-measurement is 60.00mm. Add 60.00 and 4. The nominal measurement of the forward gear is 39.50mm.
0.85, which yields 60.85. The tolerance (±) is engraved on the gear. All engraved
numbers are decimal millimeters. In this instance, -10 equals -
When calculating the shim thickness for the lower 0.10mm. The real measurement of the gear is 39.50 – 0.10 =
unit gears, remember: 39.40mm.

The lower unit gear housing nominal dimension has two 5. Add the height of the forward roller bearing to the real
values
values. measurement of the forward gear:

If the stamped number is 50 or more,

more, use the lower
lower nominal ADD:
value: 60.00mm. Roller Bearing = 20.85mm
If the stamped number is 49 or less,
less, use the higher nominal Forward Gear = + 39.40mm
value: 61.00mm. Total forward gear length 60.25mm

EXAMPLE:
This sum should be subtracted
subtracted from the G-stamping resulting
in a shim thickness for the front bearing:
Stamping is 50 or more
G-measurement 60.85mm
G stamping: 85 = 00.85mm Total forward gear length – 60.25mm
Use Nominal Dimension= +60.00mm Shim Thickness = 00.60mm
G-measurement 60.85mm

Stamping 49 or less

G stamping: 02 = 00.02mm
Use Nominal Dimension= +61.00mm
61.02mm

44
 1

6. Lubricate the bearing position before assembly. Place the 8. Use special tool P/N 884263 to press the gear and
calculated shim thickness in the gear housing and install the bearing assembly onto the propeller shaft. Use special t ool
884799 to protect the bearing.
outer bearing race (marked 30209) with special tool P/N
884795.
Do not press on by using the bearing
race!
The plastic disk (1) should be pressed as far in as
possible on the tool.

7. Press on the front roller bearing onto the forward gear.

Use special tool P/N 88480 1. Use special tool 884797 to
protect gear teeth.

45

Shimming the Vertical Shaft

 Shimming the Vertical Shaft

884241

884792

2259
2262
9. Grease the bearing location. Carefully align the needle 12. Place the thin spacer pad (1) on the ball bearing and
bearing when installing it in the gear housing. Use special tool press on the roller bearing. Use special tool 884266.
884792 in combination with 884241. Turn the bearing to
allow the tool 884792 to press against the text on the
bearing. Tighten the screw until the bearing bottoms.

2263
13. Install the thick spacer ring and tighten the plastic insert
2260 locknut. Use a hook spanner wrench.
10. Press a new inner bearing race onto t he vertical shaft. Use
special tool P/N 884793-1.

H=37
F=91
G=85
H=37

2264
14. Find the H-stamping on the parting plane of the lower
gear housing. The H-stamping in this instance is 37. Remem-
ber, the stamping is in hundreds of millimeters. The nominal
2261 H-measurement is 277. Add the H-stamping to the nominal
11. Press a new ball bearing onto the vertical shaft. Use dimension of 277. The sum will be 277.37mm.
special tool 884266.
ADD:

Install the bearing so that the thick part of the inner H-Nominal 277.00mm
race faces up. H-Stamping +00.37mm
H-Measurement 277.37mm

46
 2265
15. Find the marking on the pinion gear. In this instance the
pinion etching is -5. Remember, the etching is in hundreds of
millimeters. This etching is -0.05 mm. The nominal measure-
ment of the pinion gear is 60.00 mm. Subtract t he pinion gear
etching from the nominal measurement for a difference of
59.95mm.
16. The nominal measurement of the vertical shaft is
2292
217 .75mm. This measurement is added to t he calculated 19. Center the pinion gear and nut carefully; then, with the
pinion measurement of 59.95mm. This combined distance other hand, install the vertical shaft.
equals 277.70mm, as illustrated below:
ADD: The groove of the nut must face the pinion gear.
Vertical Shaft Nominal 217.75mm 20. Install the nut on the vertical shaft.
Pinion Calculated +59.95mm
Vertical Shaft Calculated 277.70mm A new nut must be used for final assembly.

Subtract the H-stamping dimension from the Vertical Shaft

Calculated (277.70) to arrive at the shim thickness:
SUBTRACT:
Vertical Shaft Calculated 277.70mm
H-Measurement – 277.37mm
Calculated Shims 0.33mm

2298
21. Hold the pinion nut with a 23mm socket. Use special tool
884830-6, or 3850598-8 as an alternative, and a torque
2266 wrench. Torque the vertical shaft to 110 N•m (81.5 ft. lb.).
17. Place the propeller shaft with gear installed in the gear
housing. Be careful not to allow the counter-hold
wrench to damage the lower gear housing. Use a piece of
soft wood to brace the wrench and protect the housing while
applying torque to the pinion nut.

2267
18. Place the calculated shim thickness (1) in the gear
housing. In this case, it is 0.33mm. With one hand, hold the
pinion gear and the original pinion gear nut in the gear
together in the housing.

47

The Bearing Box

 The Bearing Box
+10

0
1
+

25. The nominal measurement of the aft gear is 39.50mm.

F=91 Find the variation marking on the gear. In this case it is + 10.
F=91
Remember, hundreds of millimeters only!
G=85
H=37
ADD:
Gear nominal 39.50mm
22. The nominal dimension of the F-measurement is 80.00mm Gear marking +0.10mm
± 0.10 mm. Figures between 90 and 99 are stamped into the Gear measurement 39.60mm
lower gear housing indicating the amount of variation from
nominal that the housing is machined. When the F-stamping is 20.75 mm
between 90-99, add 79.00mm to the figure. If the F-stamping
is 00-10, add 80.00mm to the figure. In this case, the F- 0.817 in.
stamping is 91. Add 0.91 to the nominal figure of 79.00. The
sum for the F-measurement is 79.91.

C25

26. The nominal bearing height is 20.75mm.

The forward and aft gear bearings have

different nominal dimensions by .10 mm. DO NOT mix them
up. For the aft bearing, make sure that the inner bearing race
is marked BK-358X and the outer bearing race is marked
K354X. Installing the bearings in the wrong loc ation will cause
incorrect lower unit gear contact patterns, incorrect bearing
preload, and shorten gear life.
23. Find the stamping “C” on the bearing box. In this case,
C= 25. Again, the stamping is in decimal millimeters. The 27. Add the gear measurement to the bearing nominal
nominal dimension for the bearing box is 19.00 mm. Add the dimension.
C-stamping to the nominal dimension to get the C-measure- ADD:
ment.
Gear measurement 39.60mm
ADD: Nominal bearing height + 20.7 5mm
C-nominal 19.00mm Total aft gear dimension 60.35mm
C-stamping +0.25mm
C-measurement 19.25mm 28. Now subtract the Total aft gear dimension from the
bearing box location.
24. Now subtract the C-measurement from the F-measure- SUBTRACT:
ment.
C-measurement 60.66mm
SUBTRACT: Gear dimension -60.35mm
F-measurement 79.91mm Bearing box shims 0.31mm
C-measurement - 19.25mm
Aft gear bearing location 60.66mm
The OuterPropeller Shaft

48

ShimmingtheIntermediateBearing
Bearing
 ShimmingtheIntermediateBearing
Bearing
Start by adding the F-measurement and G-measurement.
ADD:
G-measurement 60.85mm
F-measurement +79.91mm
140.76mm
Now subtract the C-measurement of the propeller bearing
box.
SUBTRACT:
F&G combined 140.76mm
C-measurement -19.25mm
121.51mm
Now add the front and rear gear shims.
ADD:
2269
Grease the bearing location with propeller shaft grease and Forward gear shims 0.60mm
insert the calculated bearing box shims from the previous step Aft gear shims +0.31mm
(0.31mm). Install the bearing race using special tool 884795- 0.91mm
6. Add nominal value +120.00mm
120.91mm
The shim thickness is obtained by subt racting:
SUBTRACT:
121.51mm
-120.91mm
Intermediate bearing shim 0.60mm

2272
Press the bearing race into the aft gear. Use special tool
884797-2.

384a
Turn the bearing box over. Use special tool 884797-2, install
the needle bearing in the bearing box. Make sure the bearing
marking is facing the tool.

49
 28. Apply marking dye on the convex side of the aft gear.
Place the calculated shims for the intermediate bearing and
the intermediate bearing on the inner propeller shaft. Install
special tool 885197-4 onto the threads until the tool bot-
toms.

Press the needle bearing into the propeller shaft with the text
36 6
on the bearing turned facing the t ool. Use special tool
Install special tool 884798-0 on the propeller shaft with the
884806-1. Press the tool until it bottoms. washer and nut. Using a 30mm wrench, tighten the nut until
the intermediate bearing bottoms. Use special tool 884830-1
DO NOT install the seal rings, wait until the gear or 3850598-8 and a wrench as a counter hold on the vertical
tooth clearance and contact pattern are checked. shaft. After the intermediate bearing is pressed on completely,
remove the special tools from the propeller shaft.

36 7
Coat the convex side of the aft gear with marking dye. Insert
the gear assembly onto the inner propeller shaft.
Press the roller bearing onto the propeller shaft. Use special
tool 884801-2.

34 6
Grease the bearing box and install on the lower unit. Tighten
the allen bolts to 40 N•m (29 lb.ft.).

Press the inner needle bearing race onto the propeller shaft.
Use special tool 884801-2.

50

Checking Backlash
 Checking Backlash

Place the outer bearing race on the vertical shaft roller bearing
and hold it steady in position. Use a depth gauge to measure
the height of the bearing assembly “A.” Note this dimension.

Propeller Nut
Lock the vertical shaft to prevent it from being turned. Install
A DP propeller nuts and or cone on the propeller shafts. Rig a
dial indicator gauge against the wings of the rear nut as far
out on the wing as possible. Check the flank clearance of the
front gear by turning the propeller shaft (both ways) by hand
to check the backlash. The clearance at the wing should be
B
0.08 – 0.17mm (0.003-0.007”), which results in a clearance
Using a depth gauge, measure special tool 88438-4 at of 0.15 – 0.30mm (0.006-0.013” ) at the gear.
position “B.” Subtract measurement "A" from measurement
“B.” This will give you the clearance dimension. If negative
clearance is obtained, install the tool wit hout shims. If a
positive clearance is obt ained, add shims according to the
following procedure. To determine the correct bearing
preload, 0.02mm should be added t o the clearance dimen- “
m 5
1
sion. m 3
8 .
0
EXAMPLE:
SUBTRACT:
Measurement ‘A’ 10.02mm
Measurement ‘B’ -9.77mm Propeller Cone
0.25mm
If the rear propeller is locked with a propeller cone, measuring
Bearing Preload +0.02mm
the gear backlash must be done the same way as when
Shim 0.27mm
measuring using the propeller nut. The only difference is that
A 0.27mm shim should be placed on the outer bearing.
the measuring must be done 8mm (0.315 ”) in from any of the
tips of the cone’s wings, and towards the propeller shaft
center. The measuring is done at the same radius from the
propeller shaft center as when measuring is done on the
propeller nut.

38 6
Insert the bearing race on the vertical shaft roller bearing.
Install shims between the bearing race and the special tool t o
prevent the bearing from moving axially. Install special tool
884348-4. Tighten the special tool with two screws and nuts
finger tight to prevent axial movement but not enough to
preload the vertical shaft.

51

in. lb.) and maximum preload value should be 2.3 N•m (20.3 in.
 in. lb.) and maximum preload value should be 2.3 N•m (20.3 in.
lb.).
If the preload is too high, the shim thickness on top of the
bearing race should be reduced.
If the preload is too low, the shim thickness on top of the
bearing race should be increased.
ContactPattern

Move the dial indicator gauge to the outer nut. Measure the
backlash of the rear gear the same way as the front gear. The
clearance should be 0.15 – 0.27mm (0.006 –0.010 in.),
which is 0.20–0.35mm (0.008 – 0.014 in.) at the gear.

1 1
2282
Turn the vertical shaft both ways. Use the spline sleeve
884830 while applying braking action.

3
2285
If it is necessary to increase the backlash without changing the
A
contact pattern, add and remove shims from the front and
rear gears (1) and the vertical shaft (2). Add the correspond-
ing shim thickness underneath the bearing (3) to maintain
preload. Reverse the steps if the backlash needs to be
reduced.

Checking Preload 970072a

Remove the special tool and propeller shaft bearing box.
Check the contact pattern on the gear wheel. Also check the
front gear wheel inside the gear housing. The contact pattern
should be located toward the big end with a slight displace-
ment toward the root of the tooth (A).

B
2282
After calculating the shims required according to points “A”
and “B”, place the calculated shim on top of the bearing race
and install special tool 884830 on the vertical shaft. Use
GR970073
torque gauge 9999177 and turn the shaft one revolution per
second. The minimum preload value should be 1.2 N•m (10.6

52

If the contact pattern is toward the root of the tooth and at

If the contact pattern is toward the root of the tooth and at
the big end, the shims should be increased under the front
and rear roller bearing (1). To maintain correct bearing
preload, reduce the shims under the intermediate bearing (3)
by a corresponding amount. To maintain the correct backlash,
increase the shims under the vertical shaft ball bearing (2).

C
After the correct preload, backlash, and contact pattern have
been obtained, remove the preload tool and tighten the vertical
shaft nut. Remove the bearing box and outer propeller shaft.
GR970074
If the contact pattern is too far toward the top of the tooth
and toward the small end, reduce the shim thickness for under
the front and rear roller bearing (1). To maintain proper
bearing preload, increase the shim thickness correspondingly
under the intermediate bearing (3). To maintain the correct
backlash, decrease the shim thickness under the vertical shaft
ball bearing (2).

2
1 1 Remove and discard the old pinion gear nut. Grease the
threads of the vertical shaft. Install a new nut with the groove
against the pinion gear. Tighten to 110 N•m (81 ft. lb).

3
2285

FinalAssembly
Assembly

Grease the new seal rings and install in the propeller shaft.
Turn the steel edge (1) facing forward. Use special tool
884 975 -4. Turn the broad shoulder against the seal ring.
Press until it bottoms.

53
 Turn the tool over and press in the “single lip” seal ring. Turn
the spring facing aft. Press until it bottoms.
51. Install seal protector 884807 in the bearing box to
protect the seal during installation.

52. Install new O-rings on the bearing box. Coat the entire
sealing surface and O-rings with White Sealing Compound for
Drives, Volvo Penta P/N 11415 70-0. Install the bearing box in
48. Grease the seal rings and install in the bearing box with the gear housing.
the springs facing away from each other. Use special tool
8848 01-2. Press until it bottoms.

49. Insert the protective ring 884976 into the outer propeller Tighten the bolts to 40 N•m (30 lb. ft.).
shaft seals so that the seal lips are protected during installa-
tion.

50. Carefully insert the outer propeller shaft in the gear

housing. Remove the seal protector.
Remove the seal protector (1) when the bearing box has been
installed and tightened. Clean off any excess sealing com-
pound.

54
 Install the zinc ring on the lower gear housing. Check to make
sure that the contact surfaces are clean and there is a good
electrical contact. An ohmmeter may be used to ensure there
is little or no resistance between the zinc ring and the lower
unit housing. For more detailed information about
Electrochemical Corrosion, what causes it and how to GR980491
prevent it, consult publication 7733534-7, Marine Electrical Press the outer race of the vertical shaft bearing with the
Systems available from Volvo Penta. calculated shims into t he intermediate housing. Use special
tool 884168-6.
Shimming the Lower Unit to the Intermediate
Housing
1
4
A
5 2
3

Place the bearing race on the bearing and hold in position.

GR980765
Using a depth gauge, measure the bearing height above the
Insert the oil strainer (5) into the lower gear housing. Check
lower unit parting plane “A.”
that the oil pipe (4) is provided with an O-ring . Use new O-
rings (3) and (4). Install the spline sleeve (1) on the vertical
shaft with the groove in the up position. Coat the contact
surfaces with a thin coating of Volvo Penta White sealing
compound for sterndrives 1141570-0.

Using the depth gauge, measure the intermediate housing “B.”

Subtract measurement “A” from measurement “B.” This will
give the clearance dimension. Add 0.02 mm to the clearance
dimension to establish bearing preload.

Example: Measurement “A” 10.02mm

Measurement “B” – 9 .7 7mm 203174
Clearance 0.25mm Use new screws and washers. Coat the screw threads with
Bearing Preload + 0.02mm Loctite® Primer N and Volvo Pent a thread locking com-
Shim Thickness 0.27mm pound 1161053-2. First tighten the 4 larger screws holding
the lower unit to the intermediate housing diagonally and in
sequence with a torque wrench to 38 N•m (28 ft. lb.). Use
special tool 885008-3. Tighten the 3 smaller screws to 15
N•m (11 ft. lb.).

55

Pressure
PressureandVacuumTesting
 Pressure
PressureandVacuumTesting
Before filling t he drive with gear oil, it must be pressure and
vacuum tested to verify proper sealing during assembly.

Remove the oil drain plug from the lower unit housing. Install
pressure tester 3810152-3 in the drain plug hole.
Pressurize the sterndrive to 7 psi.
Rotate the universal joint clockwise while shifting into forward
and reverse.
The drive must hold pressure before making the vacuum test.
It must not loose more than 1 psi in 3 minutes.
If a pressure drop is indicated, apply a soapy water solution
to all sealing surfaces until the leak is found.
Repair the leak and re-test the unit.
Attach a vacuum tester 3858578-2 to the sterndrive.
Pull 14-16 inches of mercury (Hg”) vacuum.
Rotate the universal joint clockwise while shifting into forward
and reverse.
The drive must hold vacuum. It must not lose more than 1 inch
in 3 minutes.
If a vacuum drop is indicated, apply a heavy oil to the sealing
surfaces to find the source.
Repair the leak and re-test the unit.

56

STERNDRIVE INSTALLATION
 STERNDRIVE INSTALLATION

Install the exhaust bellows on the transom shield. Turn the

hose clamp so that the screw points downward and is
accessible. Install frame of special tool 885146-1 on the suspension pins.

Be sure the drain hole in the bellows is mounted

toward the transom and facing down.

Remove the rear cover from the sterndrive. Place the large
hose clamp on the front of the upper gear head. Install yoke
885 144 -6 on the upper gear head. Hang the yoke with the
sterndrive attached on the frame.

The sterndrive is heavy. It weighs approxi-

Install the hose clamp on the universal joint bellows. Install the mately 54 Kg (120 lb.). Attempting to lift it by hand may cause
universal joint bellows onto t he flywheel housing with “UP” injury.
where it protrudes from the transom shield. Locate the screw
and the 4 o’ clock position.

E
S
A
E
R
G

E
AS
RE
G

Remove the locking screw and remove the suspension pin.

Grease the suspension pins with Volvo Penta low tempera-
ture grease 1161417 -9 and install in the transom shield flush
with the interior face to the transom shield. Grease the locking
bolt with Volvo Penta low temperature grease 1161417-9. Thread the shift cable through the shift cable hose on the
Put the locking bolts aside for installation later. inside of the transom until it protrudes from the transom
shield. Slide the sterndrive up to t he transom shield close
enough to install the shift cable. Once the shift cable is
installed, clamp the cable housing in place.

57
 2
Align the sterndrive suspension yoke with the pins in the
transom shield. Using a plastic mallet, drive the pins into the
1 transom shield until approximately 4mm of the pin is left on the
outside of the transom shield. Remove the special tool.

DO NOT use a metal hammer to drive the

Install the plastic bushings (1) in the suspension yoke (2).
pins. This will damage the suspension pin and make pin
removal impossible.

Slide the sterndrive forward. While turning t he u-joint assem-

bly align the U-joint with the primary shaft. The U-joint has a
counterbore to aid in alignment of the splines.

While looking into the locking screw hole of the transom

shield, drive the pin in until the grove in the pin aligns with the
locking screw hole. Grease the threads of the locking screw
with Volvo Penta low temperature grease 1141644-3. Install
the locking screw and washer. Torque the screws to 24 N•m
(17 lb. ft.).

Lift the trim cylinders simultaneously and push the sterndrive

forward.

58
 Hang the hose clamp on the exhaust bellows. Turn the
Push the rubber U-joint bellows onto the upper gear head. sterndrive to port. Hold the port side of the bellows against
Check to make sure the ring on the inside of the bellows is the port side of the exhaust opening. While holding the
completely in the groove of the upper gear head. bellows in place move the sterndrive to the starboard posi-
tion. At this point, the bellows will be much easier to attach
the starboard side of the bellows to make the connection
complete. After the hose attachment is complete, tighten t he
hose clamp in the indicated position.

Lift the sterndrive and install special tool 885143-8 between

the transom shield and the suspension yoke. Hang the hose
clamp on the water intake hose and connect the hose to the
hose attachment on the suspension yoke. Turn the hose
clamp so that the screw is vertical on the starboard side.
Only use special tool 885143-8 to secure
outdrive. Serious injury may result if sterndrive is not properly
blocked.

The hose clamp must be positioned Check to make sure that all bellows and hoses have been
vertically and on the starboard side of the attachment. Any installed correctly and the clamps are positioned properly and
other position will damage either the U-joint bellows or the tight. Tilt the sterndrive and turn it fully in both directions.
exhaust bellows. Check that the screws on the clamps do not touch the
sterndrive, transom shield, or the other bellows. Loosen the
clamps and adjust if necessary to keep the screws from
cutting other bellows around them. Use special tool 885060-
4 and 884573-7. The illustration demonstrates the correct
orientation of the clamps.

59
 Lift sterndrive enough to remove special holding tool. While
holding the trim cylinders up slightly, carefully lower the
sterndrive onto the trim cylinders until the holes align betw een 1
the trim cylinder ram and the suspension yoke.
3
2

Lower the steering helmet and align the helmet bushing with
the recessed hole of the upper gear head. Grease the
attachment (2) with Volvo Penta low temperature grease
11614 17-9. Install the attachment in the helmet bushing with
the recessed holes vertical (one hole over the other). W hile
moving the sterndrive slightly from side to side, push home the
attachment until it bottoms in the upper gear head recessed
hole. Install the two allen head bolts (1) and tighten to 35
Nm (25 ft. lb.).

Be sure the attachment is aligned in the

970119
upper gear recess before tightening the allen head bolts.
Apply generous amounts of Volvo Penta low temperature
grease 1161417-9 to the trim pins and install.

A
1 2
A

Before connecting the shift cable be sure that if the remote

control moves forward, the shift cable extends from the cable
housing, (i.e. cable pushes for forward gear, pulls for reverse
gear). Set the sterndrive shift lever to horizontal making sure
Install the cotter pins (1) and carefully bend the ends back- that it is in the neutral detent position. Set the remote control
wards. shift lever to neutral. Push the shift cable in as far as possible.
Using a fiber tip marker or suitable substitute, mark the
position of the cable at the cable housing (A). Pull the control
cable as far out as possible. Note the distance between the
cable housing and the marked position on the cable. Push the
cable into the housing half the distance to t he mark (A2).
Install the swivel onto the shift cable to the point it will attach
to the shift lever without moving the lever for attachment.
Install the washer and cotter pin. Bend the tabs backwards
onto the swivel.

60

FillingtheUnit TwinEngine Installation

 FillingtheUnit TwinEngine Installation
A

1
Install the oil drain plug with a new o-ring.
A-
15 - 25mm
(9/16 - 1 in.)

In a twin inst allation the “Toe-out angle between the

sterndrives must be adjusted until an operation free from
1
ventilation has been obtained. Increase the angle between the
sterndrives on a boat with a deeper V-hull. Adjust the stern-
drive according to the following illustration. If the measure-
ment at the center of the steering pivot is “A”, the measure-
ment between the outside edges at the exhaust outlet must
be “A” minus 15-25mm (9/16 - 1 in.). Push the sterndrives
apart by hand when taking the.

Tilt the sterndrive to t he full up position. Remove the fill plug

(1) and fill with approx. 2.2 litres of DuraPlus™GL-5 synthetic
gear oil. Install the fill plug with a new gasket. Tighten the fill
plug to 35 N•m (26 ft. lb.). Lower the sterndrive and check the
oil level with the dipstick. If necessary, top off the sterndrive
with oil through the dip stick hole.

Install the shift mechanism cover.

61

NOTES
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62

TRANSOM SHIELD
Changing Trim Cylinders
 TRANSOM SHIELD
Changing Trim Cylinders
Removal
Removal

B C D
A

Install a grease nipple 94019 4-4 where the ground terminal

bushing or plastic plug was removed.

Remove the 2 hoses (A) from the starboard cylinder. If only

the port cylinder is to be replaced, remove the pipe connec-
tions on that cylinder (B).

Be sure to catch any oil which will leak when

the hydraulic lines are disconnected.

Remove the lock bolt from the trim cylinder attachment pin.

Port Cylinder:
If the port cylinder is to be removed, remove the ground strap
terminal (C) and insert from the transom shield.
Starboard Cylinder:
Remove the plastic plug (D) adjacent to the trim cylinder
attachment pin.

Use a grease gun to pump the pin out of the hole.

63
 If the pin will not come out by using a grease gun, special tool
884978-8 (2) should be used as follows:
Remove the grease fitting. The transom shield must have cutouts called
for on the transom template to allow sufficient clearance for
Fill the tool (2) with grease. the pins to be removed. If the cutouts are not made, the
Screw the tool into the transom shield and carefully tighten. transom shield must be removed from the boat to enable trim
cylinder pin removal.
Unscrew the locking trim cylinder pin locking bolt approx.
10mm (¼ in.).
Hit the tool piston with a hammer so that the trim cylinder pin
is forced against the locking bolt.
Unscrew the locking bolt completely. Force the pin the rest of
the way out of the hole.

The locking bolt may be used in the trim cylinder pin to pull the
pin completely out of the hole.

64
 Always use a new O-ring on the dowel pin during reassembly.
Check the pin hole and pin for scratches or other damage.
Remove the trim cylinder from the shield.
Install the ground strap insert, attach the ground strap to the
insert.

Be sure there is good electrical contact (low

resistance) between the trim cylinders and the transom shield.
High resistance between the transom shield and the trim
cylinders will result in corroded t rim cylinders. For more
information on electrochemical corrosion, consult publication
7733534-7 “Marine Electrical Systems” available from Volvo
Penta parts.
Starboard Cylinder:
Install the plastic plug.
Install the sterndrive according to “Sterndrive Installation”
found elsewhere in this book.
Remove the grease fitting that was used to remove the Raise and lower the sterndrive several times to bleed any air
attachment pin. trapped in the hydraulic system.
Installation
Remove any shipping plugs installed in the new trim cylinder.
Install the new trim cylinder and pipes and hoses.

Make sure all the pipes and hose fittings are

attached finger tight before torquing any of the fittings. Final
tightening of any of the fittings before all fittings are started
could cause cross-threaded fittings and damage the cylinder.
Install the trim cylinder attachment pin.
Remove the attachment bolt from the end of t he pin and lock With the sterndrive lowered as far as possible, check the oil
the pin in position with the bolt. level in the hydraulic trim pump. Refill with Volvo Penta power
steering and power trim fluid 3851039-2 to the MAX indica-
Port Cylinder: tor on the reservoir.
Remove the block off plugs from the old cylinder and install in
the same holes of the new cylinder. For cold weather operation or prolonged commer-
cial operation, use only Volvo Penta power steering and
power trim fluid 3851039-2. If the system is filled with engine
oil, the system must be drained completely before using
power steering and power t rim fluid. Keep the pump and oil
clean to prevent dirt from entering the hydraulic system.

65

Changing Steering Helmet

 Changing Steering Helmet
Steering Fork

Steering Helmet

980615
Gently pry the steering fork down from the transom shield.

To ensure the integrity of the steering system the steering

helmet is not serviceable as a separate part from the steering
fork as in years past. If there is a problem with the steering
helmet or the steering fork, they must be replaced as a unit.
Removal
Remove the sterndrive according t o procedure elsewhere in
this book.

11315
Install a new bushing (8) into the new steering fork.

GR980759
Disconnect the power steering (A) if equipped.
Disconnect and remove the trim sending unit.

GR980763
Align the square on the steering fork wit h the square in the
tiller arm and install into the transom shield.

980616
Loosen the tiller arm set screw using a 5/32 allen wrench.

66
 GR980762
Make sure the square on the steering fork and the tiller arm
are aligned.

11351
Install a new seal (9) and O-ring (7 ) on the gear wheel.
Install the trim sending unit, gear wheel and gear rack. See
“Trim System” elsewhere in this manual.

GR980764
Using a rubber mallet tap the steering helmet into posit ion

980616
Lock the setscrew with a 5/ 32 in. allen wrench.

67

NOTES
NOTES

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68

TRIM SYSTEM
Changing the Sending Unit
 TRIM SYSTEM
Changing the Sending Unit
15 Kg
(33 lb)

Lower the sterndrive to its bottom position. Ensure

the sterndrive is at its lowest position, place a 15 Kg
Lower the sterndrive to the full down position. Turn the helm
load on the rear of the sterndrive.
full starboard. Using a 13mm wrench, remove the trim sender
holding bracket and the trim sender. Unplug the sender from
the wiring harness.

-4

-4 should be shown in the instrument window for a 12°

transom angle. Move the sending unit in either direct ion until
Plug the new sending unit into the wiring harness. Align the
the correct number is displayed on the trim gauge. Other
white notch on the drive coupling with the white notch on the
transom angle settings are as follows:
sending unit housing.
Transom angle Insturment indication
10° —2
11° —3
12° —4
13° —5
14° —6
15° —7

Install the sending unit housing into the steering shaft on the
transom shield. Rotate the sending unit slightly to align the
drive coupling with the gear wheel.

Do not force the sending unit into the hole. This may
damage the sending unit and/or the gear wheel.

Install the trim sender bracket and hold down sc rew. Finger Tighten the trim sender bracket hold down screw. B e sure the
tight only, do not tighten until all adjustments have been made. sending unit does not move when the bracket is tightened.

69

Changing the Trim System Gear Rack

 Changing the Trim System Gear Rack

39 8
Remove the damaged gear rack by removing the screw.
Install the new gear rack with the marked toot h of the gear
wheel in the first slot of the gear rack.

39 7
Bend the gear rack up slightly to clear the nut and pull it our Align the gear rack with t he hole in the steering helmet. Push
from the steering helmet. the nut (1) through the helmet and into the gear rack.

39 6
Turn the gear wheel until the tooth with a white recessed
marking appears.
Install the screw and carefully tighten.

It is recommended that a new screw be used

whenever the gear rack is removed.

Do not overtighten the screw. Use extreme

caution to prevent stripping the threads from the screw.

70

Changing the Trim System

System Gear
Gear Wheel
Wheel
 Changing the Trim System
System Gear
Gear Wheel
Wheel
15 Kg Remove the sterndrive according to the section installation
(33 lb) and removal.

Lower the sterndrive to its bottom position. Ensure the

sterndrive is at its lowest position, place a 15 Kg load on the
rear of the sterndrive.

-4

Pull the steering helmet aft far enough to clear the gear wheel.
-4 should be shown in the instrument window for a 12° Turn the gear wheel so that the digital trim instrument indi-
transom angle. If not, loosen the trim sender hold down clamp cates -4.
and move the sending unit in either direct ion until the correct
number is displayed on the trim gauge. Other transom angle
settings are as follows:

Transom angle Insturment indication

10° —2
11° —3
12° —4
13° —5
14° —6
15° —7

Pull the gear wheel straight down. There will be some resist-
ance because of the retaining pawl in the bushing. Note t he
position of the drive end of the shaft when removing it. This
will ease installation of the new shaft in the same position.

After all adjustments are made, tighten the trim sender bracket
hold down screw. Be sure the sending unit does not move
when the bracket is tightened.

71
 1 Push the steering helmet into position with the marked tooth of the
GR980498 gear wheel engaging the first notch of the gear rack. Push the
steering helmet as far forward as possible. Install the sterndrive
Always use a new O-ring whenever the gear wheel is
according to the installation section earlier in this chapter. Check the
removed.
trim adjustment according to adjusting the trim instrument section.
Grease the new gear wheel shaft and O- ring liberally with Volvo
Penta Propeller shaft grease 828250-1. Install the new gear wheel
with the marked tooth pointing starboard just enough aft to be
visible from under the steering fork. If the shaft will not fit easily into
place, rotate the gear wheel slightly in either direction to engage the -4
gear wheel shaft and the trim sender coupling. Be sure the gear is
completely seated before trying to engage the gear rack on the
steering helmet.

-4 should be shown in the instrument window for a 12° transom

angle. If not, loosen the trim sender hold down clamp and move the
sending unit in either direction until the correct number is displayed
on the trim gauge. Other transom angle settings are as follows:

Transom angle Insturment indication

10° —2
11° —3
12° —4
13° —5

Position the gear wheel as shown. 14° —6

15° —7

After all adjustments are made, tighten the trim sender bracket hold
down screw. Be sure the sending unit does not move when the
bracket is tightened.

72
 Trim sender

1
(30) 2 2 W Y
N L / O
G B N V
G
(85) (86) B
B
S /S
(87) W W B
(87 a) / W
/ S
/W N B
N
R G S G
W
1
BL
/W
L
B BL/R
(30)
R
(85) (86)

(87)
(87 a)
R/W
GN /W /W
N B
B
BL G S
S

7 9 5 1
2 1 8 8 6 4 B 2 3 /
B L/
R L N /W /W B O B 7 S/ L N R
B N /S V S Y W L
SB
G R G W W B G B
R
B L/
SB

W1
GR 2
BN 3
Y4
BL /R 1
GN 5
GN 2
BL 3
W4
W1
SB 5
GR 2
BN 3 BN 8
Y4 W6
GN 5 R/W 4 2
W/SB 2 4 3 2 1 4 5 1
/R
L O L N L L L
VO 7
W B V B B B B B
BL/R 5

Y SB 3
GN/W 1
GR 2
W/GN 4
BL 6 W/SB 1
R8 Y2

SB 7
VO 5
W3
BN 1

W/BN 1
(30)
P2
Relay
(85) (86)
(30)
(87)
(85) (86)

Digital trim instrument (87 a)

73

NOTES
NOTES

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74

WELDING
Welding on cert ain parts of the sterndrive and the transom exhaust channel except around the bearing positions. The
 WELDING
Welding on cert ain parts of the sterndrive and the transom exhaust channel except around the bearing positions. The
shield is allowed. Extreme caution must be used to prevent lower fin provided no more that 2/ 3 of it is missing measured
damage to the precision machined surfaces or precision parts vertically. The water intake channel at the front of the housing,
used in the sterndrive (i.e. near bearing locations). Always use however, it is important to maintain the channel profile. The
Volvo Penta welding electrode 839643-4 when making any correct profile is important to prevent restricted water flow to
welding repairs to the sterndrive or transom shield. the engine. The exhaust outlet, trim tab and propeller cone
may be welded. It is important to protect the rubber exhaust
Parts that cannot be welded flap during welding.
The steering fork, steering helmet, clamp ring, tiller arm,
6. Pressurize the housing after repair. See Pressure and
suspension yoke and exhaust elbows, trim cylinders, trim
Vacuum Testing earlier in this book.
cylinder attachment, power steering cylinder attachment,
power steering cylinder, and the area around the suspension Repair instructions
pins. On or around precision machined surfaces or precision
Dismantle and clean the damaged part of the sterndrive. Grind
parts.
the area to be welded according to industry standard for
Parts which can be welded welding aluminium. The welding should not be done at less
than 20°C (68°F). If a part has been broken off and hasn’t
1. The neck of the flywheel housing for the attachment of the
been lost, it should be used. Even if the surfaces are to be
rubber bellows. Grind the neck smooth after welding to get
welded, there should be a V groove approximately 45° on
an even surface.
both sides of the joint. Make the repair using Argon welding
2. The transom shield except on and around the suspension and Volvo Penta electrode 839 643 -4. Always pressure and
ears, steering journals, around the suspension pins and the vacuum test the sterndrive as an assembly before returning to
attachment of the trim cylinders. service. The shaded portions of the sterndrive and flywheel
housing indicate where welding is permitted except where
3. The shift mechanism cover.
noted above.
4. The exhaust channel in the intermediate housing except at
the steering spindle and around the upper and lower bearing
positions of the vertical shaft.
5. The lower unit housing on the cavitation plate and the

75

NOTES
NOTES

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76

PAINTING
Recommendations must have good electrical contact to function properly.
 PAINTING
Recommendations must have good electrical contact to function properly.
All antifouling paints preventing marine growth are poison- Never paint the zinc or magnesium anodes!
ous and may harm our marine environment. The legislation Painting the anodes will prevent them from working properly.
concerning antifouling paints has also been changed in many
countries and others have announced coming changes in Blister in the paint may also be caused by unsuitable antifoul-
their legislation. ing paint, galvanic currents, unpainted stem fittings etc . Be
sure the anodes are not above the waterline when the
In general, the new legislation is or will be considerably more sterndrive is tilted. They must be submerged in order to
restrictive as far as the allowed leakage of the active ingredi- function properly.
ents in the paints to the water is concerned. Several countries
have put into practice (or will put into practice) a more Always read, understand and follow the
restrictive legislation for pleasure boats than for commercial paint manufactures instructions for the safe and proper use of
boats and vessels. The reason is that leisure boat harbors the paint product to be used.
often are situated in shallow waters, which are spawning
grounds for fish. Contrary to commercial boats, leisure boats
Painting withAntifouling Paints
spend most of their time tied up in the harbor, which adds to
Do not use an airborne paint processes (i.e.
the impact on the environment in these waters. aerosol, airless, or HVLP) to apply antifouling paint. The same
Since the protect ion of the environment is in the best interest toxic material that makes antifouling paint work will make you
of all, it is important to minimize the use of antifouling paints. sick. Always read, understand and follow the paint manufactures
As far as smaller boats are concerned (trailer boats) which instructions for safe and proper use.
can be taken out of the water, we recommend teflon type
only, combined with cleaning a few times during the season. Only use antifouling paint specifically de-
signed for use on aluminium sterndrive components. Never
This procedure can prove somewhat impractical as far as
use copper-based antifouling paints. Serious damage will
larger boats are concerned and therefore antifouling paints
result.
might have to be used. However, always take care to find
out the valid legislation in the area where you intend to use When making the purchase make sure that you receive the
the boat prior to starting the treatment of the boat! Please correct product meeting the legislation prevailing in the area
note that it might be completely forbidden to use antifouling where you are going to use the boat. The product must
paints on leisure boats for instance in fresh water. The contain the correct properties for the boat hull type. Alu-
legislation can also provide rules as to the boat weight or minium hulls often require an initial treatment with an etching
overall length. Always follow local laws and regulations. primer. Use a pure copper based antifouling paint, containing
copper tiocyanate, not copper oxide. Leave a 1“ strip
Preparing the Sterndrive
unpainted around the transom shield/sterndrive.
Prior to painting the sterndrive with antifouling paint, check and Tin-based (TBT-paints) are no longer allowed. Make sure to
repair possible paint damage to the finish coat. If the paint has prepare the hull in accordance with the direct ions of the paint
been removed to bare metal, grind the area with 220 or finer manufacturer.
aluminium oxide sandpaper. Wash the area clean with mineral
spirits or its equivalent. Any porus area must be filled with The complete sterndrive including the trim cylinders, cooling
putty. After applying putty the surface must be sanded water intake and transom shield should be painted in order to
smooth and washed. maximum protection. Do not allow the antifouling paint on the
transom shield (which is tin based) to come into contact with
Paint the area with Volvo Penta primer 1141561-9 (2 the antifouling bottom paint on the boat (which is usually copper
component ½ litre can) if bare aluminium is visible. The primer based). This will cause severe galvanic corrosion of the
does not have to be sanded before applying the finish coat. sterndrive and/ or thru hull fittings. Always allow a
Paint the repair area with two coats of finish paint Volvo 25.4mm (1 in.) border between the transom shield and
Penta 11415 75-9 (spay can) or 1141578-3 (2 component the bottom paint on the transom. Also, any metallic thru
½ litre can). Wet sand with 220 grit sandpaper between hull fittings that are bonded to the engine must have a
finish coatings. border around each fitting.

Do not sand to bare metal. If bare metal is For the paint to be effective you should allow the paint to dry
exposed during finish sanding, the area must be repaired overnight between coats . The boat should remain out of the
with primer and the process repeated. water at least 12 hours after the last coat of paint is applied.

If paint repair is needed due to paint blistering, the cause must The quantity of the paint determines the longevity of the
be found and remedied before paint repairs are made. protection it gives. One can (¼ litre) is a suitable quantity of
Repairing the paint without finding the cause will only post- paint for the sterndrive and the transom shield.
pone damaged pant. Consult Volvo Penta publication
7733534-7 Marine Electrical Systems, Part 1 under chapter
1:14 Electrochemical Corrosion for more information.
Check the zinc anodes. There must be at least 50% of the
anodes remaining to provide adequate protection of the
sterndrive and transom shield. If there is less than 50% of
the anodes remaining, they must be replaced. The anodes

77

NOTES
NOTES

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78

TECHNICAL DATA
General Data DP-E
 TECHNICAL DATA
General Data DP-E
Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aquamatic DUOPROP
Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self adjusting Silent Shaft type of cone clutch, servo as-
sisted disengagement.
Maximum tilt angle, approx . . . . . . . . . . . . . . . . . . . . . . . . . 60"
Power Trim & tilting device . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim
Steering angle, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 °
Overall gear ratio
Model DP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.95:1, 2.30:1, 1.78:1
Weight
Model DP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Kilos (127.9 lb)

Gear backlash
Lower gear, measured on the wings of the inner propeller
shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08-0.17 = 0.15-0.30 mm (0.003-0.007 in.) backlash
in the gear
Lower gear, measured on the wings of the outer propeller
shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11-0.34 = 0.20-0.35 mm (0.008-0.014 in.) backlash
in the gear
Upper gear, ratio 1.95:1 and 1.78:1,
measured directly on the gear . . . . . . . . . . . . . . . . . . . . . 0.15-0.25 mm (0.006-0.010")
Upper gear, ratio 2.30:1, measured
directly on the gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08-0.18 mm (0.003-0.070")
Lubricating system Pump, type . . . . . . . . . . . . . . . . . . . . . Circulation pump for distribution of oil to all lubricating
points
Lubrication System
Oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API-GL5*
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 90 or 80W90
Oil quantity, approx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 liters (2.4 UK Ots. 2.8 IS Qts.)
Oil quantity, 1 in. extension, approx . . . . . . . . . . . . . . . . . 2.7 liters (2.4 UK Ots. 2.8 US Qts.)
Oil quantity, 4" extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 liters (2.6 UK Ots. 3.0 US Qts.)
Oil quantity between min. & max. marks . . . . . . . . . . . . . . 0.15 liters (0.13 UK Qts. 0.16 US Ots.)
Power Trim, oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexron II

Tighteningtorques
NM Kpm Lb. ft.
Upper nut on vertical shaft (upper gear) . . . . . . . . . . . . . . 125 12.5 92
Tightening universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 7.5 55
Assembly double bearing box - gear housing . . . . . . . . . . 3 5 3.5 26
Assembly of top cover to upper gear housing . . . . . . . . . 15 1.5 11
Lower nut on vertical shaft . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.0 81
Bearing box with propeller shaft in gear housing . . . . . . . 4 0 4.0 30
Interm. housing - lower gear housing . . . . . . . . . . . . . . . . . 1 5 1.5 11
Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 1.0 7.5
Oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 3.5 25
Interm. housing - upper gear housing . . . . . . . . . . . . . . . . 2 0 2.0 15
Steering helmet 'attachment bolt’ . . . . . . . . . . . . . . . . . . . 3 5 3.5 25
Prestressing
Input gear in double bearing box . . . . . . . . . . . . . . . . . . . . 5-10 N (0.5-1.0 kp/ 1.102-2.205 lb.)
Input gear in double bearing box, run-in gears . . . . . . . . . 2.5-5 N (0.25-0.5 kp/0.55-1.102 lb.)
Lowergear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2-2.3 N (0.12-0.23 kp/0.265-0.507 lb.)
*Synthetic oil grade 75W90 corresponding to API GL5 requirements is recommended for commercial use.

79

General Data SP-E

 General Data SP-E
Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aquamatic SP-E
Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self adjusting Silent Shaft type of cone clutch, servo as-
sisted disengagement.
Maximum Propeller Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16”
Maximum tilt angle, approx . . . . . . . . . . . . . . . . . . . . . . . . . 60"
Power Trim & tilting device . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim
Steering angle, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 °
Overall gear ratio
Model SP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.61:1
Weight
SP-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Kilos (127.9 lb)
Gear backlash
Upper gear,
ratio 1.61:1, measured directly on the gear . . . . . . . . . . . 0.15-0.25 mm (0.006-0.010")

Lower gear,
measured on the intermediate shaft spline joint . . . . . . . 0.06-0.10 = 0.15-0.25 mm gear backlash in the gear
(0.002-0.004 in)
Lubrication System
Pump, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circulation pump for distribution of oil to all lubricating
points
Oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . API-GL5*
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 90 or 80W90
Oil quantity, approx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 liters (2.25 UK Ots. 2.75 US Qts.)
Oil quantity, 1 in. extension, approx . . . . . . . . . . . . . . . . . 2.6 liters (2.25 UK O ts. 2.75 US Qts.)
Oil quantity, 4" extension . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 liters (2.5 UK Ots. 3.0 US Qts.)
Oil quantity between min. & max. marks . . . . . . . . . . . . . . 0.15 liters (0.13 UK Qts. 0.16 US Ots.)
Power Trim, oil quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexron II

Tighteningtorques
NM Kpm Lb. ft.
Upper nut on vertical shaft (upper gear) . . . . . . . . . . . . . . 125 12.5 92
Tightening universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . 75 7.5 55
Assembly double bearing box - gear housing . . . . . . . . . . 3 5 3.5 26
Assembly of top cover to upper gear housing . . . . . . . . . 1 5 1.5 11
Lower nut on vertical shaft . . . . . . . . . . . . . . . . . . . . . . . . . 110 11.0 81
Bearing box with propeller shaft in gear housing . . . . . . . 4 0 4.0 30
Interm. housing - lower gear housing . . . . . . . . . . . . . . . . . 15 1.5 11
Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 1.0 7.5
Oil filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 3.5 25
Interm. housing - upper gear housing . . . . . . . . . . . . . . . . 2 0 2.0 15
Steering helmet 'attachment bolt’ . . . . . . . . . . . . . . . . . . . 3 5 3.5 25
Prestressing
Input gear in double bearing box . . . . . . . . . . . . . . . . . . . . 5-10 N (0.5-1.0 kp/1.102-2.205 lb.)
Input gear in double bearing box, run-in gears . . . . . . . . . 2.5-5 N (0.25-0.5 kp/0.55-1.102 lb.)

*Synthetic oil grade 75W90 corresponding to API GL5 requirements is recommended for commercial use.

80

TOOLS
885322-8 Upper Gear Housing Tool Kit 885324-4 Lower Gear Housing Tool Kit
 TOOLS
885322-8 Upper Gear Housing Tool Kit 885324-4 Lower Gear Housing Tool Kit
Standard Handle, Slide Hammer, Sp Bearing Remover,
9991801-3 884316-1
Used On Upper & Intermediate Lower
3850608-5 Snap Ring Plyers, Upper 3850598-8 Spline Socket, Upper & Lower
Bearing Press Drift, 3855876-3 New Style Fwd Prop Nut Tool, Lower
884168-6
Upper, Intermediate, Lower Standard Handle, Pointed, Lower &
884143-9
Press Tool, Bearing Installer, Upper & Intermediate
884263-5
Lower 884161-1 Tool, Slide Hammer, Lower
884265-0 Press Tool, Upper & Lower 884241-1 Bearing Installer, Lower
884266-8 Press Tool, Tube, Upper 884267-6 Shaft Remover, Lower
884312-0 Seal Installer, Upper 884283-3 Drift, Seal & Bearing Installer, Lower
884386-4 Press Tool, Sleeve, Upper 884348-4 Holding Fixture, Lower
884483-9 Tension Tool, Upper 884381-5 Bearing Drift, Remover, Lower
884793-1 Seal Install Tool, Upper 884385-6 Bearing Installer, Lower
884932-5 Mandrel, Seal Installer, Upper 884789-9 Puller, DP Prop Shaft, Lower
884933-3 Mandrel, Bearing Install Tool, Upper 884791-5 Drift, Bearing Remover, Lower
884938-2 Sleeve, Bearing Press, Upper 884792-3 Bearing Install Tool, Lower
90 Deg Allen Wrench, Puller, Fwd Bearing Race Remover,
885008-3 884794-9
Upper, Intermediate & Lower Lower
885009-1 Wrench, Upper & Intermediate 884795-6 Bearing Install Tool, Lower
885043-0 Torx 50 Bit, _ Inch Drive, Upper 884796-4 Drift, Bearing Remover, Lower
885152-9 Mounting Plate, Upper 884797-2 Press Tool, Bearing & Seal, Lower
885153-7 Spacer Ring, Mounting Plate, Upper Install Tool, Prop Shaft Bearing
884798-0
9985494-5 Spring Gauge/Scale, Upper Installer, Lower
884799-8 Press Fixture, Lower
885323-6 Intermediate Housing Tool Kit Press Tool, Bearing & Seal Installer,
884801-2
Expander, Axial Bearing Remover, Lower
884140-5
Intermediate 884802-0 Shaft Puller, DP, Lower
3810105-1 Pin Installer, Intermediate Drift, Tube Gear Brg & Seal Remover,
884803-8
Drift, Bearing Installer/Remover, Lower Unit
884259-3
Intermediate Drift, Tube Gear Bearing Installer,
884806-1
Drift, Bearing Installer/Remover Lower
884311-2
Intermediate Large Protective Sleeve/Ring, Black,
884807-9
Flex Driver, Bellows Clamps, Lower
884573-7
Intermediate Press Fixture, Bearing Race Remover,
884831-9
884874-9 Tool, Remover, Intermediate Lower
884978-8 Trim Cyl Removal Tool, Intermediate Drift Set, Tube Gear Race Remover,
884832-7
884982-0 Tool, Bearing Remover, Intermediate Lower
Drive Support Kit, Attachment, DP Prop Shaft Runout,
885143-8 884940-8
Intermediate (885142-0) Lower
885148-7 Pin Remover, Intermediate Small Protective Sleeve/Ring, White,
884976-2
Lower
885325-1 SP-DP Power Steering Cylinder Tool Kit, (884975 & 884976), Seal
884977-0
885207-1 Hook Spanner Installer, Lower
3810152-3 Drive Pressure Tester 885127-1 Old Style Fwd Prop Nut Tool, Lower
3858578-2 Drive Vacuum Tester 885149-5 Drilling Sleeve, DP, Lower
Alignment Wedge, Engine To Transom 885197-4 Tool, DP, Threaded Screw, Lower
884502-6
Shield
885208-9 Hook Spanner Drive Tools Not Included On New Tool Boards
885209-7 Sleeve 884521-6 280 Drive Hanging Tool
Drive Repair Welding Rod (Aluminum
839643-4
Tool Boards Electrode)
885326-9 Upper Gear Housing 854668-1 Prop Wrench For16mm Bolt Cone
885327-7 Intermediate Gear Housing 873058-2 Prop Wrench For 20mm Bolt Cone
885328-5 Lower Gear Housing Drive Support, Part Of Kit 885143-8,
885142-0
885329-3 SP-DP Power Steering Cylinder Tools Intermediate
885146-1 290 Drive Hanging Tool

81

8
2

Shimming the front bearing Shimming the bearing box

G – nominally (60.00 or 61.00) F – nominally (79.00 or 80.00)

G – stamped + F – stamped +
8
2

Shimming the front bearing Shimming the bearing box

G – nominally (60.00 or 61.00) F – nominally (79.00 or 80.00)

G – stamped + F – stamped +

G= (61.00 ± 0.15) F= (80.00 ± 0.15)

Front gear wheel, nominally = 39.50 C bearing box, nominally = 19.00

Front gear wheel, stamped = ± C bearing box, stamped = ±

Front gear wheel = C=

Front bearing, height = + 20.85
F=
G= C=–
–

X = Shim thickness =
Rear gear wheel, nominally = 39.50
Shimming the vertical shaft Rear gear wheel, stamped = ±

H – nominally 277.00
H – stamped + Rear bearing, height + 20.75

H=

Pinion, nominally = 60.00

Pinion, stamped = ±
–
Pinion =
Vertical shaft = + 217.75 Z = Shim thickness

H=– Shimming the intermediate bearing

Shim thickness = G= X=
F= Z=
Constant = + 120.00

C=–

Shim thickness =

H 217.75
 H 217.75

217.75mm = 8.57"
39.50 mm = 1.56"
20.85 mm = 0.821"
20.75 mm = 0.817"
39.50
20.85 39.50 C
20.75

G F

   

   
    
   


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AB Volvo Penta
Technical Information
SE-405 08 Göteborg
Sweden