Mercury Bravo Three Service Manual Page 284
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BRAVO THREE GEAR HOUSING SERVICE MANUAL NUMBER 28
Page 3D-22 90-863160 MAY 2000
d. Mount dial indicator to gear and position so that indicator probe aligns with mark on
indicator rod.
72231
a
b
c
a-Dial Indicator
b-Indicator Rod (91-806192)
c-Mark Stamped on Indicator Rod
e. Rotate gear back and forth while observing dial indicator. Record spline lash reading
(for use later in this section). This reading is required to determine true backlash be-
tween pinion and driven gear.
2. Check outer propeller shaft spline lash following the same procedures as for the inner
propeller shaft listed in Steps “a” through “e” above using indicator rod (91-806192).
INDEX
- Number 28 1
- 90-863160 2
- 90-863160 MAY 2000 Page i 3
- Engine Mechanical Components 4
- Replacement Parts 4
- Service Manual Outline 5
- Page vi 90-863160 MAY 2000 8
- POWER TRIM 10
- STEERING SYSTEMS 11
- CORROSION PROTECTION 12
- ACCESSORIES 12
- IMPORTANT INFORMATION 13
- How To Use This Manual 14
- How to Read a Parts Manual 15
- Power Steering Pump Assembly 15
- Introduction 16
- Directional References 16
- Propeller Rotation 16
- Replacement Gears) 17
- INDEXINDEX 18
- Maintenance Schedules 21
- Gas Sterndrive 21
- Gas Sterndrive(Continued) 22
- Torque Specification 23
- Fluid Capacities 23
- Lubrication 23
- Steering System 24
- Tie Bar Pivot Points 25
- Changing Sterndrive Oil 28
- MAINTENANCE 29
- General Maintenance 30
- Power Package Layup 31
- Power Package Recommissioning 32
- Troubleshooting 34
- Drive Unit Shifts Hard 35
- Gear Housing Noise 36
- Drive Shaft Housing Noise 36
- TROUBLESHOOTING 37
- Power Shift 39
- Performance Troubleshooting 40
- Power Steering 42
- Compact Hydraulic Steering 43
- Power Trim Electrical System 44
- IN/DOWN Direction 45
- IN/DOWN SOLENOID CLICKS 46
- OUT/UP SOLENOID CLICKS 46
- TRAILER SWITCH OPERATES 47
- TRIM OUT/UP SWITCH FUNCTIONS 47
- Power Trim Hydraulic System 49
- Movements 50
- UNIT THUMPS WHEN SHIFTING 51
- SOLENOIDS CLICK 54
- SOLENOIDS DO NOT CLICK 55
- AUTO MODE FUNCTIONS PROPERLY 57
- DOWN SOLENOID DOES NOT CLICK 57
- DOWN SOLENOID CLICKS 57
- UP SOLENOID CLICKS 57
- PROPERLY 58
- TRIM UP/OUT SWITCH FUNCTIONS 59
- Corrosion Protection 61
- Protection 62
- DRIVE CORRODING - CONTINUED 63
- READINGS 65
- CORROSION SYMPTOMS 65
- Table of Contents 69
- Transom Thickness and Surface 71
- Sterndrive Unit Removal 74
- Transom Assembly Removal 76
- Transom Assembly Installation 80
- Sterndrive Unit Installation 90
- SERVICE MANUAL NUMBER 28 101
- STERNDRIVE UNIT 103
- Specifications 104
- Bearing Preloads 105
- Complete Housing 106
- DRIVE SHAFT HOUSING 107
- Exploded Parts View (Clutch) 108
- Exploded Parts View (Shifter) 109
- Bravo One 112
- Bravo Two 112
- Bravo Three 113
- Bravo XZ 113
- Bravo XR 114
- Diesel Bravo One X 114
- Diesel Bravo Two X 114
- Diesel Bravo Three X 115
- Separate Housings 116
- Shifter Repair 124
- Shifter Inspection 127
- Shifter Reassembly 128
- U-Joint and Pinion Gear 132
- Reassembly 136
- Disassembly 144
- Inspection 146
- Roller Bearing Removal 151
- Steel Bearing Adaptor Removal 153
- Bearing Sleeve Installation 155
- Roller Bearing Installation 156
- BRAVO ONE GEAR HOUSING 175
- Drive Shaft Components 176
- Pre-Disassembly Inspection 182
- Gear Housing Disassembly 185
- Inspection and Cleaning 191
- Drive Shaft Disassembly 191
- Pinion Bearing Removal 192
- Pinion Bearing Installation 193
- Drive Shaft Reassembly 194
- Bearing Carrier Inspection 195
- Bearing Carrier Disassembly 195
- Bearing Carrier Reassembly 196
- Propeller Shaft 197
- Driven Gear Bearing 198
- Driven Gear Bearing Removal 199
- Speedometer Water Passage 201
- Installing Bearing Carrier 217
- BRAVO TWO GEAR HOUSING 223
- Bearing Carrier 239
- BRAVO THREE GEAR HOUSING 265
- Lubricants/Sealants/Adhesives 266
- Driveshaft And Pinion Bearing 278
- Pinion Bearing 280
- Front Driven Gear And Bearing 286
- Bearing Cup Removal 287
- Bearing Cup Installation 287
- Installation 288
- Seal Removal 290
- Seal Installation 290
- Checking Backlash 298
- Propeller Installation 305
- TRANSOM ASSEMBLY 307
- Torque Specifications 308
- Bell Housing Components 311
- Gimbal Ring Components 312
- Gimbal Housing Components 314
- Special Information 316
- Trim Limit Switch Adjustment 322
- Trim Limit Switch 324
- Gimbal Bearing 325
- Shift Cable 328
- Shift Cable Installation 329
- Exhaust Bellows (If Equipped) 333
- Exhaust Tube (If Equipped) 336
- Water Hose and Water Fitting 338
- Crimp Clamp Tool 341
- Special Tools 344
- Bell Housing Removal 352
- Access Plug Kit Installation 356
- Gimbal Ring Servicing 362
- Gimbal Housing Servicing 368
- Exhaust Bellows Replacement 374
- Speedometer Hose Replacement 376
- Bell Housing Installation 387
- Trim Pump Specifications 402
- Trim Pump Exploded View 403
- Bleeding OUT/UP Trim Circuit 405
- Bleeding IN/DOWN Trim Circuit 405
- Testing Power Trim Pump 406
- Internal Restriction Test 407
- OUT/UP Pressure Test 408
- IN/DOWN Pressure Test 410
- Trim Pump Hydraulic System 411
- OILDYNE TRIM PUMP 413
- Reading OK 414
- Reading NOT OK 414
- Solenoid Test (Pump In Boat) 419
- 20 Amp Fuse Test 423
- Trim Pump Removal 424
- Hydraulic Repair 425
- Filter Replacement 427
- Pump Replacement 430
- Adapter Replacement 431
- Adapter Repair 433
- 76891 76892 435
- Motor Repair 439
- Armature Tests 442
- Field Tests 443
- Test for Short in Field 444
- Brush Replacement 446
- Trim Pump Installation 455
- Trim Pump Wiring Diagrams 456
- Trim Cylinder Exploded Views 461
- Bravo Trim System Components 462
- TRIM CYLINDERS 463
- Trim Cylinder Repair 465
- Important Information 482
- Diode Module Test 483
- Trailer Switch Test 484
- Starboard Trim Switch Test 484
- Port Trim Switch Test 484
- Relay Replacement 485
- Diode Module Replacement 487
- Wiring Diagrams 490
- Electrical Box Wiring 491
- Auto Trim II System 494
- Auto Trim II Operation 494
- Auto Mode Operation 495
- “Manual” Mode Operation 496
- AUTO TRIM II 497
- Auto Trim Limit Adjustment 498
- Control Module Adjustment 501
- Wiring Diagram 503
- Description 507
- Power Steering System 508
- RIGHT TURN 508
- LEFT TURN 509
- Steering Helm and Cable 511
- Steering Cable Specifications 512
- Checking Fluid Level 513
- Engine Warm 513
- Engine Cold 513
- Filling and Bleeding 514
- Power Steering Assembly 515
- POWER STEERING 517
- Pump Pressure Test 521
- Power Steering Pump 523
- Flow Control Valve Servicing 524
- Cleaning And Inspection 530
- EXTERNAL POWER STEERING 537
- Determining Tie Bar Length 538
- Selection 539
- Page 6B-390-863160 MAY 2000 545
- 90-863160 MAY 2000Page 6B-4 546
- Page 6B-590-863160 MAY 2000 547
- 90-863160 MAY 2000Page 6B-6 548
- Page 6B-790-863160 MAY 2000 549
- 90-863160 MAY 2000Page 6B-8 550
- Page 6B-990-863160 MAY 2000 551
- Connecting The Clevis 552
- Hydraulic Fluid Level 553
- Continuity Circuit 556
- Trim Cylinder Anodes 559
- Anodic Plate 560
- Bravo Two Sterndrive Units 562
- Bravo Three Sterndrive Units 562
- Integral MerCathode System 563
- Installing Electrode Assembly 564
- MerCathode Controller 568
- Quicksilver Isolator 569
- Test Equipment Set-Up 572
- Low Readings 573
- Low Readings (continued) 574
- High Reading 575
- Power Shift (P/N 38638A4) 580
- General Information 581
- Checking Vacuum Drop-Off 583
- Power Shift Cylinder Repair 584
- ACCESSORIES - ALL MODELS 585
- Installation Preparation 592
- Shift Cable Barrel Adjustment 592
- Installing Input Cable 593
- Installing Output Cable 594
- Attach Dust Cover 594
- Mounting Power Shift Cylinder 595
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