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Bellows Installation

J

Jmunk

New member
I’m putting new bellows, shift kit, and trim senders on my Alpha 1 Gen 2. I’m about to start reassembly and have a few questions.

Does the speedometer hose go behind the water intake hose? Mine seemed to be that way when it came apart.

The gear oil hose that came in the OEM kit is 9.5” long and the manual states to cut a piece 10” long, any issues with the shorter hose?

Manual states to clean the u-joint bellow with soapy water to clean mold release agent, never seen anyone mention doing that.

Anyone want to share their preferred order of installation for the bellows, hoses, and shift cable?
 
o2batsea said:
Since you mention having the manual, I suggest that you follow the steps there
Click to expand...
That doesn't really answer any of the questions.

Everyone’s preferred order isn’t the manual, I’m sure people who do these jobs often have tricks do the trade not listed in the manual.

The hose length issue is one that Mercury themselves can’t figure out when they state one length and supply you with another in their kits.
 
Jmunk said:
That doesn't really answer any of the questions.

Everyone’s preferred order isn’t the manual, I’m sure people who do these jobs often have tricks do the trade not listed in the manual.

The hose length issue is one that Mercury themselves can’t figure out when they state one length and supply you with another in their kits.
Click to expand...
Mercury doesn't care what someone prefers when they reassemble this, they want it done in the method THEY use. It works from the factory when done that way, so it's probably a good idea to follow the manual.

One trick of the trade that I learned while working for boat dealers, which seems to work pretty well- follow the manual.

Do you actually need to replace the speedo hose? If not, you don't need to use the part that came with the kit. Not sure why it would be short- you could contact Mercury/Quicksilver about this.

Does the manual shop that the hose needs to be 10" or the hose needs to be 10" with the fitting on the end? That would add about 1/2".
 
Water hose, Should have purchased the shaped hose. Works perfectly out of package.
hard straight hose, if you purchased OEM mecruiser/Quicksilver parts, nothing to be done. Its cut to the correct length. I have NEVER had to cut one. Use some dish soap and install to transom side first.

Install bellows for gen 2 with aluminium ring, to transom side first with hose clamp .
Short shift cable and bellows can be partially installed meaning outer core can be threaded in place and bellows slipped on using dish soap to aid. Routing of cable is very important once in engine area so read carefully and ask if needed.

Not sure how much you have dissassembled so its hard to give more advice.

The biggests tricks are expirence. Its hard to write a book for someone like you who is asking us to hold your hand.

Read the manual if something doesnt make sense, ask.
 
kghost, has the best answers.
As to the speedohose, be sure to clip it to the intake H20 hose to keep from pinching.
Use the Stainless Steel Bellows Clamps not glue.
Positioning the clamp screw is important, don't think tightening with a screwdriver.
Use a 1/4" wobble extension with a 1/4" Socket.
You do need the molded Water hose for a proper install.
Install the bellows Dry.
When installing the drive side of the bellows lower till you can slip on the lip of the bellows and tighten the prepositioned SS Clamp then it won't come off when raised.
 
Boatyarddog said:
kghost, has the best answers.
As to the speedohose, be sure to clip it to the intake H20 hose to keep from pinching.
Use the Stainless Steel Bellows Clamps not glue.
Positioning the clamp screw is important, don't think tightening with a screwdriver.
Use a 1/4" wobble extension with a 1/4" Socket.
You do need the molded Water hose for a proper install.
Install the bellows Dry.
When installing the drive side of the bellows lower till you can slip on the lip of the bellows and tighten the prepositioned SS Clamp then it won't come off when raised.
Click to expand...

Hose clamp should be 5/16" hex.

Always use bellows adhesive at hose clamped locations,
ujoint bellows at transom (gimbal housing on gen 2 uses a aluminum pinch ring), shift cable bellows at transom mount and exhaust bellows both ends (this is the hardest install). There is a shaped (Oval) exhaust bellows from merc. Installs much easier!

Yes I DONT MINCE WORDS!
 
Boatyarddog said:
I find the 1/4" easier, and less likely to rub when trimmed up or Raised.
Never used the glue.
No need, never saw an issue.
No leakage.
Click to expand...

Hex hed of hose clamp is 5/16. And yes 1/4 " drive is required.

Maybe you have never had an issue when NOT using the bellows adhesive.
BUT, THAT IS WHAT IS STATED IN THE MANUAL and I use it as much as I use Vodka... so it is specified and needed!!!
Dont give back yard opinions. Stick with OEM specifications!
 
kghost said:
Hex hed of hose clamp is 5/16. And yes 1/4 " drive is required.

Maybe you have never had an issue when NOT using the bellows adhesive.
BUT, THAT IS WHAT IS STATED IN THE MANUAL and I use it as much as I use Vodka... so it is specified and needed!!!
Dont give back yard opinions. Stick with OEM specifications!
Click to expand...
Welcome Advise😉
Other experience shows without doubt that Other yet to be explained " solutions" exist...
And work as good as or better than " factory" Manuals prescribe.
Procedures, as well as Products, outdate "Old School" procedures, and Products.
It's how Evolution Works😁
 
I did have the contoured water inlet hose. Didn’t replace Speedo line, just asked which side of water inlet hose it went. Hose length referenced the gear oil hose. Bellows are on and it’s done. It wasn’t a technical job at all, just small space to work.

Ended up using some ingenuity on the gear lube fitting e-clip. Had the fitting and clip done in about 15min. The trick wasn’t in the manual!

Picked up a cheap exhaust bellow tool from Amazon, well worth the few bucks and only took a few minutes.

Thanks for advice and tips.
 
Boatyarddog said:
kghost, has the best answers.
As to the speedohose, be sure to clip it to the intake H20 hose to keep from pinching.
Use the Stainless Steel Bellows Clamps not glue.
Positioning the clamp screw is important, don't think tightening with a screwdriver.
Use a 1/4" wobble extension with a 1/4" Socket.
You do need the molded Water hose for a proper install.
Install the bellows Dry.
When installing the drive side of the bellows lower till you can slip on the lip of the bellows and tighten the prepositioned SS Clamp then it won't come off when raised.
Click to expand...
Mercruiser shows that Perfect Seal should be used- it's also used as a cement for gaskets and is the same stuff as NAPA or Permatex gasket seal. I bought some when I was working on my outdrive because I couldn't find either container of the other two and as soon as I pierced the end, I realized that I had wasted my money because between ordering and arrival, I found them.

The clamp is used on all bellows at the transom assembly and on the drive, but only on the older Alpha models. The newer ones have a ring that goes in from the rear and presses in, to position the bellows between it and the opening in the upper gearcase. It doesn't slide over.

The plastic clip for the speedo line comes with the kit.
 
I used the Permatex aviation form-a-gasket for where the manual called for perfect seal. Went out today, no leaks so I’m going to call it a success.
 
Jmunk said:
I used the Permatex aviation form-a-gasket for where the manual called for perfect seal. Went out today, no leaks so I’m going to call it a success.
Click to expand...
I would recommend checking it- any cement acts like a lube when until it sets and one way to prevent squirming off is by letting it start to dry before assembly. It will grab and stay in place. Another thing I would recommend to anyone- leave the drive in the vertical position (trimmed neutral) while it dries, so the bellows won't be pulled off of the transom plate at the bottom.
 
Only place manual called for perfect seal on the bellows installation is the threads of shift cable and trim sender retainer bolt.

If you’re referring to the bellows adhesive, you put light coats on the two items and let sit for 5-10min and then assemble. The glue is well setup when you assemble and tighten the clamp. If it slides apart then you used too much adhesive.
 
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