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Mercury BRAVO Service Manual
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BRA
VO ONE GEAR HOUSING
SERVICE MANUAL
NUMBER 28
Page 3B-30
90-863160 MA
Y 2000
W
ater Passage Seal Replacement
1.
Pry seal out with a suitable tool.
22085
a
a-
Seal
2.
Lightly
coat outside diameter of seal with 3-M adhesive and install in speedometer water
passage
bore. Ensure that top edge of seal is flush with gear housing surface.
22085
a
a-
Seal
201
203
Table of Contents
Engine Mechanical Components
4
Replacement Parts
4
Service Manual Outline
5
Table of Contents
6
Power Trim
10
Steering Systems
11
General Information
13
How to Use this Manual
14
Page Numbering
14
How to Read a Parts Manual
15
Directional References
16
Propeller Rotation
16
Sterndrive Unit 10-Hour Break-In Period (New or with Replacement Gears)
17
Serial Number Locations and Engine Designation Decal
17
Transom Assembly Serial Number Location
17
Maintenance
19
Lubricants/Sealants/Adhesives
20
Maintenance Schedules
21
Maintenance Intervals
21
Gas Sterndrive
21
Specifications
23
Propeller Shaft
24
Steering System
24
Tie Bar Pivot Points
25
Checking and Adding Sterndrive Oil
26
Inspection
27
Changing Sterndrive Oil
28
General Maintenance
30
Power Package Layup
31
Power Package Recommissioning
32
Troubleshooting
33
Sterndrive Unit Troubleshooting
34
Sterndrive Unit will Not Slide into Bell Housing
34
Drive Unit Does Not Shift into Gear; Remote Control Shift Handle Moves
34
Drive Unit Does Not Shift into Gear; Remote Control Shift Handle Does Not Move
35
Drive Unit Shifts Hard
35
Drive Unit in Gear, will Not Shift out of Gear
35
Gear Housing Noise
36
Drive Shaft Housing Noise
36
Power Shift Troubleshooting
39
System Does Not React
39
System Binds
39
Performance Troubleshooting
40
Low WOT Engine RPM
40
High WOT Engine RPM
40
Propeller Ventilating/Cavitating
40
Poor Boat Performance And/Or Poor Maneuverability-Bow too Low
41
Poor Boat Performance And/Or Poor Maneuverability-Bow too High
41
Power Steering Troubleshooting
42
Hard Steering - Helm and Cable
42
Hard Steering (Engine Running) - Power Steering System
42
Power Steering System External Fluid Leaks
42
Compact Hydraulic Steering Troubleshooting
43
Helm Becomes Jammed During Filling
43
Steering Hard to Turn
43
Helm Unit Bumpy - Requires too Many Turns
43
Power Trim Electrical System Troubleshooting
44
Power Trim Pump Motor will Not Run in the OUT/UP or IN/DOWN Direction
44
Solenoids Do Not Click
44
Both Solenoids Click
45
Power Trim Pump Motor Runs in the OUT/UP Direction, but Not in the IN/DOWN Direction
45
In/Down Solenoid Does Not Click
45
In/Down Solenoid Clicks
46
Power Trim Pump Motor Runs in the IN/DOWN Direction, but Not in the OUT/UP Direction-Both Trim and Trailer Switches Inoperative
46
Out/Up Solenoid Does Not Click
46
Out/Up Solenoid Clicks
46
Trim Control OUT/UP Trim Switch Inoperative
47
Trim Control Trailer Switch Inoperative
47
Trim Out/Up Switch Functions
47
Trim System Functions While Unattended
47
Power Trim System Wiring Diagram
48
Power Trim Hydraulic System Troubleshooting
49
Drive Unit Cannot be Trimmed OUT/UP or Trims Slowly or with Jerky Movements
49
Drive Unit will Not Stay in Trimmed OUT/UP Position
49
Sterndrive Unit Trails OUT/UP on Deceleration or When Shifting into Reverse
49
Oil Foams out of Pump Fill/Vent Screw
50
Sterndrive Unit Cannot be Lowered from up Position or Lowers with Jerky Movements
50
Sterndrive Unit will Not Stay in Full up Position for Extended Periods
50
Sterndrive will Not Stay in the Trimmed OUT/UP Position When Underway
51
Sterndrive Unit Trails out / up on Deceleration or When Shifting into Reverse
51
Unit Thumps When Shifting
51
Oil Foams out of Pump Fill / Vent Screw
51
Trim Motor Runs but Does Not Pump Oil
52
Trim Pump Runs Slowly in both Directions
52
Trim Pump Runs Slowly with a Laboring Sound
52
Power Trim Hydraulic Schematic
53
Auto Trim II Electrical System Troubleshooting
54
Pump Motor will Not Run up or down in Either Manual or Auto Mode
54
Pump Motor will Not Stop Running down in Auto Mode
56
Pump Motor will Not Run up or down in Auto Mode
56
Trim System Completely Inoperative in Manual Mode
57
Pump Motor will Run UP, but Not down in both Manual and Auto Modes
57
Pump Motor Runs DOWN, but Not up in both the Manual and Auto Modes
57
Pump Motor will Run DOWN, but Not up in Auto Mode
58
Pump Motor will Run UP, but Not down in Auto Mode
58
Trim DOWN/IN Switch Inoperative in Manual Trim Control
58
Trim UP/OUT Switch Inoperative in Manual Trim Control
59
Trailer Switch in Manual, Trim Control Inoperative
59
Boat Is on Plane Well before Drive Unit Begins to Trim out
59
Boat Is Not on Plane before Drive Unit Begins to Trim out
59
Auto Trim II System Wiring Diagram
60
Corrosion Protection Troubleshooting
61
Corrosion on Underwater Parts, Without Mercathode or Impressed Current Protection
61
Corrosion on Underwater Parts, with Mercathode or Impressed Current Protection
62
Corrosion on Underwater Parts with Mercathode or Impressed Current Protection
64
Testing Procedure for Corrosion Protection
65
Corrosion Symptoms
65
Mercathode Controller Diagram
66
Removal, Installation and Adjustments - All Models
69
Torque Specifications
70
Lubricants/Sealants/Adhesives Table
70
Tools
70
Transom Thickness and Surface
71
Bravo Three Notice: Trim-In Limit Insert
72
Sterndrive Unit Removal
74
Transom Assembly Removal
76
Transom Assembly Installation
80
Sterndrive Unit Installation
90
Shift Cable Installation and Adjustment
97
Troubleshooting Shift Problems
101
Proper Cable Bend
101
Improper Cable Bend
101
Sterndrive Unit. Drive Shaft Housing
103
Drive Shaft Housing Specifications
104
Drive Shaft Housing Exploded View
106
Exploded Parts View (Clutch)
108
Exploded Parts View (Shifter)
109
Standard Bravo U-Joint Assembly
110
Bravo X, XZ, XR and Diesel Bravo U-Joint Assembly
111
Drive Shaft Housing and Gear Case Separation
112
Drive Unit Gear Ratio Identification
112
Separate Housings
116
Drive Shaft Housing Disassembly
119
Shifter Repair
124
Shifter Inspection
127
Shifter Reassembly
128
U-Joint and Pinion Gear Inspection
132
U-Joint and Pinion Gear Disassembly
132
U-Joint and Pinion Gear Reassembly
136
Gear Disassembly, Inspection and Reassembly
144
Gear Disassembly
144
Gear Inspection
146
Gear Reassembly
146
Drive Shaft Housing and Top Cover - Bearings and Bearing Sleeves Inspection
149
Bearing Sleeve Removal (Top Cover)
149
Bearing Sleeve Removal (Drive Shaft Housing)
150
Roller Bearing Removal
151
Steel Bearing Adaptor Removal
153
Steel Bearing Adaptor Installation
154
Bearing Sleeve Installation
155
Roller Bearing Installation
156
Drive Shaft Housing Reassembly
157
Torque Conversion Chart for U-Joint Retainer Nut Tool
161
Torquing Bravo U-Joint Bearing Retainer Nut
161
Install Gear Housing to Drive Shaft Housing
168
Bravo One Gear Housing
173
Bravo One Gear Housing Specifications
174
Bravo One Gear Housing Exploded View
176
Drive Shaft Components View
176
Bravo One and Diesel Bravo One X Propeller Shaft Components View
178
Bravo XZ and Bravo XR Propeller Shaft Components View
180
Pre-Disassembly Inspection
182
Drive Shaft Housing and Gear Housing Separation
183
Gear Housing Disassembly
185
Drive Shaft and Pinion Bearing 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 Inspection
197
Propeller Shaft Bearing Removal
197
Propeller Shaft Bearing Installation
198
Driven Gear Bearing Inspection
198
Driven Gear Bearing Removal
199
Driven Gear Bearing Installation
199
Driven Gear Bearing Cup Removal and Inspection
200
Driven Gear Bearing Cup Installation
200
Speedometer Water Passage
201
Pickup Inspection and Cleaning
201
Water Passage Seal Replacement
202
Gear Housing Reassembly and Shimming
203
Bravo XZ and XR Heavy Duty Propeller Shaft
217
Gear Housing Disassembly/Reassembly
217
Installing Bearing Carrier
217
Installing Propeller Hub Assembly
219
Bravo Two Gear Housing
221
Bravo Two Gear Housing Specifications
222
Bravo Two Gear Housing - Tools Needed
223
Bravo Two Gear Housing Exploded View
224
Drive Shaft and Propeller Shaft Components View
224
Bravo Two Gear Housing Pre-Disassembly Inspection
226
Separation of Drive Shaft Housing and Gear Housing
227
Gear Housing Disassembly (Bravo Two)
228
Drive Shaft and Pinion Bearing Inspection and Cleaning (Bravo Two)
234
Drive Shaft Disassembly (Bravo Two)
235
Pinion Bearing Removal (Bravo Two)
236
Pinion Bearing Installation (Bravo Two)
237
Drive Shaft Reassembly (Bravo Two)
238
Bearing Carrier Inspection (Bravo Two)
239
Bearing Carrier Disassembly (Bravo Two)
240
Bearing Carrier Reassembly (Bravo Two)
241
Propeller Shaft Inspection (Bravo Two)
243
Propeller Shaft Bearing Removal (Bravo Two)
244
Propeller Shaft Bearing Installation (Bravo Two)
244
Driven Gear Bearing Inspection (Bravo Two)
245
Driven Gear Bearing Removal (Bravo Two)
245
Driven Gear Bearing Installation (Bravo Two)
246
Driven Gear Bearing Cup Removal and Inspection (Bravo Two)
246
Driven Gear Bearing Cup Installation (Bravo Two)
247
Speedometer Water Passage (Bravo Two)
247
Pickup Inspection and Cleaning (Bravo Two)
247
Water Passage Seal Replacement (Bravo Two)
248
Gear Housing Reassembly and Shimming (Bravo Two)
249
Bravo Three Gear Housing
263
Bravo Three Gear Housing Specifications
264
Torque Conversion Chart for Bearing Carrier
265
Torque Conversion Chart for Bearing Retainer Nut
265
Torquing Outer Prop Shaft Bearing Retainer and Bearing Carrier
266
Lubricants/Sealants/Adhesives (Bravo Three)
266
Bravo Three Gear Housing - Tools Needed
267
Bravo Three Gear Housing Exploded View
268
Drive Shaft and Propeller Shaft Components View (Bravo Three)
268
Pre-Disassembly Inspection (Bravo Three)
270
Gear Housing Disassembly (Bravo Three)
271
Driveshaft and Pinion Bearing Inspection and Cleaning (Bravo Three)
278
Drive Shaft Disassembly (Bravo Three)
279
Drive Shaft Reassembly (Bravo Three)
279
Pinion Bearing Removal (Bravo Three)
280
Pinion Bearing Installation (Bravo Three)
281
Propeller Shaft Inspection (Bravo Three)
281
Propeller Shaft Disassembly (Bravo Three)
282
Propeller Shaft Spline Lash Check (Bravo Three)
283
Outer Propeller Shaft Servicing
285
Front Driven Gear and Bearing Inspection (Bravo Three)
286
Bearing Removal (Bravo Three)
286
Bearing Installation (Bravo Three)
286
Bearing Cup Removal (Bravo Three)
287
Bearing Cup Installation (Bravo Three)
287
Bearing Carrier Seal and Bearing Inspection
288
Bearing Carrier Seal and Bearing Removal
288
Bearing Carrier Seal and Bearing Installation
288
Speedometer Water Passage (Bravo Three)
289
Inspection and Cleaning (Bravo Three)
289
Seal Removal (Bravo Three)
290
Seal Installation (Bravo Three)
290
Gear Housing Reassembly and Shimming (Bravo Three)
291
Checking Backlash (Bravo Three)
298
Installing Gear Housing on Drive Shaft Housing
304
Propeller Installation
305
Transom Assembly: Service Procedures Requiring Minor Disassembly
307
Bravo Transom Assembly Specifications
308
Bravo Transom Assembly - Tools Needed
308
Bravo Transom Assembly Exploded Views
310
Inner Transom Plate Components
310
Bell Housing Components
311
Gimbal Ring Components
312
Gimbal Housing Components View
314
Bravo Transom Assembly: Special Information
316
Trim Limit Switch
316
Trim Position Sender Removal
316
Trim Position Sender Installation
318
Trim Position Sender Adjustment
322
Trim Limit Switch Adjustment
322
High Performance Transom Assembly - Without Electrical Trim Sender and Trim Limit Switch
324
Gimbal Bearing Inspection
325
Gimbal Bearing Removal
325
Gimbal Bearing Installation
326
Shift Cable Removal
328
Shift Cable Installation
329
Exhaust Bellows Removal
333
Exhaust Bellows Cleaning and Inspection
333
Exhaust Bellows Installation
334
Exhaust Tube Removal
336
Exhaust Tube Cleaning and Inspection
336
Exhaust Tube Installation
337
Water Hose and Water Fitting Removal
338
Water Hose and Water Fitting Installation
339
Crimp Clamp Tool
341
Service Procedures Requiring Major Disassembly
343
Bravo Transom Assembly: Specifications
344
Service Procedures Requiring Major Disassembly: Tools Needed
344
Bravo Transom Assembly: Exploded Views
346
Inner Transom Plate Components View
346
Bell Housing Components View
347
Gimbal Ring Components View
348
Gimbal Housing Components
350
Bell Housing Removal
352
Access Plug Kit Installation
356
Gimbal Ring, Swivel Shaft and Steering Lever Removal
358
Gimbal Ring Servicing
362
Gimbal Ring Identification
362
Bushings Installation
363
Gimbal Housing Servicing
368
U-Joint Bellows Replacement
368
Shift Cable Bellows Replacement
371
Exhaust Bellows Replacement
374
Speedometer Hose Replacement
376
Gear Lube Monitor System Components
377
Monitor to through Bulkhead Fitting Hose
377
Through Bulkhead to Bell Housing Gear Lube Monitor Hose
377
Bell Housing to Drive Shaft Housing Check Valves
378
Gear Lube Monitor System Reassembly
379
Trim Position Sender and Trim Limit Switch Wire Replacement
380
Gimbal Ring/Swivel Shaft and Steering Lever Installation
381
Bell Housing Installation
387
Standard Transom Assembly
387
High Performance Transom Assembly
388
Standard and High Performance Transom Assemblies
389
To Install the Shift Cable
393
Bravo Access Plug Drilling Template
397
Power Trim: Oildyne Trim Pump
401
Trim Pump Specifications
402
Oildyne Trim Pump: Tools Needed
402
Trim Pump Exploded View
403
Maintaining Power Trim Pump Oil Level
404
Air Bleeding Power Trim System
405
Bleeding OUT/UP Trim Circuit
405
Bleeding IN/DOWN Trim Circuit
405
Testing Power Trim Pump
406
Test Gauge
406
Internal Restriction Test
407
OUT/UP Pressure Test
408
IN/DOWN Pressure Test
410
Trim Pump Hydraulic System
411
Trim Cylinder Internal Leak Test
412
Trim Cylinder Shock Piston Test
415
Motor and Electrical Bench Tests
416
Trim Pump Motor Test (in Boat)
416
Trim Pump Motor Test (out of Boat)
418
Solenoid Test (Pump in Boat)
419
Solenoid Test (Pump out of Boat)
420
110 Amp Fuse Test (Pump in Boat)
422
110 Amp Fuse Test (Pump out of Boat)
423
20 Amp Fuse Test
423
Trim Pump Removal
424
Hydraulic Repair - Disassembly
425
Filter Replacement
427
UP Pressure Relief Valve Replacement
428
DOWN Pressure Relief Valve Replacement
429
Thermal Relief Valve Replacement
430
Pump Replacement
430
Adapter Replacement
431
Adapter Repair
433
Internal O-Ring and Poppet Valve Replacement
433
Pump Shaft Oil Seal Replacement
437
Motor Repair - Disassembly
439
Armature Tests
442
Continuity Test
442
Test for Shorts
443
Cleaning Commutator
443
Field Tests
443
Test for Open Circuit
443
Test for Short in Field
444
Thermal Switch Continuity Test
445
Brush Replacement
446
Motor Reassembly
449
Trim Pump Installation
455
Trim Pump Wiring Diagrams
456
Model with Three-Button Trim/Trailer Panel
456
Model with Trim in Handle and Trailer Switch Separate
457
Power Trim: Trim Cylinders
459
Trim Cylinders Specifications
460
Trim Cylinders: Tools Needed
460
Trim Cylinder Exploded Views
461
Bravo Trim Cylinders View
461
Bravo Trim System Components View
462
Power Trim Hydraulic Schematic Diagram
463
Trim Cylinders: Special Information
464
Bravo Three Notice - Trim-In Limit Insert
464
Trim Cylinder Repair
465
Trim Cylinder Removal
465
Trim Cylinder Disassembly
467
Trim Cylinder Reassembly
472
Trim Cylinder Installation
479
Dual Power Trim System
481
Dual Power Trim System: Important Information
482
Testing Dual Power Trim System
482
Relay Test
482
Diode Module Test
483
Trailer Switch Test
484
Starboard Trim Switch Test
484
Port Trim Switch Test
484
Dual Power Trim System Component Repair
485
Relay Replacement
485
Diode Module Replacement
487
Trim Control Panel Switch(Es) Replacement
488
Trim Control Panel Switch(Es) Removal
488
Trim Control Panel Switch(Es) Installation
489
Wiring Diagrams
490
Dual Trim Harnesses Wiring Diagram
490
Electrical Box Wiring Diagram
491
Auto Trim II
493
Auto Trim II System Description
494
Auto Trim II Operation
494
Auto Mode Operation
495
Boat Running above Planing Speed - Diagram
495
Boat Running below Planing Speed - Diagram
495
“Manual” Mode Operation
496
Raising Sterndrive Unit to Trailer Position
496
Trimming Sterndrive Unit out (Bow Up)
497
Trimming Sterndrive Unit in (Bow Down)
497
Electrical System Overload Protection
498
Auto Trim Limit Adjustment
498
Boat Properly Trimmed - Diagram
498
Boat too High/Too Low - Diagrams
498
Adjusting Sterndrive Unit Trim Angle
499
Dry Dock Procedure
499
On-Water Procedure
500
Control Module Adjustment
501
Trim Position Indicator Adjustment
502
Auto Trim II Wiring Diagram
503
Power Steering
505
Power Steering Specifications
506
Power Steering: Tools Needed
506
Power Steering Description
507
Control Valve
507
Power Steering System Diagram - Right Turn
508
Power Steering System Diagram - Left Turn
509
Power Steering System Diagram - Neutral
510
Steering Helm and Cable
511
Locking Sleeve
511
Steering Cable Specifications
512
Filling and Air Bleeding Power Steering System
513
Checking Fluid Level
513
Filling and Bleeding the Power Steering System
514
Power Steering Assembly Removal
515
Power Steering Assembly Installation
516
Power Steering System Pressure Test
519
Pump Pressure Test
521
Power Steering Pump Removal
523
Flow Control Valve Servicing
524
To Replace the Pump Shaft Oil Seal
525
Power Steering Pump Disassembly
527
Power Steering Pump Cleaning and Inspection
530
Power Steering Pump Reassembly
530
Power Steering Pump Installation
536
Multiple Sterndrive Steering Tie Bar Arrangements
537
Determining Tie Bar Length
538
Tie Bar Selection
539
Tie Bar Installation
539
Dual Installations with Steering Cable Attached to Starboard Power Package
539
Dual Installations with Steering Cable Attached to Port Power Package
540
Steering Systems
543
Compact Hydraulic Steering
543
Important Information about Thru-Transom Exhaust
544
Compact Hydraulic Steering Torque Specifications
544
Installing the Steering Cylinder
546
Filling and Purging the System
548
Twin Station And/Or Twin Cylinder
548
Single Station with Single Cylinder - Filling
549
Single Station with Single Cylinder - Purging
550
Connecting the Clevis
552
Hydraulic Fluid Level
553
Setting Fluid Level
553
Maintaining Fluid Level
553
System Check
553
Corrosion Protection
555
Corrosion Protection - Tools Needed
556
Continuity Circuit
556
Trim Cylinder Anodes
559
Anodic Plate
560
Bravo One Sterndrive Units
560
Bravo Two Sterndrive Units
562
Bravo Three Sterndrive Units
562
Integral Mercathode System
563
Removing Electrode Assembly
563
Installing Electrode Assembly
564
Connect Electrical Leads to Controller Assembly
566
Mercathode Monitor Wiring Diagram
567
Mercathode Controller Wiring Diagram
568
Quicksilver Isolator
569
Corrosion Protection Testing and Troubleshooting
569
Digital Multimeter and Mercathode Reference Tester 76675A1 View
570
Electrode Mounted on Bottom of Transom Assembly
571
Electrodes Mounted on Boat Transom
571
Test Equipment Set-Up
572
Low Readings
573
High Reading
575
Normal Reading but Corrosion Is Evident
575
Corrosion on the Entire Sterndrive Unit
575
Corrosion Problem Developed after Refinishing the Drive Unit, Paint Blistering on Drive Unit
575
Trim Cylinder Corroding
576
Only One or Two Components Corroding
576
Corrosion in the Exhaust Outlet Area
576
Aluminium Corroding in Lubricated Areas
576
Stainless Steel Components Corroding
577
Stainless Steel Propeller Corroding
577
Paint Blistering - the Metal under the Blistered Paint Is Not Pitted
577
Accessories
579
Accessories Specifications
580
Power Shift (P/N 38638A4)
580
Attaching Output Shift Cable to Sterndrive Unit
581
Cable Replacement
581
General Information
581
Determining Input Cable Length
582
Determining Output Cable Length
582
If Relocating the Power Shift Cylinder
582
Checking Vacuum Drop-Off
583
Power Shift Cylinder Repair
584
Power Shift Cylinder Removal
584
Power Shift Cylinder Disassembly
584
Power Shift Cylinder Reassembly
587
Shift Cable Replacement and Adjustment
592
Shift Cable Barrel Adjustment
592
Installing Input Cable
593
Installing Output Cable
594
Attach Dust Cover
594
Mounting Power Shift Cylinder
595
Connecting Vacuum Hose to Engine
595
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Mercury BRAVO Specifications
General
Brand
Mercury
Model
BRAVO
Category
Engine
Language
English
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