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Mercury Bravo Three Service Manual Page 309
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SERVICE PROCEDURES REQUIRING MINOR DISASSEMBL
Y
SERVICE MANUAL
NUMBER 28
90-863160 MA
Y 2000
Page 4A-3
THIS P
AGE IS INTENTIONALL
Y BLANK
INDEX
1
2
...
304
305
306
307
308
309
310
311
312
313
314
...
595
596
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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