Workshop Manual Drives BC 2(0) 280, 280-DP, 285, 290, 290-DP SP-A, SP-C, DP-A, DP-B, DP-C
Drives AQ 280, AQ 280-DP, AQ 285, AQ 290, AQ 290-DP SP-A, SP-C, DP-A, DP-B, DP-C Contents General Information ......................................................... 3 Safety Information ........................................................ 3 Introduction ............................................................. 3 Important ................................................................ 3 General Information ..................................................... 6 About the Workshop Manual ......
Contents Installing the sterndrive .............................................. Models 280 and 285 ............................................... Checking and adjusting controls ...................... Checking the retaining pawl when test running ........................................................ Oil filling ............................................................. Propeller installation ......................................... Installing a ‘long hub’ type of propeller ........
Safety Information Introduction The Workshop Manual contains technical data, descriptions, and repair instructions for the designated Volvo Penta products or product versions. Make sure that the correct workshop literature is used. Read the following safety information and the General Information and Repair Instructions in the Workshop Manual carefully before starting service work. Important The following special warning symbols are used in the Workshop Manual and on the product.
General Information Stop the engine and close the bottom valve before working on the cooling system. Only start the engine in a well-ventilated area. Exhaust fumes and crankcase gases should be led out of the engine compartment or workshop when working in closed environments. Always use protective glasses for work where there is a risk of splintering, sparks, or splashing of acid or other chemicals.
General Information Use the lifting hooks mounted on the engine/ reverse gear when lifting the drive unit. Always check that the lifting equipment is in good condition and has the correct capacity for the lift (weight of engine plus reverse gear and extra equipment where appropriate). For safe handling, and to avoid damaging the components mounted on top of the engine, the engine should always be lifted with a lifting bar adjusted to the engine.
General Information About the Workshop Manual Spare parts This Workshop Manual contains technical information, descriptions, and repair instructions for the standard versions of the drive units 280, 280T, 280PT, 285, 285A, 290, 290A, 280-DP, 280-DP/PT, 290-DP, 290A-DP, SP-A, SP-A1, SP-A2, SP-C, DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1. Spare parts for the electrical and fuel systems are subject to different national safety requirements, e.g. U.S. Coast Guard Safety Regulations.
Repair Instructions The work methods described in the Workshop Manual are applicable for a workshop environment. The drive has removed from the boat and is installed in an overhaul fixture. Unless otherwise stated reconditioning work which can be carried out with the drive in place follows the same working method.
General Information Size Tightening torque, Nm (lb.ft) M5 ...................................................... 6 (4.4) M6 ...................................................... 10 (7.4) M8 ...................................................... 25 (18.4) M10 .................................................... 50 (36.9) M12 .................................................... 80 (59.0) M14 .................................................... 140 (103.
General Information Sealant A number of different types of sealant and locking fluids are used on the engine. The sealant has different properties for different union strengths, temperature ranges, resistance to oil and chemicals, and for the different materials and slot sizes in the engine. It is therefore important to use the correct type of sealant and locking fluid for those unions that require them, in order to ensure satisfactory service work.
Special tools In all cases where it has been practically possible tools have been punched with their tool number, excluding the last digit. The last digit (after the hyphen) is a check number.
Special tools 884267 884283 884316 884298 884348 884387 884381 884483 884573 884311 884385 884502 884789 884312 884386 884521 884792 884793 884267-6 Tool, dismantling vertical shaft 884386-4 884283-3 Drift for the installation of sealing rings in propeller bearing housing and of propeller shaft needle bearing Sleeve, dismantling and installing gear wheels in upper gear 884387-2 Attachment plate for upper gear housing 884483-9 884298-1 Puller, propeller shaft needle bearing.
Special tools 884794 884795 884799 884807 884801 884830 884932 884796 884802 884831 884933 884797 884803 884832 884936 884938 884798 884806 884874 884941 884794-9 Puller, forward bearing race remover, lower 884831-9 Press fixture, bearing race remover, lower 884795-6 Bearing install tool, lower 884832-7 Drift set, tube gear race remover, lower 884796-4 Drift, bearing remover, lower 884874-9 884797-2 Press tool, bearing & seal, lower Support, dismantling the sterndrive from
Special tools 884975 884976 885009 885043 885148 885197 884978 885127 885149 885207 884982 885008 885143 885146 885153 885192 885209 885208 885226 885227 884975-41) Installation tool 885148-7 Pin remover, intermediate 884976-21 ) Protection sleeve 885149-5 Drilling jigg, duoprop, lower 884978-8 Trim cylinder removal tool, intermediate 885152-9 Kit containing tools 884387 and 885153 884982-0 Disassembly tool for outer bearing race. Intermediate housing, extension.
Special tools 3810105 3810152 3850598 3856761 3855876 9985494 3850608 3858578 9991801 9992520 3810105-1 Pin installer, intermediate 3856761-6 Holding plate, shift mechanism 3810152-3 Drive pressure tester 3858578-2 Drive vacuum tester 3850598-8 Spline socket, upper & lower 9985494-5 Spring gauge/scale, upper 3850608-5 Snap ring plyers, upper 9991801-3 Standard shaft 3855876-3 Tool, new type of propeller nut 9992520-8 Stand Chemicals Volvo Penta part no.
Drive models and generations AQ 280 AQ 280T Power trim/tilt Oil: Same as engine Qty: 2.6 liters (2.74 qts) Ratio: 1.61:1 1.89:1 2.15:1 Oil: Same as engine Qty: 2.6 liters (2.74 qts) Ratio: 1.61 AQ285 AQ 285A AQ 280 PT Power trim Electro mechanical tilt Power steering Oil: Same as engine Qty: 2.6 liters (2.74 qts) Ratio: 1.61:1 1.89:1 Oil: Same as engine Qty: 2.6 liters (2.74 qts) Ratio: 1.
Drive models and generations AQ 280-DP/PT AQ 280-DP Dual hydraulic cylinders Oil: 1) API GL-5, SAE 90 Qty: 2.7 liters (2.85 qts) Ratio: 1.95:1 2.30:1 1) Ratio: 1.95:1 2.30:1 AQ 290 AQ 290A AQ 290-DP AQ 290A-DP New transom shield Hook up fork Transom shield Double bearing box Hook up fork Oil: Same as engine Qty: 2.6 liters (2.74 qts) Oil: Same as engine Qty: 2.6 liters (2.74 qts) Oil: 1) API GL-5, SAE 90 Qty: 2.7 liters (2.85 qts) Ratio: 1.61:1 1.89:1 2.15:1 Oil: 1) API GL-5, SAE 90 Qty: 2.
Drive models and generations SP-C SP-A2 Sliding sleeve (steel) Sliding sleeve (brass) Intermediate housing Cover Hydraulic cylinder Hook up fork Support plate Sliding sleeve (brass) Gear set Sliding sleeve (steel) Cover Gear set Oil: Same as engine or Fully synthetic API GL-5 SAE 75W–90 Qty: 2.6 liters (2.74 qts) Ratio: 1.61:1 1.89:1 Oil: Same as engine (all SP-C drives) or Fully synthetic (ratio 1.61:1, 1.89:1) API GL-5 SAE 75W–90 Qty: 2.6 liters (2.
Drive models and generations DP-B1 DP-C Sliding sleeve (steel) Cover Intermediate housing Hydraulic cylinder Hook up fork Transom shield Cover Ball bearing Universal joint Intermediate housing Oil: Fully synthetic API GL-5 SAE 75W–90 Qty: 2.7 liters (2.85 qts) Ratio: 1.78:1 1.95:1 2.30:1 DP-C1 Propeller shaft Propeller cone Oil: Fully synthetic API GL-5 SAE 75W–90 Qty: 2.7 liters (2.85 qts) 18 Ratio: 1.78:1 1.95:1 2.30:1 Oil: Fully synthetic API GL-5 SAE 75W–90 Qty: 2.7 liters (2.
Design and function Model 280 Section through the sterndrive 1. Steering arm 2. Electro-mechanical tilting device 3. Steering yoke 4. Rubber cushion 5. Universal joint 6. Steering helmet 7. Input gear 8. Forward/reverse gear 9. Forward/reverse cone 10. Upper gear housing 11. Coupling box 12. Shift mechanism 13. Shift plate 14. Vertical shaft 15. Intermediate housing 16. Trim tab 17. Circulation pump 18. Propeller shaft 19. Propeller shaft gear 20. Water intake 21. Lower gear housing 22. Retaining pawl 23.
Design and function Models 290-DP, DP-A, DP-B, DP-C Section through the sterndrive, showing model DP 1. 2. 3. 4. 5. 6. 7. 8. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removing the sterndrive Models 280, 285 and 290 B A Alt 2 Alt 1 1. Remove the propeller of the Singleprop sterndrive according to the picture. A-propeller 2. Remove the propellers of the Duoprop sterndrive according to the picture. (The picture shows the earlier model.) B-propeller NOTE! Never mix propellers from different drives.
Removing the sterndrive 3. Remove the Allen-head bolts holding the zinc ring and remove it. 5b. Sterndrive model 290: Remove the cover over the shift mechanism and disconnect the shift cable from the shift plate and remove the swivel. Remove the screws holding the locking plate, then push the locking plate down. 1 4. Remove the oil drain plug and drain off the oil. Also remove the oil dipstick to facilitate the oil drainage. Replace the O-ring on the drain plug and on the oil dipstick. 2 884936 6a.
Removing the sterndrive WARNING! Never start working on the rubber bellows of the sterndrive until you have secured it in its raised position and then in a way which definitely keeps it up. A sterndrive ‘falling’ down can cause severe bodily injuries. The suspension tool 884936, when properly installed, prevents the sterndrive from ‘falling’ down. The suspension tool locks the sterndrive in its raised position.
Removing the sterndrive 7b. Sterndrive model 290: Remove the steering helmet and the universal joint rubber bellows from the upper gear housing (1), the exhaust bellows from the intermediate housing (2) and the cooling water hose from the cooling water connection (3). The universal joint rubber bellows must be replaced every other year. 8a. Sterndrive models 280 and 285: Remove the two locking screws holding the shaft journals in the transom shield.
Removing the sterndrive Models SP and DP 1. Disconnect power to prevent accidental starting. 4. Move control to forward gear. 2. Move control to reverse. 5. Remove the aft line cutter, forward propeller nut, and forward propeller. Return the shift control to neutral. 3. Loosen propeller cone lock bolt. Remove the aft propeller cone. 6. Remove the shift linkage cover.
Removing the sterndrive 1 3 2 7. Remove the cotter pin and washer from the shift cable end. Remove the end pivot pin from the cable. 9. Remove the two screws (1) holding the steering pin to the upper gear head (2). Using two M6 screws (3) 30 mm 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. 884573 8. Loosen screw holding the shift cable clamp and release shift cable.
Removing the sterndrive 885143 885143 11. Remove the cotter pin on the trim cylinder pin. Remove the trim cylinder pin. Raise the drive manually and insert special tool 885143. 13. Remove the clamp on the raw water hose. Remove the raw water hose. Remove special tool 885143 and carefully lower the drive. 884573 12. Using special tool 884573, disconnect the exhaust bellows. 14. Remove the hook-up fork pin lock bolt. Using Pin removal tool 885148, pull the pin half way out of the transom shield.
Removing the sterndrive 885146 15. Install special tool 885146 and remove the sterndrive from the transom shield.
Repair instructions Upper gear housing Removal 1 1. Place a drain pan under the sterndrive. Remove the drain plug (1) and drain oil from drive. Reinstall the drain plug after the oil has drained. 3. Remove two retaining nuts from upper gear head studs. 2. Remove cotter pin and washer from gear shift linkage, and remove the linkage. 4. Remove two allen head retaining bolts. Remove the gear head.
Repair instructions Disassembly, models 280, 285 and 290 1. Remove the shift rod (1) from the shift plate (2). Remove the screws (3) and the nuts (4) holding the intermediate housing to the upper housing. Use a rubber mallet to knock the housings apart. Knock carefully. 2. Keep check on the number of shims (1) between the different housings and for all the gear sets in case neither the gears, housing nor the bearings need to be replaced. In this case the same shim thickness is to be used. 3.
Repair instructions 5. Remove the 4 screws holding the shift mechanism and remove the mechanism. NOTE! Be sure to remove the shift shoe (1) with the shift mechanism. 7. Remove the 4 screws holding the gear housing cover and remove the cover. NOTE! The front right hand screw (1) is a hollow screw with an O-ring seal. Take care of the shims (2). 1 6. Remove the 4 Allen-head screws holding the clamping ring (1) and pull out the universal joint and the double bearing box. 8.
Repair instructions 1 2 9. Lift out the upper gear and the bearing box as well as the engagement sleeve. 11. Remove the needle bearings (1) and the spacer rings (2) from the upper and lower gear sets. NOTE! The needle bearings are matched in pairs and must not be mixed! 1 2 884259 884386 10. Lift off the upper gear housing from the special tool. Dismantle the lower gear set and the shaft by removing the split locking ring (1) and the washer (2).
Repair instructions 884265 884386 13. Press out the bearings of the bearing sleeves. Use special tools 884386 and 884265. 15. Remove the collar washer (1) from the double bearing box. NOTE! Take care of the shims (2). Input gear (Double bearing box) 16. Remove the locking ring (1) and the sealing (2). NOTE! Always replace the sealing! 884259 14. Remove the Allen-head screw (1) and the collar washer (2) in the center of the universal joint shaft.
Repair instructions 18. If required press off the roller bearing (1) from the gear using a knife puller. The bearings (1) and (4) can be changed separately. When changing the outer races of the bearings, these must be ”knocked” off. Knock evenly all around. Always replace the oil deflector washer together with the outer races. Wash the parts and check for wear. Replace parts when necessary. NOTE! Gears with cones are sold in sets in order to obtain the correct gear contact.
Repair instructions Assembly, models 280, 285 and 290 NOTE! When assembling the upper gear housing it is very important that the gears are correctly positioned in relation to each other. This applies not only to the backlash between the gear teeth but also to the gear teeth contact. Correct gear teeth contact spreads the load to which the gears are subjected over a larger area of the gear tooth. This preventing gear breakdown and abnormal wear and at the same time providing a quiet operation. 3.
Repair instructions Forward and reverse gears 884265 1 3 2 884168 4 5 5. Measure the depth of the recess in the collar washer “E” and add to this measurement a number of shims (5) that the measurement “B” is obtained. 7. Lubricate the bearings (1) and press the bearings into their respective bearing boxes (2). NOTE! Turn the bearings with the recesses in the bearing races (3), for the assembly of the balls, facing away from the gear wheels. Use special tool 884168.
Repair instructions Shimming the forward and reverse gears Method 1 B88 C78 11. 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 61.00 mm (2.40”). Add this value to the value stamped into the gear to calculate shims for the forward and reverse gears. The shim calculations can be seen in the example below: Measurement “A”: 62.05 mm + 0.05 mm 9. Measurement “A” is fixed at 62.05 mm (2.443").
Repair instructions NOTE! When calculating the shim thickness for the forward and reverse gears, remember: Checking the gear backlash and contact pattern The upper gear housing nominal dimension has two values. If the stamped number is 50 or more, use the lower nominal value, 61.00 mm. If the stamped number is 49 or less, use the higher nominal value, 62.00 mm. Example: Stamping 50 or more “C” stamping: 78 = 00.78 mm Use Nominal Dimension = 61.00 mm 61.
Repair instructions 884387 15. Brace the special tool 884387 in a vice and install the gear housing in the tool. 17. Install the clamp ring and the cover with sufficient number of shims to ensure a proper compression of the bearings. There must be a clearance (1) between the housing and the clamp ring. See also the picture under point 19. 16. Install the preassembled double bearing box with 0.4 mm (0.016") shims. 18. Install a dial indicator to measure backlash. The correct backlash should be 0.15–0.
Repair instructions 19. When the correct backlash has been obtained, dismantle the double bearing box and the clamp ring. In order to obtain a clear picture of the contact pattern, the gear teeth are coated with a thin coating of marking dye. Once again assemble the double bearing box and the clamp ring. NOTE! The cover must still be installed with an excess number of shims (1). 20.
Repair instructions Final assembly 23. If the dye pattern reflects a contact pattern as shown in picture “C” the shim thickness underneath the drive gear (double bearing box) must be increased. The drive then moves away from the center. NOTE! If the drive is moved in or out respectively, also the gears must be moved in or out in order to maintain the correct backlash. Having obtained the correct backlash and dye pattern, the upper gear must be dismantled and the marking dye removed.
Repair instructions 1 1 884830 2 3. Install the needle bearings (1) and the spacer ring (2) between the bearings in the lower gear and insert the shaft in the gear. NOTE! The needle bearings are matched in pairs and must not be mixed up. 5. In order to obtain the correct axial shaft clearance there are 3 left hand threaded nuts (1) with different steps available. Select a nut and tighten it (tightening torque: 120 Nm (88.5 lb.ft.). Use special tool 884830 as a counter hold.
Repair instructions 9991801 884312 7. Measure the shim thickness between the clamp ring and the gear housing as follows: Hold the double bearing box as indicated in the picture with its calculated number of shims (see point 16, page 39). 8. Remove the recessed washer and the shims in it. Press the new sealing ring against the collar in the double bearing box, with the open part against the bearing. Use special tools 9991801 and 884312.
Repair instructions 10. Install the shims and the 2 new O-rings on the double bearing box. 12. Apply Volvo Penta part no. 1161099-5, Permatex® no. 3 on the surfaces between the clamp ring and gear housing. Install the double bearing box along with the universal joint in the gear housing. The guide pin in the double bearing box should be turned downwards. Lock the screws with thread locking compound, Volvo Penta part no. 1161053-2 and tighten them with a torque of 35 Nm (25.8 lb.ft.).
Repair instructions 14. Coat the contact surface with Volvo Penta part no. 1141570-0 sealant and install the sealing ring (1) in a way that the sealing for the front right hand screw aligns with the corresponding recess in the cover. 15. Install the calculated number of shims and tighten the cover. NOTE! The front right hand screw is a hollow screw and shall be provided with an O-ring (1) under its head. Tighten the screws with a torque of 15 Nm (11 lb.ft.).
Repair instructions Disassembly, models 290A, SP and DP NOTE! The illustrations show drives model DP, but the working methods are the same as for models 290A and SP. 3. Loosen and remove the 4 allen head bolts holding the double bearing box. 884264 884830 1 1. Install the upper gear housing on special tool 884830. This special tool, of earlier manufacture, also carries the part no 884264. 4. Pull out the double bearing box by pulling and turning simultaneously.
Repair instructions 7. Remove the left hand thread nut on the vertical shaft. Use special tool 884830 and the spline shaft as a counter-hold while removing the nut. 5. Remove the 4 screws holding the gear housing cover. 1 2 8. Lift out the upper bearing assembly along with the sliding sleeve and the spring. 1 2 6. Remove the cover. NOTE! The front right hand screw (1) is a hollow screw with an O-ring. Do not damage or lose the shims (2) for the cover. 9.
Repair instructions 1 884259 1 2 SP & DP 1 290A 884938 11b. Drives without intgrated bearings: Press out the bearings from the bearing sleeves. Use special tools 884938 and 884265. 10. Remove the needle bearings (1) from the upper and lower gear cup assemblies. Model 290A only: Also remove the spacerring (2). NOTE! Do not mix upper and lower needle bearings. Input gear (Double bearing box) 884259 885043 884938 11a.
Repair instructions 884263 3850608 1 2 3 13. Use special tool 3850608 to remove the locking ring (1), remove the shoulder washer (2). NOTE! The seal ring (3) can be removed at a later time. 15. Turn over the double bearing box and press out the seal ring along with the roller bearing. Use special tool 884263. NOTE! The bearing will be damaged if removed, only remove if a new bearing will be installed. 884266 884266 884938 14. Press out the input gear. Use special tools 884938 and 884266.
Repair instructions 9991801 884933 Assembly, models 290A, SP and DP NOTE! When assembling the upper gear housing it is very important that the gears are correctly positioned in relation to each other. This applies not only to the backlash between the gear teeth but also to the gear teeth contact. Correct gear teeth contact spreads the load to which the gears are subjected over a larger area of the gear tooth.
Repair instructions 884263 9991801 884932 1 884938 2. Install the bigger roller bearing on the gear wheel by pressing it on. Use special tool 884263. NOTE! Protect the gear teeth. Then install a new clamping sleeve (1). 4. Press down the sealing ring to the shoulder. Use special tool 884932 with handle 991801 and special tool 884938. Then install the locking ring with special tool 3850608. 884263 1 3.
Repair instructions 885043 9985494 6. Insert the universal joint into the double bearing box and brace the universal joint in a vice. Install the conical washer and tighten the screw by hand. NOTE! Apply thread locking compound, Volvo Penta part no. 1161053-0 or Loctite® 243 on the screw. Use a new screw. Use special tool 885043 to tighten the TX50 torx head screw with short intervals.
Repair instructions Forward and reverse gears 2 884265 1 3 2 1 884168 4 5 8a. Drives without integrated bearings: Lubricate the bearings (1) and press the bearing into their respective bearing boxes (2). NOTE! Turn the bearings with the recesses in the bearing races (3), for the assembly of the balls, facing away from the gear wheels. Use special tool 884168. Then press on the bearings and the bearing boxes onto the gear wheels. Use special tool 884265. 9. Always start by adjusting the forward gear.
Repair instructions Shimming the forward and reverse gears Method 1 B88 C78 12. 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 61.00 mm (2.40”). Add this value to the value stamped into the gear to calculate shims for the forward and reverse gears. The shim calculations can be seen in the example below: Measurement “A”: 62.05 mm + 0.05 mm 10. Measurement “A” is fixed at 62.05 mm (2.443").
Repair instructions NOTE! When calculating the shim thickness for the forward and reverse gears, remember: Checking the gear backlash and contact pattern The upper gear housing nominal dimension has two values. If the stamped number is 50 or more, use the lower nominal value, 61.00 mm. If the stamped number is 49 or less, use the higher nominal value, 62.00 mm. Example: Stamping 50 or more “C” stamping: 78 = 00.78 mm Use Nominal Dimension = 61.00 mm 61.
Repair instructions 884387 885153 16 a. Drives with integrated bearings From models SP-A1 and DP-A1 on Brace the special tool 884387 plate and ring 885153 (tool kit 885152) in a vise and install the gear housing in the tool. 18. Use sufficient number of shims to create clearance of max. 0.1 mm (0.004”) between the top cover and the upper gear housing as shown in the picture. Install the cover and tighten the cover screws. 16 b.
Repair instructions 20. Remove the double bearing box when the correct backlash has been obtained. To gain a clearer picture of the contact pattern, coat the gear teeth with a thin coating of marking dye. Then install the double bearing box again. NOTE! The cover is still installed with an excessive number of shims! 21. Rotate the gears in the normal direction of rotation (clockwise) while at the same time braking the gear forcefully by wedging a wooden brace against the gear cups.
Repair instructions Final assembly 24. If the dye pattern reflects a contact pattern as shown in picture “C” the shim thickness underneath the drive gear (double bearing box) must be increased. The drive then moves away from the center. NOTE! If the drive is moved in or out respectively, also the gears must be moved in or out in order to maintain the correct backlash. Having obtained the correct backlash and dye pattern, the upper gear must be dismantled and the marking dye removed.
Repair instructions 1 2 SP & DP 1 1 290A SP & DP 1 290A 1 2 1 3. Install the needle bearings (1) and the spacer ring (2, model 290A only) between the bearings in the lower gear and insert the shaft in the gear. NOTE! The needle bearings are matched in pairs and must not be mixed up. 5. Place the upper gear wheel with the calculated shims in the gear housing. Install the needle bearings (1) along with the spacer ring (2, model 290A only) between the bearings. 1 4.
Repair instructions 7. Measure the clearance between the nut and the bearing. The axial clearance should be 0.1–0.5 mm, 0.00394–0.0197"). If it should not be possible to obtain the correct clearance with any of the nuts, most probably the bearing is defective. 9. Coat the surfaces between the double bearing box and the gear housing with sealing compound, Volvo Penta part no. 1161099-5 or Permatex® no. 3. Install the double bearing box with the universal joint in the gear housing.
Repair instructions 11. Coat the cover with sealant, Volvo Penta part no. 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. 12. Insert the calculated shims and tighten the cover. NOTE! The front, right hand screw is a hollow screw, to be installed with an O-ring underneath the head of the screw. Tighten the screws with a torque of 15 Nm (11.04 lb.ft.) in diagonal sequence.
Repair instructions Reconditioning the universal joint 1 1. Remove the locking rings (1) holding the needle bearing in the yoke. NOTE! To avoid having the locking rings “jump out” and getting lost, hold a rag over the universal joint when removing the locking rings. 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.
Repair instructions 5. Use a small amount of water resistant EP bearing grease, Volvo Penta part no. 1161246-2, to retain the needle bearings in the cap. Push the spider through the yoke in one direction 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 to be installed.
Repair instructions Reconditioning the shift mechanism Types of shift mechanisms Shift mechanism type 1 For the models 280, 290, 285, 285A and 290A there are 3 different types of shift mechanism. The first type was installed up to and including serial no PZ 2829528. As from serial number PZ 2829529 the second type – where the ball, spring and the locking wire were removed – was installed. There is a somewhat different dismantling and assembly sequence for each type.
Repair instructions Assembly Oil all moving parts prior to the assembly. 3. Lubricate the sealing ring abundantly and install it with the steel edge (small clearance} facing inwards the gear housing. 4. Insert the excentric piston (1). Install the pin (2) and lock it with the load pin (3). Make sure that the load pin centers in the excentric piston. 5. Install the balls and the springs (1). Insert a locking wire (2) in the groove of the cover and compress the springs as indicated in the picture.
Repair instructions Shift mechanism type 2 1 4 2 3 7. Install the shift mechanism in the gear housing in a way that the screw (1) will be displaced towards starboard. NOTE! Make sure that the sliding shoe (2) is turned to a position corresponding the one in the picture. The shift mechanism will not function if the sliding shoe is turned the opposite way. Now install the shift mechanism in the sterndrive. Set the shift mechanism in neutral and remove all adjustment pads (3) and tighten the screw.
Repair instructions Assembly Oil all moving parts prior to assembly. 9. Lubricate the sealing ring abundantly and install it with the steel edge (small clearance) facing inwards the gear housing. 11. Install the spring (1), the sliding shoe (2) and the O-ring (3) and coat the contact surfaces with sealing compound, Volvo Penta part no. 1161099-5, or Permatex® no. 3. 10. Install the excentric piston (1). Install the pin (2) and lock it with the load pin (3).
Repair instructions Shift mechanism type 3 13. Set the shift mechanism in a position between forward and neutral or between reverse and neutral. The pin (1) should be positioned on one of the ‘cams’. Install the shift mechanism in the sterndrive. 1 2 3 15. Remove the sliding shoe (1) and the spring (2) and the O-ring (3). 14. Remove all adjustment shims (1) and tighten the screws. Now it is not possible to turn the vertical shaft in the upper gear housing.
Repair instructions 1 1 19. Tap the eccentric piston lightly on a wooden surface to remove the spring pin (1). Inspect the eccentric piston for scoring, distortion, or damage that may cause it to leak or bind in the housing. 16. Knock in the load pin as far as necessary to free the pin (1). 20. Using a screwdriver, pry out the eccentric piston seal. Clean all surfaces and check for damage that may cause leaks. Replace parts as necessary. 17. Pull out the pin.
Repair instructions 1 2 3 22. Install the eccentric piston (1) in the housing. Do not damage the seal! Push in the locating pin (2). Align the hole with the housing. Lock it in place with a new spring pin (3). 24. Install the shift mechanism in the gear housing in a way that the screw (1) is displaced towards starboard. NOTE! Make sure that the sliding shoe (2) is turned to a position as indicated in the picture.
Repair instructions 1 2 3 28. Install the eccentric piston (1) in the housing. Do not damage the seal! Push in the locating pin (2). Align the hole with the housing. Lock it in place with a new spring pin (3). 26. Remove all adjustment shims (1) and tighten the screw. Now it is no longer possible to turn the vertical shaft in the upper gear housing. Insert an adjustment shim at the time on the screw until the shaft can be turned again without any sort of resistance.
Repair instructions 3856761 With the special tool installed, add one shim to the shimming screw (1) and install finger tight while rotating the propeller shaft by hand. If propeller shaft binds, repeat this step, adding one shim at a time, until no resistance is felt through 360° of rotation. NOTE! 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.
Repair instructions Intermediate housing Reconditioning the intermediate housing, model 280 and 285 3. Remove the plastic washers (1) and the wear washer (2). 1. Remove the 2 screws holding the hose connection (1) on the yoke. Remove the hose connection and the gasket. 9991801 9991801 884311 884259 4. Press out the sealing rings and the needle bearing. Use special tool 884259 and 9991801. NOTE! There is a sealing ring on each side of the needle bearing. 2.
Repair instructions 884259 7. Dismantle the axial bearing race. Use special tools 884140 and 884143. Also replace the O-rings (1). One at each end of the tube. 5. Press out the bushing (1). Use special tool 884259. 6. Should the shift yoke need to be replaced, remove the cotter pin (1). Then it is possible to pull out the shaft (2) and the shift yoke (3). 8. The retaining pawl is dismantled, when necessary, as follows: Remove the shaft journals (48).
Repair instructions Assembly Oil all moving parts and the screws prior to assembly. 10. Paint the retaining pawl with a thin layer of ‘touch-up paint’. Painting is hard to do when the pawl is assembled. The picture reflects an assembled retaining pawl. 9991801 884259 9. Install the shaft (53) on one of the retaining pawls (42) and the spacer washer (44) and the spring catch (52). Install one of the nuts (55) on the shaft.
Repair instructions 12. Press in both sealing rings. Use special tool 884259. NOTE! The sealing rings are to seal against water and thus have to be installed ”facing” each other. 14. Install the retaining pawl in the yoke and place the yoke with the retaining pawl in its location in the intermediate housing. NOTE! Insert the wear washer (1) between the lower attachment of the yoke and the intermediate housing and the two plastic washers (2) with one on each side of the bearing.
Repair instructions Reconditioning the intermediate housing, model 290 and 290A 16. Install the shift yoke (3) and push in the shaft (2) and lock it with the cotter pin (1). NOTE! A washer must be installed on either side of the cotter pin. 1. Remove the 2 screws holding the hose connection. Remove the hose connection and the gasket. 9991801 884311 2. Remove the yoke by driving out the steering spindle. Use special tools 884311 and 9991801.
Repair instructions 9991801 884259 3. Press out the sealing rings and the needle bearing. Use special tools 884259 and 9991801. 5. Should the shift yoke be in need of being replaced, remove the cotter pin (1). Then pull out the shaft (2) and remove the shift yoke (3). NOTE! There is a sealing ring on each side of the needle bearing. 9991801 884259 4. Press out the bushing. Use special tools 884259 and 9991801. 78 6. Remove the bearing race of the axial bearing. Use special tools 884140 and 884143.
Repair instructions 7. If necessary the retaining pawl is dismantled as follows: Remove the shaft journals (42). Remove the spring (43) the spring (40) and the springs (44). 9. Paint the retaining pawl with a thin layer of ”touch-up paint”. Painting is hard to do when the pawl is assembled. The picture reflects an assembled retaining pawl. NOTE! Hold the spring shaft (45). Remove the nuts (38) and spring catches (34) and (37) and the spacer washers (36) as well as the retaining pawl (33).
Repair instructions 11. Press in both sealing rings. Use special tool 884259. NOTE! The sealing rings are to seal against water and thus have to be installed ”facing” each other. 13. Place the yoke and the wear washer (1) on the intermediate housing and push in the steering spindle (2) as far as to hold the wear washer. NOTE! Be careful not to damage the lower sealing rings. 9991801 884259 12. Press the bushing into the yoke. Use special tool 884259 and 9991801. 14.
Repair instructions 15. Insert the wear washer (1) between the steering yoke and the intermediate housing and push in the steering spindle until the collar bottoms. 17. If the trim cylinder attachment is in need of repair or in need of being replaced, remove the 2 collar screws. Use a socket wrench (17 mm) as a counter hold. Then install the new cylinder attachment. NOTE! Use the same screws, washers and nuts unless they are damaged. 16. Install the hose connection and the gasket on the yoke.
Repair instructions Reconditioning the intermediate housing, models SP and DP 9991801 884259 3. Press out the lower steering spindle bushing. Use special tools 884259 and 9991801. 1. Remove the 2 screws holding the hose connection. Remove the hose connection and the gasket. 9991801 9991801 884311 884259 2. Remove the hook up fork by driving out the steering spindle. Use special tools 884311 and 9991801. 82 4. Press out the upper steering spindle bushing using special tool 884259 and 9991801.
Repair instructions 9991801 884259 5. Should the shift fork require replacement, remove the cotter pin (1). Remove the shaft (2) and remove the shift yoke (3). To install reverse procedure. NOTE! Always use a new cotter pin when reinstalling. 7. Grease the lower hook up fork bushing with Volvo Penta part np. 828250-1 water resistant grease. Using special tool 884259 and 9991801, press in the bushing. 9991801 884259 6. Remove the bearing race of the axial bearing. Use special tool 884140 and 884143.
Repair instructions 9. Place the wear washer (1) on the intermediate housing and push the steering spindle (2) in far enough to hold the wear washer. 11. Insert the plastic wear washer (1) between the intermediate housing and the hook up fork. Push the steering spindle in until the collar bottoms. 10. Push the steering spindle (1) through the intermediate housing exhaust port (2) stopping short of the upper hook up fork bushing. 12. Install the O-ring and the hose connection on the yoke.
Repair instructions 13. 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).
Repair instructions Lower gear Reconditioning the lower gear, models 280, 285, 290 and SP Disassembly The propeller shaft 885192 9992520 1. Install the suspension fixture 885192 in stand 99922520 and brace the lower unit in the stand. 3 1 884830 3. Use special tool 884830 and install the lower gear upside down. 884161 2 4. Remove the 2 screws holding the propeller bearing housing. Remove the propeller shaft and the propeller bearing housing. Use special tool 884161.
Repair instructions 884168 1 5. Remove the 6 nuts holding the washer (1) and knock the propeller shaft out of the bearing housing. Use a copper mallet or its equivalent in order not to damage the threads. 7. Press off the gear wheel and the bearing from the propeller shaft simultaneously. Use special tool 884168. 1 3 3 2 1 6. Fold down the locking washer (1) remove the round nut (2). 2 8. Remove the locking ring (1) and the oil deflector (2) from the gear wheel.
Repair instructions 1 9. Knock out the 2 sealing rings (1) off the propeller bearing housing. 11b. Models 280, 290 of later manufacture: Lift the gear housing off the special tool and place it back in the work stand. Remove the nylock® nut with a hook spanner wrench. The vertical shaft 1 10. Fold down the tab on the locking washer (1) and remove the nut holding the pinion to the vertical drive shaft. 884267 884830 12. Use special tools 884267 and 884830 to remove the pinion. 2 1 3 11a.
Repair instructions 884381 884143 1 2 3 13. Lift out the pinion (1) and the needle bearing washer (2). NOTE! The needle bearing is a full needle type of bearing with loose needles (3). Remove all 27 needles. 15. Press (knock) off the outer ring of the needle bearing. Use special tools 884381 and 884143. Insert the tool from underneath and the shaft from above. 1 14. Carefully lift off the lower gear housing from the vertical drive shaft. 16.
Repair instructions Assembly Oil all moving parts and the screws prior to assembly. 884316 1 17. Should the needle bearing of the propeller shaft be damaged, use special tool 884316 to remove it. Insert the puller into the needle bearing in a way that the barbs of the puller end up at the backside of the needles. Then tighten the puller forcing the barbs apart and pull out the bearing. 1. Fill up with grease between the two sealing rings (1) and press them home in the propeller bearing housing.
Repair instructions 1 884266 1 3. Grease abundantly the outer race (1) with grease and insert the 27 needles, well cleaned, into the ring letting the grease hold them. Insert special tool 84385 in the bearing and insert the bearing from underneath into the gear housing. Then install the special tool 884241 from above and pull the bearing into its seat in the gear housing. 5. Install the spacer pad (1) on the ball bearing and press on the roller bearing. Use special tool 884266.
Repair instructions 1 6b. Models 280, 290 of later manufacture: Install the thick spacer ring and tighten the plastic insert locknut. Use a hook spanner wrench. 8. Install the vertical shaft with a 0.35 mm (0.14") thick shims package (1) consisting of a paper shim 0.25 mm (0.01") between two metal shims 0.05 mm (0.002") each. 884830 1 2 3 7. Insert the pinion (1) along with the washer (2) for the needle bearing (3) into the gear housing. 9. Install the washer and the nut.
Repair instructions The propeller shaft 884140 884143 1 2 3 10. Remove the conical roller bearing race in the intermediate housing (if the old bearing can still be used). Use special tools 884140 and 884143. 12. Install the oil deflector (1) and the locking ring (2) on the gear wheel (3). NOTE! Make sure that the two holes on the oil deflector coincide with the carrier pins (on sterndrives of earlier manufacture). On sterndrives of later manufacture a load pin acts as carrier of the oil deflector.
Repair instructions 884263 3 884265 2 1 16. Install the locking washer (1) and the round nut (2). Tighten the nut and lock it with the locking washer (3). 14. Press on the gear wheel on the propeller shaft. Use special tools 884265 and 884263. Shimming Method 1 B 884168 C 884265 2 1 F G 15. Install the locking washer (1) and press on the ball bearing (2). Use special tools 884265 and 884168.
Repair instructions Method 2 1 2. The gear length is fixed at 5.85 mm (0.230"). Add or subtract the plus or minus marking of the gear wheel. Subtract from this sum the sum of the ‘F’ and ‘G’ measurements. The sum thus obtained denotes the thickness of the shim. 3. Insert the 0.2 mm (0.008") shim (1) in the propeller bearing housing. This is a value of experience. NOTE! On some gear housings for instance the figures 03 can be stamped or some other figure. In these cases add the number 5.
Repair instructions 2 1 5. Install the propeller shaft with its bearing box in the gear housing. Tighten the screws with a torque of 40 Nm (29.5 lb.ft.). NOTE! The two O-rings (1) on the bearing housing should not be installed. 1 7. If the backlash is found not to be correct, adjust as follows: If the method 1 has been used: If the backlash is too small, increase the shim thickness underneath the ball bearing (1) and if the backlash is too big, decrease the shim thickness.
Repair instructions 884830 11. Should the contact pattern correspond to that of picture “B”, reduce the shim thickness for the vertical shaft and the propeller shaft. 9. Install special tool 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. Contact pattern 12.
Repair instructions Final assembly 884830 1 1. Dismantle pinion and gear and clean parts from marking dye and then assemble with the calculated shims. Then install the spacer ring, the locking ring and the nut on the vertical shaft. Tighten the nut and lock with the locking washer. Use special tool 884830 as a counter hold. 3. Install the O-rings (1) in the propeller bearing housing. Coat the contact surfaces and the screws with sealing compound, Volvo Penta part no. 1161099-5 or Permatex® no. 3.
Repair instructions Reconditioning the lower gear, models 280-DP, 290-DP and DP 885192 Disassembly 1. Clean the sterndrive externally. 9992520 1 4. Install the suspension fixture 885192 in stand 99922520 and brace the lower unit in the stand. 2. Drain the oil by removing the screw (1), if not already drained in previous steps. NOTE! Place a drain pan under the sterndrive. Tilt the sterndrive all the way down to allow all the oil to drain. 3a.
Repair instructions 10. Install special tool 885197 on the inner propeller shaft. 7. Remove the two Allen-head screws from the propeller bearing housing. Key width: 3/8”. 884802 884789 884161 8. 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. 11. Install special tool 884802 over the inner propeller shaft. Add the washer and nut from tool 885197.
Repair instructions 2 1 3 13. Remove the nut from the pinion gear. Use a 23 mm wrench. NOTE! Do not discard the nut. Put it aside for use in the shimming procedure later. 14b. NOTE! Sterndrives model 280 and 290 of earlier manufacture have a lock washer (1) and a round nut (2) instead of a Nylock® nut. Knock down the locking tab of the washer and remove the round nut with a hook spanner wrench. Remove the lock washer and the spacer ring (3). 884830 884267 14a.
Repair instructions Inner propeller shaft 884797 16. 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. 19. Press off the roller bearing from the propeller shaft, using special tool 884797. 884794 NOTE! Take care of the shims. Outer propeller shaft 884161 17. Remove the forward gear bearing outer race from the lower unit, using special tool 884794 and slide hammer 884161.
Repair instructions 1 23. Remove the inner needle bearing and seals using special tools 884803 and 884143. Install special tool 884789 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. 21. Install a knife puller on the outer propeller shaft roller bearing. Using a press, remove the roller bearing.
Repair instructions Vertical shaft 884796 9991801 25. Remove the outer bearing race using special tools 884796 and handle 9991801. IMPORTANT! Center the tool carefully. Locate a pair of wooden blocks underneath the bearing box to protect the bearing box while pressing out the bearing race. 27. Use a knife puller to remove the bearings one by one or together. IMPORTANT! Use spline socket 3850598 to protect the splines when pressing off the bearings Forward gear 28.
Repair instructions NOTE! When calculating the shim thickness for the lower unit gears, remember: The lower unit gear housing nominal dimension has two values: If the stamped number is 50 or more, use the lower nominal value: 60.00 mm. If the stamped number is 49 or less, use the higher nominal value: 61.00 mm. Example: Stamping is 50 or more: “G”-stamping: 85 = 30. Check the bearing race. Replace as necessary, using a knife puller. Clean and check all parts for wear.
Repair instructions 1 3. The nominal measurement of the forward gear is 39.50 mm. The tolerance (±) is engraved on the gear. All engraved numbers are decimal millimeters. In this instance, “-10” equals -0.10 mm. The real measurement of the gear is 39.50 - 0.10 = 39.40 mm. 884793 Add the height of the forward roller bearing to the real measurement of the forward gear: Add: Roller Bearing = 20.85 mm Forward Gear = + 39.40 mm Total forward gear length 60.
Repair instructions 884793 884263 8. Press a new inner bearing race onto the vertical shaft. Use special tool 884793. 884799 6. Use special tool 884263 to press the gear and bearing assembly onto the propeller shaft. Use special tool 884799 to protect the bearing. WARNING! Do not press on by using the bearing race! 884266 Shimming the vertical shaft 9. Press a new ball bearing onto the vertical shaft special tool 884266.
Repair instructions 11a. Sterndrives model 280 and 290 of earlier manufacture: Install the thick spacer ring (1), the locking washer (2) and the round nut (3) on the vertical shaft. NOTE! Install the nut with the even side facing upwards. Tighten the nut but don’t lock it with the washer. Use a hook spanner wrench. 12. Find the “H”-marking on the parting plane of the lower gear housing. The “H”-stamping in this instance is 37. Remember, the stamping is in hundreds of millimeters.
Repair instructions 14. The nominal measurement of the vertical shaft is 217.75 mm. This measurement is added to the calculated pinion measurement of 59.95 mm. This combined distance equals 277.70 mm, as illustrated below: Add: Vertical Shaft Nominal 217.75 mm Pinion Calculated +59.95 mm Vertical Shaft Calculated 277.70 mm Subtract the “H”-stamping dimension from the Vertical Shaft Calculated (277.70 mm) to arrive at the shim thickness: Subtract: Vertical Shaft Calculated 16.
Repair instructions 18. Hold the pinion nut with a 23 mm socket. Use special tool 884830, or 3850598 as an alternative, and a torque wrench. Torque the vertical shaft to 110 Nm (81.5 lb.ft.). WARNING! 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. 20. Find the stamping “C” on the bearing box. In this case, “C”=25. Again, the stamping is in decimal millimeters.
Repair instructions Shimming the outer propeller shaft 23. Add the gear measurement to the bearing nominal dimension. Add: Gear measurement Nominal bearing height Total aft gear dimension +10 39.60 mm + 20.75 mm 60.35 mm Now subtract the total aft gear dimension from the bearing box location. Subtract: 21. The nominal measurement of the aft gear is 39.50 mm. Find the variation marking on the gear. In this case it is +10.
Repair instructions 27. Now add the front and rear gear shims. Add: Forward gear shims 884797 Aft gear shims 0.60 mm + 0.31 mm 0.91 mm Add nominal value + 120.00 mm 120.91 mm The shim thickness is obtained by subtracting: Subtract: 25. Turn the bearing box over. Use special tool 884797, install the needle bearing in the bearing box. Make sure the bearing marking is facing the tool. 121.51 mm - 120.91 mm Intermediate bearing shim 0.60 mm Shimming the intermediate bearing 26.
Repair instructions 884806 29. Press the needle bearing into the propeller shaft with the text on the bearing turned facing the tool. Use special tool 884806. Press the tool until it bottoms. 32. 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 onto the threads until the tool bottoms.
Repair instructions 884348 B 35. Grease the bearing box and install on the lower unit. Tighten the allen bolts to 40 Nm (29 lb.ft.). 37. Using a depth gauge, measure “B” in special tool 884348. Subtract measurement “A” from measurement “B”. B – A = positive result ( clearance dimension) B – A = negative result (preload) Tolerances: Max. allowed clearance dimension 0.05 mm (0.002”) Max. allowed preload 0.02 mm (0.0008”) A clearance dimension of 0.02 mm (0.0008”) shall be aspiring to attain.
Repair instructions Checking preload Checking backlash Propeller Nut 39. 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 torque gauge 9999177 and turn the shaft one revolution per second. The minimum preload value should be 1.2 Nm (10.6 lb.ft.) and maximum preload value should be 2.3 Nm (20.3 lb.ft.).
Repair instructions 884795 43. 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– 0.27 mm (0.006–0.010”), which is 0.20–0.35 mm (0.008–0.014”) at the gear. 45. Turn the vertical shaft both ways. Use the spline sleeve 884830 while applying braking action. Contact Pattern 2 1 1 3 4 44.
Repair instructions Final assembly 47. 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, figure under point 44). 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). 48.
Repair instructions 884975 884976 1 3. Grease the new seal rings and install in the propeller shaft. Turn the steel edge (1) facing forward. Use special tool 884975. Turn the broad shoulder against the seal ring. Press until it bottoms. 6. Insert the protective ring 884976 into the outer propeller shaft seals so that the seal lips are protected during installation. 7. Carefully insert the outer propeller shaft in the gear housing. Remove the seal protector. 4.
Repair instructions 1 9. Install new O-rings (1) on the bearing box. Coat the entire sealing surface and O-rings with Volvo Penta part no. 1141570-0 sealant. Install the bearing box in the gear housing. 12. 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.
Repair instructions Shimming the lower gear to the intermediate housing 884168 A 3. Press the outer race of the vertical shaft bearing with the calculated shims into the intermediate housing. Use special tool 884168. 1. Place the bearing race on the bearing and hold in position. Using a depth gauge, measure the bearing height above the lower unit parting plane “A”. B 2. Using the depth gauge, measure the measurement “B” in the intermediate housing . Subtract measurement “A” from measurement “B”.
Repair instructions 5. Use new screws and washers. Coat the screw threads with thread locking compound, Volvo Penta part no. 1161053-2, or Loctite® 243. Tighten the 4 larger screws diagonally and in sequence with a torque wrench to 38 Nm (28 lb.ft.). Use special tool 885008. Tighten the 3 smaller screws to 15 Nm (11 lb.ft.). 280 drives: Earlier 280 drives do not have washers while later versions do.
Repair instructions Shimming the upper gear to the intermediate housing B mm -A mm Clearance mm + 0.06 mm Shims Required mm 3. Subtract the upper gear head bearing thickness (A, figure under point 1) from the intermediate housing measurement to find the bearing clearance. Add enough shims to take up the clearance plus 0.06 mm shim to preload the upper gear head bearing. 1. Measure the distance from the bottom of the upper gear housing to the top of the outer bearing race (A).
Repair instructions 1 7. Install the shift linkage rod, washer and cotter pin. 5. Install the O-ring (1) on the upper gear. WARNING! Always use a new cotter pin. Never reuse a cotter pin that has been removed. 2 1 885009 3 885008 6. Install the upper gear housing on the intermediate housing. Use new Allen bolts (1, 2 pcs), washers (2, 2 pcs) and nyloc nuts (3). Many drives do not have washers under the bolt heads. When overhauling however, washers shall always be fitted. This applies to all drives.
Repair instructions Pressure and vacuum testing Before filling the drive with gear oil, it must be pressure and vacuum tested to verify proper sealing during assembly. a) Connect a pressure tester 3810152 to the drain hole and pressurise the drive to 21–35 kPa. Turn the propeller shaft(s) and the drive shaft universal joint to check for tightness. If any pressure loss is indicated, use a soapy water solution, or dip the drive into water to find the leakage point.
Repair instructions Installing the sterndrive Models 280 and 285 There are 2 types of exhaust bellows. One type with an exhaust valve and one without. The exhaust bellows with an exhaust valve installed should be used on sterndrives not having a rubber exhaust flap installed on the exhaust outlet in the cavitation plate. Otherwise exhaust bellows without exhaust valve should be installed.
Repair instructions 4. Hang the hose clamp for the rubber bellows of the universal joint on the “neck” of the gear housing. Grease the splines of the universal joint and those of the shaft with grease. Push the sterndrive gently against the drive shaft. Turn simultaneously the universal joint to allow the shaft splines to find the corresponding female splines of the joint more easily. NOTE! Be careful during the assembly not to damage either splines thus making the mating more difficult.
Repair instructions Checking and adjusting controls Then push the sterndrive forwards against the adjusting pin and check that the upper end of the push rod (3) does not touch the thrust plate of the lift device. The lifting device (1), when tilting, will disengage the retaining pawl. The retaining in the adjusting pin of the retaining pawl is checked by first pulling the sterndrive backwards and then in the two outer positions.
Repair instructions Oil filling 1. Install the oil drain plug with a new O-ring. Installing a ‘short hub’ type of propeller (B) 1. Grease the propeller shaft with a thin layer of grease. 2. Install the fishing line deflector (5, figure on previous page). Tighten the fill plug to 35 Nm (26 lb.ft.). 3. Install the propeller. Lower the sterndrive and check the oil level with the dipstick. If necessary, Top off the sterdrive with oil through the dip stick hole. 4.
Repair instructions The Duoprop, earlier model Check the speed range of the relevant boat and select the correct propeller. See Propeller recommendations. Changing the direction of the propeller rotation NOTE! The propellers are supplied matched in pairs and must not be mixed. Install the propellers as follows: Grease the propeller shaft and install the fishing line deflector (1) and the propeller (2). Then install the folding washer (3) and the nut (4).
Repair instructions The electro-mechanical sterndrive tilting device, model 280/285 Install the overload circuit breaker as follows: Install the overload circuit breaker (1) on the transom, close to the sterndrive tilting device. Remove the minus wire (earth), (blue), from the flywheel housing sufficiently to allow the wire to be connected to the overload circuit breaker and then back to the flywheel housing. Cut the wire and connect two terminals (2).
Repair instructions 1c. Mechanical fault Checking after reconditioning Check to make sure that the cover does not press against the limit switch by removing the cover and testing the function of the tilting device. If the tilting device functions with the cover removed but not with the cover installed, remove part of the cover over the limit switch, pressing on the switch. Check the clearance between the cover and the limit switch.
Repair instructions Models 290, SP and DP 1. Install the exhaust bellows on the transom shield. Turn the hose clamp so that the tightening screw ends up at two o’clock with the head pointing downwards. NOTE! Turn the drainage hole in the bellows facing downwards. 3. Remove the locking screw and remove the suspension pin. Grease the suspension pins with Volvo Penta low temperature grease 1161417-9 and install in the transom shield flush with the interior face to the transom shield.
Repair instructions 885146 5. Remove the cover over the shift mechanism. Hang a hose clamp on the sterndrive and install the yoke on the sterndrive. Then lift up the sterndrive and hang it in the tool 885146. 7. Install the plastic bushings (1) in the holes (2) of the suspension yoke. UP 8. Push the sterndrive forwards against the engine primary shaft and turn the universal joint simultaneously to better allow the primary shaft splines to enter the universal joint.
Repair instructions 9. Push the sterndrive forwards. Lift up the trim cylinders simultaneously and continue to push the sterndrive forwards. 11. Use a screwdriver to turn the dowels so that the locking grooves coincide with the locking screw holes in the ears of the transom shield. Tighten the locking screws. Prior to the tightening of the screws, grease them with low temperature grease, Volvo Penta part no. 1141644-3. NOTE! Don’t forget the washer under the screw heads. Tighten torque: 24 Nm (17 lb.ft).
Repair instructions 885143 13. Pull down the retaining pawl and lift up the sterndrive sufficiently to allow the installation of special tool 885143 between the transom shield and the suspension yoke. Hang the hose clamp on to the cooling water hose and connect the hose to the hose attachment on the suspension yoke. IMPORTANT! Turn the hose clamp so that the tightening screw ends up at two o’clock on the starboard side. This is important.
Repair instructions 17. Install the cotter pins (1). Fold the ‘legs’ backwards carefully. 1 2 18. Lower the steering helmet and align the helmet bushing with the recessed hole of the upper gear head. Grease the attachment (2) with low temperature grease, Volvo Penta part no. 1161417-9. Install the attachment in the helmet bushing with the recessed holes vertical (one hole over the other).
Repair instructions Oil filling 1 1. Install the oil drain plug with a new O-ring (1). Adjusting the retaining pawl, model 290 a) Set the control lever in the ‘Forward’ position and check that the lever (8) does not touch the housing. See position “C” on the picture. Check with the control lever in ‘Forward’, ‘Reverse’ and in ‘Neutral’ that the swivel (9) and the cable attachment (7) does not strain in the shift plate (8).
Repair instructions Propeller installation Locking the propeller cone on sterndrives of earlier manufacture is done by a folding washer and on sterndrives of later manufacture by a locking screw through the cone center. Installing a ‘long hub’ type of propeller (A) 1. Grease the propeller shaft with a thin layer of grease. 2. Install the fishing line deflector (5). 3. Install the propeller. 4. Insert the plastic washer (3). 5. Install and tighten the propeller cone (1). 6.
Repair instructions Changing the direction of the propeller rotation, SP drives On the propeller hub there is a ‘L’ for left hand rotating and a ‘R’ for right hand rotating propeller. Also the size of the propeller is stamped into the hub, for instance 15×19 where 15 denotes the diameter in inches and 19 the pitch, also in inches. This is not valid for Duoprop propellers. The sterndrives are supplied adjusted for left hand rotation ‘A’.
Repair instructions Adjustment of trim fin The trim fin is factory set at 5 ° towards port side. After installation the adjustment of the trim fin should be checked and, if necessary, corrected according to figures below. This is a basic adjustment. An exact adjustment can only be done after a test run with the servo unit disconnected.
Repair instructions NOTE! that later propellers, both A and B propellers, are painted black. To identify the two types, the rear propeller has a sticker on the front end of the hub. Propellers with a green/yellow sticker (A propellers) shall only be used with diesel engines. Propellers with a red/yellow sticker (B propellers) shall only be used with petrol/gasoline engines. Duoprop (later model) Check which speed range the boat in question operates in, and select the correct propeller.
Transom shield Changing trim cylinders, models 290, SP and DP Trim cylinders, later models B C D A 1. Remove the sterndrive when the boat is on land. Also remove the exhaust bellows and the universal joint bellows. Remove if necessary barnacles etc and clean the shield. Trim cylinders, earlier models 4. Remove the 2 hoses (A) from the starboard cylinder. If only the port cylinder is to be replaced, remove the pipe connections on that cylinder (B).
Transom shield Trim cylinders, all models Part no. 940194 6. Install a grease nipple where the ground terminal bushing (late models) or plastic plug (early models) was removed. 8. Use a grease gun and inject grease into the grease nipple. The dowel pin will then be pushed out and the trim cylinder can be removed. Use grease nipple, Volvo Penta part no. 940194. 884978 1 2 7. Remove the locking bolt for the trim cylinder dowel pin. Key width 10 mm. 9.
Transom shield 11. Always use a new O-ring (1) on the dowel pin during reassembly. Check the pin hole and pin for scratches or other damage. Position (2) is the locking bolt. IMPORTANT! The transom must have cutouts called for on the transom template to allow sufficient clearance for the pins to be removed. If the cutouts are not made, the transom shield must be removed from the boat to enable trim cylinder pin removal. 12. Remove the grease fitting that was used to remove the attachment pin.
Transom shield Trim cylinders, earlier models Trim cylinders, later models B C D A 13. Remove any shipping plugs installed in the new trim cylinder. 14. Remove any shipping plugs installed in the new trim cylinder. Install the pipes and the hoses on the new trim cylinder. Install the pipes and the hoses on the new trim cylinder. Hoses to starboard cylinder (A) and port cylinder (B). WARNING! Make sure all the pipes and hose fittings are attached finger tight before torquing any of the fittings.
Transom shield Trim cylinders, all models Trim pump, earlier model Trim pump, earlier model Trim pump, later model IMPORTANT! The hydraulic pump must be installed vertically, as reflected by the picture. 16. Remove the oil filler/indicator plug to check the oil level. Top up if necessary. Install the sterndrive in the transom shield. Raise and lower the drive simultaneously to facilitate the topping up and to make sure that the system is properly filled up.
Transom shield Changing steering helmet Steering Fork Steering Helmet 21. Loosen the tiller arm set screw using a 5/32 allen wrench. A To ensure the integrity of the steering system the steering helmet is not serviceable as a separate part from the steering fork. If there is a problem with the steering helmet or the steering fork, they must be replaced as a unit. WARNING! The bolted joints steering helmet – steering fork (A) shall not be dismounted. Removal 19.
Transom shield 25. Make sure the square/the splines on the steering fork and the tiller arm are aligned. 23. Install a new bushing (8) into the new steering fork. 26. Using a rubber mallet tap on the steering fork into position 24. Align the square/the splines on the steering fork with the square in the tiller arm and install into the transom shield. 27. Lock the setscrew with a 5/32 in. allen wrench.
Transom shield 28. Install a new seal (9) and O-ring (7) on the gear wheel. Install the trim sending unit, gear wheel and gear rack. See chapter Trim System.
Trim system Changing the sending unit 1. Lower the sterndrive to the full down position. Turn the helm full starboard. Using a 13 mm wrench, remove the trim sender holding bracket and the trim sender. Unplug the sender from the wiring harness. 3. 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. NOTE! Do not force the sending unit into the hole.
Trim system Changing the trim system gear rack 5. -4 should be shown in the instrument window for a 12º transom angle. 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 Instrument indication 10° -2 11° -3 12° -4 13° -5 14° -6 15° -7 6. Tighten the trim sender bracket hold down screw. Be sure the sending unit does not move when the bracket is tightened. 1.
Trim system 3. Turn the gear wheel until the tooth with a white recessed marking appears. 6. Install the screw and carefully tighten. NOTE! It is recommended that a new screw be used whenever the gear rack is removed. WARNING! Do not overtighten the screw. Use extreme caution to prevent stripping the threads from the screw. 4. Install the new gear rack with the marked tooth of the gear wheel in the first slot of the gear rack. 7. Lower the sterndrive to its bottom position.
Trim system Changing the trim system gear wheel 1. Remove the sterndrive according to the section installation and removal. 8. -4 should be shown in the instrument window for a 12º transom angle. 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 Instrument indication 10° -2 11° -3 12° -4 13° -5 14° -6 15° -7 2. Pull the steering helmet aft far enough to clear the gear wheel.
Trim system 4. 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 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. 6.
Trim system 8. 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. The power trim pump The parts illustrated are those available as replacement parts or complete assemblies. The following instructions cover the replacement of parts making up the trim pump unit. 1 Motor assembly 2 Motor, incl.
Trim system Removing the trim pump from the boat Removing the oil reservoir Turn off the main battery switch. Disconnect the trim pump wiring harness, ground cable from the flywheel housing, and the positive (+) cable from the starter motor. Remove the center bolt (1), together with the O-ring (2) and sleeve (3) that holds the plastic reservoir, using an 8 mm socket. Remove the reservoir and the rubber seal (8) (fig. showing the exploded view). Note how the hydraulic hoses are connected to the pump.
Trim system Replacing adapter and pump assembly To install a new filter, place a 5/8" socket over the filter and gently tap it down using a hammer. Removing the electric motor The adapter and pump assembly contain no serviceable parts and are replaced as a complete unit. Remove the oil reservoir, motor and coupling. Remove the valve assemblies using a 7/16" wrench. The original factory fitted valves cannot be installed in a new adapter/pump assembly.
Trim system The relief valve assemblies Venting system If the original factory fitted valves have to be removed, this will alter the factory setting, and new valves will have to be installed. Reconnect main battery switch and operate the trim pump (system is self-bleeding). Re-check the oil level and add if necessary. NOTE! Replacement valves are set from the factory and must not be opened. Test Once the system has been vented, operate the trim pump for proper operation.
Trim system Checking the trim figure 1. Turn the ignition key to the ignition position (the lights are on). 4. The instrument, when trimmed down and with a known transom angle, shows the following figures, see table below: Transom angle Instrument indication 10° -2 11° -3 12° -4 13° -5 14° -6 15° -7 2. Trim down the drive to its bottom position. NOTE! Push the switch upwards. 5.
Sterndrive extensions 1" extension 4" extension Tightening torques: A-G-K = 33 Nm B-F-M = 18 Nm Installation instructions for 1" and 4" extensions: Press in the outer bearing race of the axial bearing in the extension. See under Shimming the intermediate housing and the lower gear housing. Drain the oil from the sterndrive. NOTE! Measure the measurement ‘B’ on the extension! Remove the cover over the shift mechanism.
Sterndrive extensions The 1" extension Tightening torques – see the picture! Coat the contact surfaces with a sealant. Use the 3 new O-rings and the oil pipe from the extension kit. Install the extension on the lower gear housing. Install the cover over the shift mechanism. Install the locking ring in the splines sleeve. Turn the end with locking ring downwards and then install the sleeve on the lower vertical shaft. Fill up with lubrication oil.
Welding Welding on certain parts of the sterndrive and the transom shield is allowed. Extreme caution must be used to prevent damage to the precision machined surfaces or precision parts used in the sterndrive (i.e. near bearing locations). Always use Volvo Penta welding electrode 839643-4 when making any welding repairs to the sterndrive or transom shield. 4.
Painting Painting the sterndrive and underwater hull General Most countries have introduced legislation controlling the use of anti-fouling agents. In some cases these agents are completely forbidden for use on leisure craft. In these cases ask your Volvo Penta dealer for advice about alternative methods. Underwater hull Anti fouling agent containing copper oxide can increase the risk of galvanic corrosion and therefore should never be used.
Electrical wiring diagrams R 1.5 Model 280, tilting device Up R 1.5 Gas Diesel BR 1.5 GN / Y 1.5 BL 1.5 BL 1.5 Down GN / Y 1.5 No No Y 1.5 GN 1.5 BL 1.5 BR 1.5 GN 1.3 GN / Y 1.5 SB 1.5 SB 1.3 SB 1.3 Com GN / Y 1.3 References: 1. Relay box 2. Relay 3. Limit switch 4. Push rod, retaining pawl 5. Connector 6. Electrical motor 7. Switch 8. Warning light 9. Key switch 10. Connected to 30 (+) on the starter motor 11. Connected to engine (-) 12. Connector 13. Fuse, 20 Amps R 1.
Electrical wiring diagrams Model 280, Power trim SB GN Down GN R Ground BL Up OR PU W R R IV/SB GN/R SB Attach to flywheel housing GN/Y SB PU To engine fuse battery side Power lead 1. 2. 3. 4. 5. Pump motor Relay Fuse Switch Body 6. 7. 8. 9. 10.
Electrical wiring diagrams Model 290, Power trim Earlier model 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Electrical wiring diagrams Models 290, SP and DP, Power trim Later model 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Oil pump Fuse 55 amps Trim sender Trim indicator Switch Switch-relay, position ”Beach” Connection instrument panel Instrument lighting Throttle hook-up (optional) Relays the arrows in the electric wiring diagram refer to the trimming function up/ down.
Technical data Models 280, 280T, 280PT, 285, 285A and 290 General Data Type designation ..................................................................... Aquamatic 280, 285 & 290 Shift Mechanism ..................................................................... Self adjusting Silent Shift type of cone clutch, servo assisted disengagement. Direction of rotation adjustable. Maximum propeller diameter ................................................... 16" Tilting angle ...........................
Technical Data Lubricating system Pump, type ............................................................................. Circulation pump for distribution of oil to all lubrication points Oil quality ................................................................................ Engine oil Viscosity ................................................................................. Multigrade SAE 10W-30 aft. 10W-401) Oil quality, approx ...............................................................
Technical data Models 280-DP, 280DP/PT, 290DP and 290A-DP General Data Type designation ..................................................................... Aquamatic DuoProp Shift mechanism ..................................................................... Self adjusting Silent Shaft type of cone clutch, servo assisted disengagement. Direction of rotation adjustable. Maximum propeller diameter ................................................... 16" Maximum tilt angle, approx ....................
Technical Data Lubricating system Pump, type ............................................................................. Circulation pump for distribution of oil to all lubricating points Oil quality ................................................................................ API GL51) Viscosity ................................................................................. SAE 90 or 80W90 Oil quantity, approx ................................................................. 2.7 liters (2.
Technical data Models SP-A, SP-A1, SP-A2 and SP-C GeneralData Type designation ..................................................................... Aquamatic SP-A, SP-A1, SP-A2 & SP-C Shift mechanism ..................................................................... Self adjusting Silent Shaft type of cone clutch, servo assisted disengagement. Maximum Propeller diameter ................................................... 16” Maximum tilt angle, approx. ............................................
Technical Data Tightening torques Nm Lb. ft. Upper nut on vertical shaft (upper gear) ................................... 125 92 Tightening universal joint ......................................................... 75 55 Assembly double bearing box - gear housing .......................... 35 26 Assembly of top cover to upper gear housing ......................... 15 11 Lower nut on vertical shaft ......................................................
Technical data Models DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1 General Data Type designation ..................................................................... Aquamatic DUOPROP Shift mechanism ..................................................................... Self adjusting Silent Shaft type of cone clutch, servo assisted disengagement. Maximum tilt angle, approx ..................................................... 60" Power Trim & tilting device .......................................
Technical Data Tightening torques Nm Lb. ft. Upper nut on vertical shaft (upper gear) ................................... 125 92 Tightening universal joint ......................................................... 75 55 Assembly double bearing box - gear housing .......................... 35 26 Assembly of top cover to upper gear housing ......................... 15 11 Lower nut on vertical shaft ......................................................
References to Service Bulletins Group No. Date Concerning ......................................................................................................................................................................................... ......................................................................................................................................................................................... ..............................................................................
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7731624-8 English 06–2003
