Mercury Bravo Three Service Manual Page 370
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SERVICE PROCEDURES REQUIRING MAJOR DISASSEMBLY SERVICE MANUAL NUMBER 28
Page 4B-28 90-863160 MAY 2000
CAUTION
Bellows clamp may corrode if ground clip is not installed.
5. Position ground clip on bellows.
50383
a
a-Grounding Clip
6. Position U-joint bellows with TOP mark facing upwards and install U-joint bellows on
gimbal housing flange and position clamp as shown. Torque to 35 lb-in. (4 Nm).
IMPORTANT: Ensure that the bead on the inner mating surface of bellows is posi-
tioned in the groove in gimbal housing flange.
50383
a
b
a-U-joint Bellows
b-Hose Clamp
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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