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Bravo Drive History Section 7A - Bravo Drive Unit History

1. a Plug version that contacts carrier 22 67892A05 b New plug 22 67892A06 c Original plug 22 67892A1 A new yellow colored seal will be used with the new fill drain plug 20874 a Older blue colored fill drain plug gasket 12 19183 1 b New yellow colored plug seal 26 830749 90 899907001 JULY 2006 Page A 22 Bravo Drive Unit History Bravo XR XZ Blue Billet Aluminum Bearing Carrier 20875 a Original plug 22 67892A1 b New plug 22 67892A06 c Plug version that contacts carrier 22 67892A05 d Area of interference Water Pickups and Flushing Devices Used on Bravo Drives There are 3 types of water pickups available on Mercury MerCruiser sterndrives dual water low water and side pickups 20863 a Dual water pickup c Side pickup b Low water pickup IMPORTANT Bravo models equipped with closed cooling require dual water pickups and must be equipped with a thru hull or thru transom pickup in addition to the sterndrive water inlets 90 899907001 JULY 2006 Page 7A 23 m Bravo Drive Unit History Flushing Devices Part Number l 44357Q 2 flushing device Dual water pickup 881150Q 1 gearcase flush seal kit Side pickup 44357Q 2 Low water pickup 84996T 1 20865 Side Pickup Flushing Device 91 44357Q2 NOTE Seal Kit used to block off the front water inlet holes on the dual water inlet gear housings 20876 Low water Pickup Flushing Kit 91 84996T1
2. Pinion gear location 12 If the pinion gear location is within specification a Remove the pinion shimming tool from the driveshaft housing b Remove the the stub shaft tool complete assembly from the driveshaft housing c Proceed to Measuring Driven Gear Lash in this section 13 If the pinion gear does not meet the specification a Calculate the difference of the existing pinion gear location measurement and the specified pinion gear measurement by using the shimming charts below 90 899907001 JULY 2006 Page 8C 15 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Page 8C 16 For example if the gear is too far away from shimming tool The shim assembled with the upper driven gear measures 0 89 mm 0 035 in thick and the existing pinion gear location measurement is 0 71 mm 0 028 in NOTE Add shim thickness to move the pinion gear away from tool Remove shim thickness to move the pinion gear closer to tool The shim thickness should be decreased by 0 08 mm 0 003 in Replace the shim with a 0 81 mm 0 032 in thick shim Repeat the measurement process and check your work IMPORTANT The shimming process must be repeated until the pinion gear location specifications are met Shimming Charts Description Existing pinion gear location feeler gauge thickness 0 711 mm 0 028 in Specification 0 635 mm 0 025 in Remove shim measurement difference 0 076 mm 0 0
3. Page 7A 24 90 899907001 JULY 2006 Bravo Drive Unit History Bravo Driveshaft Housing Shift Shaft Bore O ring Replaced with a New Seal Shift Cavity Seal Plug Started with S N 0W258350 20877 a New shift cavity seal plug 19 865866 b Original O ring used to seal passage 25 62705 a New shift cavity seal plug 19 865866 90 899907001 JULY 2006 Page 7A 25 i Bravo Drive Unit History Bravo and Alpha GKN U joint Tools Following illustrates the Bravo and Alpha GKN U joint tool set Individual tools are shown in full and cut away view 20879 Bravo and Alpha GKN U joint Tool Set 91 866107A01 a 91 866107 c 25 20385 b 91 866109 d 91 866108 Bravo Standard GKN U joint and Cross Bearing Kit Cross bearing clips included in each kit will be in the sizes listed 20881 Page 7A 26 90 899907001 JULY 2006 Bravo Drive Unit History Bravo standard GKN U joint repair parts Part number Universal joint assembly 864244A 2 Stub yoke gear end 864245T Center socket 865503T Splined yoke engine coupler end 864244A01 Cross and bearing assembly 865496A01 Bravo X Series GKN U joint and Cross Bearing Kit Cross bearing clips included in each kit will be in the sizes listed 1 90 mm 0 075 in 1 95 mm 0 077 in 2 00 mm 0 079 in 20882 Bravo X GKN repair parts Part number Universal joint assembly 865425A03 Stub yoke gear end 866134 not sold separately Center socket 866137 not sold se
4. Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above b Replace only the lower thrust race c Repeat the measurement process 49 If the gear lash measurement of the upper driven gear and the lower driven gear are incorrect a Carefully remove the measuring tools stub shaft tool and assembly Remove the top cover upper thrust race and thrust bearing clutch and gear assembly and the lower thrust bearing and thrust race from the driveshaft housing b Replace the upper thrust race and the lower thrust race c Repeat the measurement process IMPORTANT The shimming process must be repeated until gear lash is within specifications CALCULATION METHOD FOR SPECIFIED GEAR LASH Page 8C 32 Using multiple thrust races to obtain the specified gear lash can cause drive damage and failure Always use the correct race 1 If the gear lash is not within specification a Calculate the difference of the existing gear lash measurement and the specified gear lash measurement by using the gear lash charts below b Make the gear lash measurement changes by removing or adding thrust race thickness For example if the gear lash measurement is too high The thrust race assembled with the driven gear measures 1 55 mm 0 061 in thick and the gear lash measurement is 0 43 mm 0 017 in NOTE Use the midpoint of the specified gear lash If the specified gear lash is 0 28 0 41 mm 0 011 0 016 in use
5. Later Models Serial Number 0M198373 and Above 31 Install the clamp block and handle tool on the end of the stub shaft tool Tighten just to snug up to shaft 15799 a Clamp block and handle tool c Gear lash flag b Stub shaft tool Clamp block and handle tool 91 865085 32 Install the dial indicator holding block to the adapter rod and nut tool 15800 a Dial indicator holding block b Adapter rod and nut tool Dial indicator holding block 91 865097 NOTE Use the short extension tip for the dial indicator 33 Install the dial indicator to the holding block using the correct drive gear ratio access hole Dial indicator 91 58222A1 34 Position the dial indicator holding block to align the dial indicator tip 90 parallel to the gear lash flag indicator mark 90 899907001 JULY 2006 Page 8C 27 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 35 Final alignment can be made to ensure that the gear lash flag is positioned vertically on the stub shaft tool 15803 Standard Bravo Bravo X Series a Gear lash flag e Adapter rod tool b Dial indicator tip f Clamp block and handle tool c Dial indicator g Stub shaft tool d Dial indicator holding block 36 Reposition the clutch for the clamp tool installation by carefully pushing the clutch up with a screwdriver to gain access to the upper driven gear 15804 a Clutch c Upper driven gear torus ring
6. 18 Position the upper thrust race on top of upper thrust bearing Z 15379 a Thrust race NOTE Ensure that the shim is positioned on the shoulder of the flanged bearing cup 19 Carefully install the stub shaft tool complete assembly into the driveshaft housing bore so not to damage the shim MerCrs MERCURY 16139 15813 a Driveshaft housing c Retainer nut b Stub Shaft tool complete assembly 20 Apply lubricant to the threads of the retaining nut Special Lubricant 101 Threads of retainer nut 92 802865A1 IMPORTANT Ensure that the retainer nut is not cross threaded by turning the retainer nut COUNTERCLOCKWISE until you feel the threads engage and then turn the retainer nut clockwise 90 899907001 JULY 2006 Page 8C 23 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 21 Install the U joint retainer nut to driveshaft housing a 18183 Standard Bravo shown a U joint retainer nut 22 Torque the retainer nut 18182 Standard Bravo shown a Bearing retainer wrench tool b Torque wrench 23 Use the specified torque chart and torque wrench as outlined in this section under Torque Conversion Chart For U joint Retainer Nut Tool Typical Bravo retainer nut tool shown a Torque wrench length b U joint retainer nut tool measurement 30 5 cm 12 in Bearing retainer wrench 91 17256 Page 8C 24 90 899907001 JULY 2006 Bravo Driveshaft Housing S
7. Bravo Three Gear Housing Setup Bravo Three Gear Housing Activity The object of the activity is to review and or perform the subjects titled in Service Manual 28 and answer the related questions on the activity sheet Propeller Shaft Spline Lash Check Bravo Three Only 1 Check inner propeller shaft spline lash as follows a Place inner propeller shaft on two V blocks 20304 a Inner propeller shaft b V blocks b Install Spline Backlash Tool on inner propeller shaft just behind shaft spline 20305 a Spline Backlash Tool b Inner propeller shaft Spline Backlash Tool 91 806192 c Slide front driven gear assembly onto spline of inner propeller shaft d Mount Dial Indicator to gear and position so that indicator probe aligns with mark on Indicator Rod 20311 a Dial Indicator c Mark stamped on Indicator Rod b Spline Backlash Tool Spline Backlash Tool 91 806192 Dial Indicator 91 58222A1 Page 8E 2 90 899907001 JULY 2006 Bravo Three Gear Housing Setup 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 between 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 Spline Backlash tool Bravo Three Backlash Shimming Setup Procedure 1 Front driven gear shimm
8. Measure distance between marks a and b and mark position c half way between marks a and b F T 7815 7 Temporarily install control cable end guide into shift lever and insert anchor clevis pin 8 Adjust control cable barrel so that hole in barrel centers with vertical center line of stud Ensure that backlash center mark is aligned with edge of control cable end guide Do not attempt to install or remove control cable barrel from stud without first removing end guide anchor pin from shift lever and removing cable Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur 90 899907001 JULY 2006 Page 8F 17 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 9 Remove control cable end guide from shift lever by removing anchor clevis pin 8593 Typical Bravo shift bracket shown without switch a Control cable end guide d Control cable barrel b Clevis pin Anchor pin e Stud c Backlash center 10 Install the control cable 11 Install the washer and cotter pin to secure the barrel 12 Install the clevis pin 13 Install the cotter pin into the clevis pin from the top and spread the ends 14 Remove the adjustment tool 15 Shift remote control lever into forward position Place end of adjustment tool in barrel retainer If slot does not fit over stud loosen shift l
9. New tool for Bravo Three 2000 models 91 863738 NEW TOOLS FOR BRAVO 2000 MODELS 91 862219A 1 Spanner Wrench for the U joint retainer nut on units with L18 U joints X series 17 862218 Replacement pins for spanner wrench 91 862531 Lower bearing chimney remover installer for units with the steel bearing chimney X series 91 862530 Bearing installer for the new shorter bearing sleeve and needle bearing on all Bravo 2000 models Used with components of the 91 90244A1 Puller Driver Assembly 91 862546 U joint bellows retention sleeve removal tool Required to remove the new larger inside diameter sleeve without damaging it 91 840383A 1 If working on the gearcase housing that has the Hi Performance propshaft kit installed factory installed on XZ and XR models you will need kit 91 840383A1 which includes one of each of the following 90 899907001 JULY 2006 Page 7A 13 Bravo Drive Unit History 91 840393 Spanner wrench 91 840385 Seal installer 91 840388 Seal protector 91 862064A 1 A new tool has been released to remove the propshaft seal and bearing from the carrier on all Bravo Three models Bearing seal remover will press out the caged needle bearing and the propshaft seal in one step preventing damage to the carrier 91 863738 Bravo Three driveshaft retaining tool Required to accommodate new larger diameter lower driveshaft BRAVO ONE XR DRIVES GEAR RATIO CHANGE New lower gear sets are now available to con
10. 4 90 899907001 JULY 2006 Bravo One Gear Housing Setup 7 Using a dial type lb in torque wrench check the rolling preload 0 3 0 6 Nm 3 5 Ib in Adjust preload as necessary to attain proper reading Add shims to increase rolling torque Subtract shims to decrease rolling torque After correct rolling torque is achieved then check pinion gear location 20292 a Dial type Ib in torque wrench b Drive shaft adaptor Pinion Gear Location Shimming Setup Procedure IMPORTANT Drive shaft bearing preload must be to specification before checking the pinion gear location height 1 Check pinion height a Insert shimming tool into gear housing b Measure clearance between shimming tool and gear with feeler gauge Clearance must be set to specification Take measurement at 3 locations on gear 120 degrees apart SS oy ae 8 a ee 4 fee ae a a a a aa _ A 20293 a Driveshaft Pinion Gear Shimming Tool b Feeler gauge Driveshaft Pinion Gear Shimming Tool 91 42840T 90 899907001 JULY 2006 Page 8D 5 Bravo One Gear Housing Setup 2 If clearance is less than specified Add appropriate thickness of shim s under lower tapered roller bearing cup Any thickness added here must be subtracted from shim thickness at upper bearing If clearance is more than specified Remove appropriate thickness of shim s from under lower tapered roller bearing cup Any thickness subtracted here must be added to shim thic
11. 6 10 lb in 0 3 0 8 Nm 3 7 Ib in Torque wrench Ib in 91 66274 2 If the nut becomes overtightened causing excessive preload release the pinion gear and bearing assembly preload a Remove the pinion gear and the bearing assembly from the U joint b Place the universal puller plate under the shoulder of the flanged bearing cup 90 899907001 JULY 2006 Page 8C 7 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Press end of pinion gear with a suitable mandrel just until the bearing cups rotate easily Failure to do this can result in premature bearing failure O O C 16412 e Pinion gear f Mandrel on pinion gear g Press on mandrel a Universal puller plate tool b Flanged bearing cup shoulder c Flanged bearing cup d Top roller bearing and bearing cup 91 37241 Universal puller plate d Reassemble the components of the U joint and repeat the preload procedures SETTING PRELOAD IN THE DRIVESHAFT HOUSING 1 Set the preload on a U joint pinion gear and bearing assembly as follows a Apply a light coat of lubricant to bearings Install the U joint and pinion gear assembly into the driveshaft housing a A rl f 9 fA EA a NE oS S AANS OSSY Ons ISSSSSSSSS 16414 Standard Bravo shown Bravo X series similar a U joint and pinion gear assembly b Retaining nut Position the driveshaft hou
12. 8A 14 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Gear housing assembly 2 Stud 3 O ring 4 Seal 5 Seal 6 Roller bearing assembly 7 Drain plug kit 8 Seal 9 Anodic plate assembly 10 Lockwasher 11 Screw 12 Washer 13 Speedometer pickup tube 14 Shim kit 15 Tapered roller bearing assembly 16 Driveshaft assembly 17 Bearing race 18 Tapered roller bearing assembly 19 Tab washer 20 Shim kit 21 Spacer 22 O ring 23 Coupling assembly Bravo Drive Unit Components 24 Retaining ring 25 Pinion gear 26 Pinion gear washer 27 Pinion gear screw 28 Shim assembly 29 Tapered roller bearing assembly 30 Propeller shaft 31 Tapered roller bearing assembly 32 Driven gear 33 Thrust ring 34 Load ring 35 O ring 36 Bearing carrier assembly 37 Roller bearing 38 Fish line cutter oil seal and oil seal 39 Key 40 Tab washer 41 Cover 42 Propeller nut 43 Screw 44 Lockwasher 45 Washer 46 Nut Page 8A 15 Bravo Drive Unit Components Bravo Three Gear Housing 5504 Page 8A 16 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Gear housing assembly 2 Stud 3 O ring 4 Seal 5 Seal 6 Screw 7 Lockwasher 8 Anodic plate assembly 9 Roller bearing assembly 10 Drain plug kit 11 Seal 12 Screw 13 Washer 14 Gear set 15 Shim kit 16 Tapered roller bearing assembly 17 Driveshaft assembly 18 Bearing rac
13. Driveshaft And Improved Durability cccccccsseeeeeeeeeeeeeees 20 Lower Driveshaft cccccccseccceeesseeeeeeeeeeeeees 10 New Improved Propshaft Seals 006 21 Lower Unit Changes ccccecccceeeeeeeeeeeeeeeeeeees 10 NS sy settee O ees snaes 21 Bravo One And Three Lower Driveshaft 10 Oil Leak When Using the Current Magnetic Drain Water PICKUPS cccccsecceeeeseeeecseeeeeeeeneeens 11 Plug in the XR or XZ Heavy Duty Blue Billet Hi Performance Propeller Shaft Assembly 11 Bearing Calrrier cccccccccseeccsseeceseeceeeeseeeeeseeens 21 Transom Assembly Changes for Bravo 2000 Water Pickups and Flushing Devices Used on Bravo MIO GIGI S aiea e ee 11 BTS S sates t meets do A E E T E E E 23 Intermediate Shift Cable Guide Extension 11 Bravo Driveshaft Housing Shift Shaft Bore O ring New Gimbal Bearing cccccseeeceeeeeeeeeeeeees 12 Replaced with a New Seal cecceeeseeeeeaeeees 25 New Universal Joint Bellows Aluminum Retention Bravo and Alpha GKN U joint Tools 26 leev E eee E ra ENE A A 12 Bravo Standard GKN U joint and Cross Bearing Kit Trim Cylinder Tilt limit Spacers c0cce ae E E E E E E E E 26 Additional Information ccccseceesseeeeeeeeeeaeees 13 Bravo X Series GKN U joint and Cross Bearing Kit Installing A Bravo X Model On An Older Transom ne eecccceecceceeeecaeeeeeeeeeeeeeeeeeeeaeseeseeeeessa
14. NOTE For a more definite feel of the gear lash channel lock pliers can be used to grip the drive Shaft splines while rotating shaft to determine amount of play c If backlash is not correct disassemble and proceed as follows If backlash is more than specified Add shim s under driven gear bearing cup If backlash is less than specified Subtract shim s under driven gear bearing cup 5 When lash is correct perform final prop shaft rolling torque preload adjustment Page 8D 8 90 899907001 JULY 2006 Bravo One Gear Housing Setup Checking Adjusting Final Propeller Shaft and Overall Gear Housing Bearing Preload Rolling Torque 1 Remove bearing carrier and items shown lt Sesesauassse ELLI J cE i 7A j i i w sae8 v t 20298 a O ring c Load ring b Thrust ring IMPORTANT Always use a new load ring when reassembling 2 Install new load ring original thrust ring and new O ring 3 Install bearing carrier and tab washer in gear housing and Tabless Spacer Washer 14 863195 if required 4 Lubricate threads on bearing carrier retaining nut with Special Lubricant 101 Install and tighten bearing carrier retainer until resistance to propeller shaft rotation can be felt to preload bearings 5 Tighten the retainer nut to achieve the proper overall gearcase preload To determine overall gearcase preload add prop shaft be
15. U joint exploded view for the parts order and orientation of U joint reassembly a Place bearing retainer wrench tool in a vise and add the retainer nut b Stack the oil seal and oil seal carrier on the retainer nut c Install the O ring to oil seal carrier 16399 Standard Bravo model shown Bravo X series and Bravo XR models are similar a Bearing retainer wrench tool c Oil seal and oil seal carrier b Retainer nut d O ring Bearing retainer wrench 91 17256 d Stack the sealing ring on the oil seal carrier e Place the thrust washer flat side up on the oil seal carrier f Stack the pinion gear and bearing assembly on the thrust washer and sealing ring 16400 Standard Bravo model shown Bravo X series and Bravo XR models are similar a Sealing ring c Pinion gear and bearing assembly b Thrust washer g Apply lubricant to the washer and threads of retainer nut 90 899907001 JULY 2006 Page 8C 35 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above High Performance Gear U joint pinion gear washer and 92 802854A1 Lubricant retainer nut h Install the U joint from the bottom of the stacked assembly i Place the washer over the U joint stub and hand start the pinion nut M 16401 a U joint c Pinion nut b Washer j Use a screwdriver to secure the U joint k Tighten the pinion nut until the washer contacts the gear Do not overtighten the nut before set
16. b Lower driven gear torus ring d Screwdriver NOTE The clutch and gear assembly timing marks and must remain aligned while measuring gearlash NOTE The driven gear clamping tool clamps to the torus ring a 16440 a Driven gear torus ring b Driven gear clamping tool Page 8C 28 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 37 Install the driven gear clamping tool to the upper driven gear of the clutch and gear assembly Position the tool so you can hold the clamping tool while reading the dial indicator 15805 a Upper driven gear torus ring c Clutch b Driven gear clamping tool Driven gear clamping tool 91 865115 38 Make final adjustments enabling holding the driven gear clamping tool with one hand and the handle tool with the other hand while reading the dial indicator Tighten the clamp block and handle tool to the stub shaft tool 39 Hold the driven gear in locked position with the driven gear clamping tool Slightly rotate the clamp block and handle tool back and forth to move the U joint pinion gear to feel the gear lash MerCruiser Se 15807 a Clamp block and handle tool c Dial indicator b Driven gear clamping tool 40 Observe the dial gauge while rotating the pinion gear back and forth to feel the gear lash Record this measurement as an upper driven gear measurement 41 Remove the driven gear clamping tool fro
17. b Lower gear negative timing mark 12 Align the timing index marks of the clutch and gear assembly with the index marks on driveshaft housing as close as possible 18180 Clutch and gear assembly properly installed in the driveshaft housing a Index marks on driven gears b Index marks on driveshaft housing 13 Ensure that the clutch and gear assembly is positioned below the top of the driveshaft housing 90 899907001 JULY 2006 Page 8C 21 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 14 If the clutch and gear assembly is above the driveshaft housing reposition the lower thrust race and lower thrust bearing 15794 15795 Positioned correctly Positioned incorrectly a Clutch and gear assembly b Driveshaft housing 15 Lightly lubricate thrust bearing aS ee Thrust bearing 92 802854A1 NOTE The thrust bearing is always aligned to the gear and the thrust race shim is aligned to the driveshaft housing 16 Position the upper thrust bearing on top of the clutch and gear assembly 15381 a Thrust bearing 17 Lightly lubricate the thrust race High Performance Gear Thrust race 92 802854A1 Lubricant NOTE If using the original thrust race install the race so the side of original contact area is in the same position as the one removed Page 8C 22 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above
18. f Screwdriver c Bearing retainer wrench tool Bearing retainer wrench 91 17256 3 Insert the stub shaft tool from the bottom of the the pinion gear and bearing assembly and the remaining components NOTE Do not overtighten the nut 4 Install the washer and nut tighten nut until the washer and nut just seat against the pinion gear and the complete assembly is firmly seated to the stub shaft tool 15811 Standard Bravo U joint assembly shown a Tool c Pinion gear and bearing assembly b Stub shaft tool d Socket on nut Stub shaft for Standard Bravo 91 865084 Stub shaft for Bravo X Series 91 865083 5 Position the shim on the shoulder of the flanged bearing cup Use the starting shim specification chart or the original shim thickness that came out of the drive as a starting point 90 899907001 JULY 2006 Page 8C 11 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Starting shim specification U joint pinion gear shim 15812 a Shim c Stub shaft tool b Shoulder of bearing spacer cup 6 Carefully install the pinion gear and bearing assembly with the stub shaft tool into the driveshaft housing bore so not to damage the shim MerCrs MERCURY 15813 16139 Standard Bravo Bravo XR a Driveshaft housing c Retainer nut b Stub shaft tool complete assembly 7 Apply lubricant to the threads of the retainer nut Tube Ref No Where Used Part No Special Lu
19. feeler gauge between a tooth and the gauging surface b Slightly rotate the shimming tool until one side of the gauging surface contacts the feeler gauge and a slight drag is felt on the feeler gauge c Without moving the shimming tool remove the feeler gauge and re insert it between the other tooth and the gauging surface 16419 2 If the feeler gauge can be inserted with only a slight drag the shimming is correct 3 If the feeler gauge inserts with no drag repeat Steps 1 a b and c with progressively thicker feeler gauges until the feeler gauge can be inserted with only a slight drag 4 If the feeler gauge cannot be inserted repeat Steps 1 a b and c with progressively thinner feeler gauges until the feeler gauge can be inserted with only a slight drag Measuring Driven Gear Lash IMPORTANT Repeat the shimming process Measuring Driven Gear Lash until the gear lash measurement is within specifications 1 Ensure that the U joint pinion gear has completed the shimming procedure and is removed from the driveshaft housing 2 Measure the upper and lower thrust race Record this measurement 3 If not using the original thrust race use a thrust race with the specified thickness as a starting point or the same thickness as the original thrust race 15380 a Micrometer b Thrust race 90 899907001 JULY 2006 Page 8C 17 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Sta
20. gear housing were split 1 i Ye il S TUH SKS WASS 20288 a Clamp plate 2 Remove O ring spacer and shims NOTE There should not be any shims between the tab washer and the bearing c Shims d Tab washer above bearing a O ring b Spacer 3 Determine shim thickness required for drive shaft bearing preload 90 899907001 JULY 2006 Page 8D 2 Bravo One Gear Housing Setup a Measure distance between top of gear housing and tab washer at three locations Y P XJ r Cd 5 os oe we NN saz e H TEAST 19835 a 0 to 1 in Depth Micrometer 4 a a b Measure thickness of spacer from top machined surface to bottom machined surface a Outside Micrometer c Location of measurement b Spacer C Calculate shim thickness as shown Measurement found in Step a minus measurement found in Step b 001 in Shim thickness required a b 001 Shim s required 90 899907001 JULY 2006 Page 8D 3 Bravo One Gear Housing Setup 4 Install calculated amount of shims spacer and new O ring c Shims a New O ring d Tab washer above bearing b Spacer 5 Reinstall clamp plate on gear housing 6 Tighten nuts to specification NOTE Use two washers on each stud under nuts so that nut does not run out of threads when torquing it down a YA WASS 20288 a Clamp plate Page 8D
21. move in direction A when control lever is placed in forward gear position IMPORTANT When installing shift cables ensure that cables are routed in such a way as to avoid sharp bends and or contact with moving parts Do not fasten any items to shift cables 1 Loosen the adjustable stud and move it to dimension as shown Retighten stud Typical Bravo shift bracket shown without switch a Adjustable stud b 76 mm 3 in center of pivot bolt to center of stud 2 Install sterndrive unit shift cable 3 Install cotter pin 4 Insert cotter pin from top and spread ends fully Y C 8523 Typical Bravo shift bracket shown without switch a Washers 2 c Short cotter pin b Long cotter pin Page 8F 16 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 5 Place adjustment tool over sterndrive unit shift cable as shown Hold tool in place using a piece of tape over the barrel retainer Typical Bravo shift bracket shown without switch 6 Locate center of remote control and control cable play backlash IMPORTANT Keep center mark c aligned with control cable end guide edge when making the following adjustment a Shift remote control to neutral b Pushin on control cable end with enough pressure to remove play and mark position a on tube c Pull out on control cable end with enough pressure to remove play and mark position b on tube d
22. the midpoint of 0 36 mm 0 014 in The thrust race thickness should be increased by 0 08 mm 0 003 in Replace the thrust race with a 1 63 mm 0 064 in thick thrust race Repeat the measurement process and check your work Gear lash chart Existing gear lash measurement 0 432 mm 0 017 in Specification 0 356 mm 0 014 in Add thrust race measurement difference 0 076 mm 0 003 in For example If the gear lash measurement is too low The thrust race assembled with the driven gear measures 1 55 mm 0 061 in thick and the gear lash measurement is 0 30 mm 0 012 in NOTE NOTE Use the midpoint of the specified gear lash if the specified gear lash is 0 28 0 41 mm 0 011 0 016 in use the mid point of 0 36 mm 0 014 in The thrust race thickness should be decreased by 0 05 mm 0 002 in Replace the thrust race with a 1 50 mm 0 059 in thick thrust race Repeat the measurement process and check your work Gear lash chart Description Thrust race thickness Specification 0 356 mm 0 014 in Existing gear lash measurement 0 305 mm 0 012 in Remove thrust race measurement difference 0 051mm Adding thrust race thickness positions the driven gear closer to the pinion gear reducing gear lash 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Removing thrust race thickness positions the driven gear farther away from the pinion gear inc
23. the pinion gear and bearing assembly from the U joint b Place the universal puller plate under the shoulder of the flanged bearing cup c Press end of pinion gear with a suitable mandrel just until the bearing cups rotate easily Failure to do this can result in premature bearing failure O A s e aa 16412 a Universal puller plate tool e Pinion gear b Flanged bearing cup shoulder f Mandrel on pinion gear c Flanged bearing cup g Press on mandrel d Top roller bearing and bearing cup 91 37241 Universal puller plate d Reassemble components to the U joint and repeat preload procedures Page 8C 40 90 899907001 JULY 2006 Bravo One Gear Housing Setup Bravo Drive Unit Service Section 8D Bravo One Gear Housing Setup Table of Contents Driveshaft Bearing Preload Shimming Setup Checking Adjusting Final Propeller Shaft and Overall FOG CNC irc alesse pts saicnge teense dodece ds eeqednesthacerSems 2 Gear Housing Bearing Preload Rolling Torque 9 Pinion Gear Location Shimming Setup Procedure Major Differences Between The Bravo One And Bravo A E eeddiestenne ec esesens 5 Two Gear HOuSIng ccccccceeeeeeeeseeeseeeeeeeesseeneee 11 Driven Gear Lash Shimming Setup Procedure 6 90 899907001 JULY 2006 Page 8D 1 Bravo One Gear Housing Setup Driveshaft Bearing Preload Shimming Setup Procedure Remove clamp plate NOTE Clamp plate was installed after drive shaft housing and
24. 0 406 mm 0 011 in 0 016 in 0 229 mm 0 381 mm 0 009 in 0 015 in 46 If the gear lash measurement of the upper driven gear and the lower driven gear are within specification a Carefully remove the measuring tools stub shaft tool and assembly Remove the top cover from the driveshaft housing Remove all components from the stub shaft tool The upper thrust race and upper thrust bearing clutch and gear assembly and the lower thrust bearing and lower thrust race remain in the driveshaft housing for complete reassembly of the driveshaft housing d Proceed to Drive Reassembly NOTE Refer to Calculation Method For Specified Gear Lash in this section 47 lf the gear lash measurement of the upper driven gear is incorrect and the lower driven gear is within the specified measurement a Carefully remove the measuring tools stub shaft tool and assembly Remove the top cover and the upper thrust race from the driveshaft housing b Replace only the upper thrust race c Repeat the measurement process 48 If the gear lash measurement of the lower driven gear is incorrect and the upper driven gear is within the specified measurement a Carefully remove the measuring tools stub shaft tool and assembly Remove the top cover upper thrust race and upper thrust bearing clutch and gear assembly and the lower thrust bearing and lower thrust race from the driveshaft housing 90 899907001 JULY 2006 Page 8C 31
25. 0 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 2 Remove monitor cap and fill gear lube monitor 5497 a Gear lube monitor cap b Fluid level full mark 3 Push in on dribble valve until gear lube appears 7334 a Dribble valve 4 Once gear lube appears release dribble valve 5 Fill monitor to FULL mark 6 Replace monitor cap 90 899907001 JULY 2006 Page 8F 9 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 7 Apply 2 4 C Marine Lubricant with Teflon to studs 7335 a Studs z l U joint and Gimbal Bearing i 8 Lubricate U joint shaft splines and U joint shaft O rings with Quicksilver Engine Coupler Spline Grease a Splines b O rings Shaft splines and O rings 92 802870A1 z U joint and Gimbal Bearing Ta Grease Page 8F 10 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 9 Check drive shaft bellows for cleanliness and absence of debris 7337 a Driveshaft bellows 10 Lubricate O ring seals with 2 4 C Marine Lubricant with Teflon 2 4 C with Teflon O ring seals 92 802859A1 90 899907001 JULY 2006 Page 8F 11 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 11 Pull out shift linkage as far as it moves Jaws will open as shown 21421 a Shift linkage IMPORTANT As sterndrive is inserted into drive unit entry of the bell housing
26. 03 in For example if the gear is too close to the shimming tool The shim assembled with the upper driven gear measures 0 89 mm 0 035 in thick and the existing pinion gear location measurement is 0 56 mm 0 022 in NOTE Add shim thickness to move pinion gear away from tool Remove shim thickness to move pinion gear closer to tool The shim thickness should be increased by 0 08 mm 0 003 in Replace the shim with a 0 81 mm 0 032 in thick shim Repeat the measurement process and check your work IMPORTANT The shimming process must be repeated until the pinion gear location specifications are met Shimming Charts Specification 0 025 in in Existing pinion gear location feeler gauge thickness 0 022 in Add shim measurement difference 0 003 in NOTE A reference chart of the U joint pinion gear shims follows C joint pinion gear shim om n 15 888927 028 15 888927 029 15 888927 030 15 888927 031 15 888927 032 15 888927 033 15 888927 034 15 888927 035 15 888927 036 15 888927 037 15 888927 038 15 888927 039 099 0 030 15 888927 040 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above FEELER GAUGE MEASUREMENT 1 To properly check gear location a Position the gear with at least 2 full teeth centered on the gauging surface One full tooth must be on each side of the gauging surface center line Insert a 0 64 mm 0 025 in
27. 07001 JULY 2006 Page 8C 33 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above U joint Pinion Gear and Bearing Assembly Reassembly Improper reassembly of the U joint and pinion gear assembly can cause damage or failure of the sterndrive Reassemble the U joint and pinion gear as specified Standard Bravo U joint assembly a Pinion nut f Thrust washer b Washer g Oil seal and oil seal carrier c Pinion gear and bearing assembly h Retainer nut d Sealing ring i U joint e O ring 15756 Bravo X series U joint assembly a Pinion nut d Thrust washer b Washer e O ring oil seal oil seal carrier and c Pinion gear and bearing assembly retainer nut f U joint 15757 Bravo XR U joint assembly a Pinion nut d Thrust washer b Washer e O ring oil seal oil seal carrier and c Pinion gear and bearing assembly retainer nut f U joint Page 8C 34 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above The stacking procedure below can be followed for the assembly of all Bravo U joint assemblies However the Bravo X series and the Bravo XR models must refer to specified U joint exploded view for the parts order and orientation of U joint reassembly 1 Stacking procedure for reassembling a Standard Bravo U joint pinion gear and bearing assembly NOTE Bravo X series and the Bravo XR models must refer to specified
28. 16 is used and the seals are pressed in from the outside rear of the carrier e A larger bearing installer 91 63626 is used to press in the driven gear race The shims under the cup are still used to set backlash e The vertical shaft and the pinion bearing are serviced in the same manner and with the same tools as the Bravo One with the exception that on earlier units there are two different bearing part numbers depending on the gearcase casting number See Service Manual 11 90 17431 4 3 98 page 3C 15 e A larger Shimming Tool 91 96512 is used to set pinion height but the specification is still 0 64 mm 0 025 in 90 899907001 JULY 2006 Page 8D 11 Bravo One Gear Housing Setup Page 8D 12 Backlash specification is 0 23 0 38 mm 0 009 0 015 in which is a little more forgiving than the Bravo One Bearing Carrier Retainer Tool 91 1725 7 Bearing Driver 91 55919 91 55918 Bearing Driver Bearing Cup Driver 91 63626 Oil Seal Driver 91 55916 Gearcase Pinion Shimming Tool 91 96512 90 899907001 JULY 2006 Bravo Three Gear Housing Setup Bravo Drive Unit Service Section 8E Bravo Three Gear Housing Setup Table of Contents Bravo Three Gear Housing Acctivity c ccseeeeeee 2 Bravo Three Backlash Shimming Setup Procedure Propeller Shaft Spline Lash Check Bravo Three Only ou eccceecccsecccceeeeceeeeceeeeeeeeeeeeeeeeeueeseeeeseeeeseeeeseeeesaeeesaes 3 90 899907001 JULY 2006 Page 8E 1
29. 9 Seal 40 Shim 41 Grounding tab 42 Self tapping screw 43 Lower shift shaft bushing 44 Tapered roller bearing 45 Flanged bearing cup 46 Bearing cup 47 Tapered roller bearing Page 8A 11 Bravo Drive Unit Components Bravo One Gear Housing Exploded View 5491 Page 8A 12 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Gear housing assembly 2 Stud 3 O ring 4 Seal 5 Seal 6 Roller bearing assembly 7 Anodic plate assembly 8 Lockwasher 9 Screw 10 Shim kit 11 Tapered roller bearing assembly 12 Driveshaft assembly 13 Bearing race 14 Tapered roller bearing assembly 15 Tab washer 16 Shim kit 17 Spacer 18 O ring 19 Coupling assembly 20 Retaining ring 21 Gear set 22 Washer 23 Screw 24 Shim kit 25 Tapered roller bearing assembly Bravo Drive Unit Components 26 Propeller shaft 27 Washer 28 Tapered roller bearing assembly 29 Load ring 30 Thrust washer 31 Bearing carrier assembly 32 O ring 33 Seal 34 Drain plug kit 35 Seal 36 Anode assembly 37 Screw 38 Lockwasher 39 Tab washer 40 Bearing carrier retainer 41 Spacer 42 Plastic drive sleeve 43 Aft propeller sleeve brass adaptor 44 Tab washer 45 Propeller nut kit 46 Screw 47 Washer 48 Nut 49 Thrust hub Page 8A 13 Bravo Drive Unit Components Bravo Two Gear Housing Exploded View s4 T 5501 Page
30. 90 899907001 JULY 2006 Page 8F 14 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 18 Insert soeedometer tube fitting into opening on topside of anti ventilation plate in position shown 7345 a Speedometer hose fitting b Opening 19 With fitting fully seated turn handle clockwise to a tightly seated position as shown 7346 a Fitting installed handle pointing forward Bravo Drive Unit Remote Control and Drive Unit Shift Cable Adjustment NOTE Bravo Models only Using Shift Cable Adjustment Tool shift cables can be adjusted without or with the sterndrive installed using the following procedure Shift Cable Adjustment Tool 91 12427 IMPORTANT Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control e Bravo One Two If shift cable end guide moves in direction A when control lever is placed in forward remote control is set up for right hand RH propeller rotation 90 899907001 JULY 2006 Page 8F 15 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup e Bravo One Two If shift cable end guide moves in direction B when control lever is placed in forward remote control is set up for left hand LH propeller rotation lt B 6614 Arrow indicates direction of motion e Bravo Three Front propeller on sterndrive unit is always LH rotation and rear propeller is always RH rotation Shift cable end guide must
31. Bell housing shift cable bore Water leakage could cause premature shift component failure Using the wrong drill may create a rough surface in the shift cable bore allowing water leakage Use a sharp straight drill with a 118 point and without nicks 90 899907001 JULY 2006 Page 8F 3 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 6 Drill through the 11 11 mm 7 16 in hole in the Drill Bushing Tool and through the bell housing shift cable bore Use the 11 11 mm 7 16 in drill provided in Service Tool Kit 91 818836A 1 21266 a Drill d Drill Bushing Tool b Nut e Bell housing stud c Washer f Bell housing shift cable bore 7 Remove the drill bushing tool and clean the debris out of the bell housing Apply 2 4 C Marine Lubricant with Teflon to the newly drilled hole 8 Install the new shift cable Bravo Drive Unit Shift Cable Installation 1 Insert shift cable end into and through shift cable bellows 21267 a Shift cable end b Shift cable bellows Page 8F 4 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 2 Apply Perfect Seal to shift cable retaining nut threads Secure shift cable to bell housing Hold inner nut with wrench and torque outer retaining nut to specifications 7 tn seme S _ AX SF ape 21268 a Shift cable d Outer retaining nut b Inner nut e Later style cable washer c S
32. Bravo Drive Unit History Bravo Drive History Section 7A Bravo Drive Unit History Table of Contents 90 899907001 JULY 2006 MAIS e E A EA E OE T E E 2 Bravo One Xr Drives Gear Ratio Change 14 WO aaa eden heat ted teens specs odes cae ee eee meee 2 Bravo 2000 Style Service Replacement Gear Sets NI 8 E a E T E E A E BE N EE 2 For All Bravo Drive Units cecccseeeeneeeees 14 Oe Waianae nee ea E E Alepeamena seca E E 2 New Gear Sets and Gear KitS 0cc seeees 14 Bravo Oil Circulation System 1991 and Newer Required New Thrust Bearing Shim Races 14 Si Sages oni sce sabes ands Gentes ieee anaes checcinseie psiaiseeeicteslseunsniedeese vse 3 Sleeve Bearing Race Drivels ccce 15 Bravo Driveshaft Housing Gear Housing Bearing Driver And Chimney For 1999 And Prior Compatibility Diagrams cccccccceeeeeeeeeeeeeeeaees 4 Units With Older Bearings And Gears 15 DI E V E E E OAE E EE A 4 Bearing Driver And Chimney For The New T e E AA nanancueaeneaneercneetesas 5 Designed Bravo Gears And Bearings When Used TIO e e A E E E E 5 In 1999 And Prior Units ccecceeeseeeeeeeeeees 15 OG r E 5 Bearing Driver And Chimney For Bravo 2000 And Shift Changes for Bravo One Two Three and Newer Model s cccccccseccceeeeeeeeceeeeaeeeaeeeeaes 16 BACK TAWK wsacscuadices jaciscaetestsanatatccunadeasadeGiewdesiadeuewnness Se 4 002 SR eee me nat eo omnes 16 NOD E E E EEE E
33. Install cable end guide over core wire and insert core wire through cable anchor Tighten anchor screws evenly and torque to specification Earlier Models a Core wire b Anchor screws c Cable end guide Bescon O O S o e e E E T Later Models a Cable end guide b Core wire c Anchor screws d Sight port bottom out core wire present on all later style and some earlier style cables 90 899907001 JULY 2006 Page 8F 7 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 10 Place Shift Cable Anchor Adjustment Tool on end of shift cable as shown ch fy AN SNE ON N NAE NNy E amp m e CCCCid A N Bt SRN NNN ANN a Shift Cable Anchor Adjustment Tool b Stud placed through hole in end guide c Hole barrel placed here Shift Cable Anchor Adjustment Tool 91 17262A1 11 Ensure that bell housing end of core wire is positioned tightly against Core Wire Locating Tool t 19445 a Bell housing b Core Wire Locating Tool c Core wire 12 Adjust cable barrel to align with hole in tool Remove tools and install cable on shift plate assembly being careful not to lose adjustment ee gt TEESE gt i m S 2 w RE 21276 a Barrel b Hole in tool Bravo Sterndrive Unit Installation 1 Remove trim cylinder support and dust cover from bell housing studs Retain elastic stop nuts and flat washers Page 8F 8 9
34. JULY 2006 Page 8C 37 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 16409 Standard Bravo shown Bravo X series similar a Dial type torque wrench lb in NOTE Bearings are used if spun once under load C a a U joint bearing preload 0 7 1 0 Nm 6 10 Ib in 0 3 0 8 Nm 3 7 Ib in Torque wrench Ib in 91 66274 2 Ifthe nut becomes overtightened causing excessive preload release the pinion gear and bearing assembly preload a Remove the pinion gear and the bearing assembly from the U joint b Place the universal puller plate under the shoulder of the flanged bearing cup c Press end of pinion gear with a suitable mandrel just until the bearing cups rotate easily Failure to do this can result in premature bearing failure lt g lt y L 4 r Do EA Ft a lt a om Ss ee 16412 a Universal puller plate tool e Pinion gear b Flanged bearing cup shoulder f Mandrel on pinion gear c Flanged bearing cup g Press on mandrel d Top roller bearing and bearing cup Universal puller plate 91 37241 d Reassemble the components of the U joint and repeat the preload procedures Page 8C 38 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above SETTING PRELOAD IN THE DRIVESHAFT HOUSING 1 Set the preload on a U joint pinion gear and bearing assembly as follows a Apply a l
35. Serial Number 0M198373 and Above Adding lower thrust race thickness positions the lower driven gear closer to the pinion gear reducing gear lash Removing lower thrust race thickness positions the lower driven gear farther away from the pinion gear increasing gear lash j TOSS ie ON i N DY a A Fr Xo D ia Va i SAAS 7 SAS q A 7 JU o MY eS gt im 17585 a Upper thrust race d Lower thrust race b Upper driven gear e Pinion drive gear c Lower driven gear Mi SSS ISS QPS SS NY The driveshaft housing is no longer stamped to indicate the thickness of the upper and lower thrust race During reassembly of the driveshaft housing use the original thrust race thickness that came out of the drive or use the thrust race thickness in the starting point specification chart Starting thrust race specification Driven gear thrust race Thrust race are color coded and graduate in 0 025 mm 0 001 in thickness 23 864596 059 White 23 864596 061 1 55 mm 0 061 in 23 864596 063 1 60 mm 0 063 in Red 23 864596 066 1 68 mm 0 066 in 23 864596 067 1 70 mm 0 067 in 90 899907001 JULY 2006 Page 8C 5 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Driveshaft Housing Assembly Teardown Inspection and Repair U joint Pinion Gear and Bearing Assembly Preload Follow only one of the procedures S
36. Service Bulletin 93 10 Propshaft bearing carrier anode added on Bravo One models Replaceable thrust wear pads added on all driveshaft housings Bravo Three changed to one piece gearcase housing anti ventilation plate was extended aft to replace separate extension plate Older housings will supercede to this housing New shift components in driveshaft housing to lower shift effort Service Bulletin 97 18 All parts will retrofit in older driveshaft housings New driveshaft housing with elongated aft trim anchor hole Service Bulletin 98 16 Aft trim anchor pin spacer must be correctly positioned to limit negative trim on Bravo Three models Shift Changes for Bravo One Two Three and BlackHawk Bravo One Two Three BlackHawk New Shift Parts a The Cone clutch has changed The spring ramp area is different The yoke groove has been increased by 0 025 cm 0 010 in in width The clutch is identified by a number 7 stamped down at the bottom of the spring groove on every clutch Cone Clutch 52 807375A2 90 899907001 JULY 2006 Page 7A 5 Bravo Drive Unit History b The garter springs now have a smaller diameter on the Bravo One Two Three only and are colored orange for easy identification 20267 Silver Color Blackhawk 24 818829 Orange Color Bravo One Two Three 24 93505 c The shift cams have a new ramp profile on them and will be identified with the casting part number molded into the top surface of the cam a
37. UTCH CHANGE Bravo cone clutch has had a change of manufacturers They are now produced with tighter tolerances 90 899907001 JULY 2006 Page 7A 17 P Bravo Drive Unit History NOTE New part is identified by a narrow groove cut on top shown and bottom not shown of the clutch and a third groove cut near the center of the clutch as shown This third groove goes down on assembly as shown 20797 SHIFT SWITCH ADDED Shift switch installed on 496 models at the shift plate Switch signals engine controller of a shift occurring This activates a revised engine management during shift event ECM PCM calibration change These changes reduce the load on the clutch for a smoother shift EFI models only Bravo Styling Change Restyle was done to the driveshaft housing top cover rear cover and decals 20798 a Original design b New restyled design Increased Bravo X durability Ribbed upper driveshaft housing top cover with steel chimney e Increased strength and stability e Improved cooling for longer gear and bearing life Increased Bravo XR durability Upper driveshaft has an improved finishing process for increased durability Caged needle bearing now used in driveshaft housing top cover chimney and at bottom chimney Page 7A 18 90 899907001 JULY 2006 Bravo Drive Unit History All Bravo Models will now have Shimmable Driveshaft Housing Gears for Increased Durability Driveshaft housing U joint pinion drive gear beari
38. Upper driveshaft 25 Thrust collar 26 Keepers 27 Washer 28 Plug 29 Nut 30 Trim in insert 31 Top cover screws X Series 32 Top cover X Series 33 Lower shift shaft bushing 34 Washers 35 Grounding tab 36 Self tapping screw Page 8A 3 Bravo Drive Unit Components Driveshaft Housing U Joint and Shift Components for Standard Bravo Models 5 13 a 18436 Page 8A 4 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Back cover 2 Back cover seal 3 Detent assembly 4 Back cover short bolt 5 Back cover long bolt 6 Wear pad 7 Shift shaft 8 Cam 9 Yoke 10 Cam screws 11 Spacer 12 Nut 13 Screw 14 Link bar 15 Shift lever 16 Washer 17 Cotter pin 18 Latch 19 U joint assembly 20 Yoke coupler end 21 O rings 22 O ring 23 Socket 24 Cross and bearing assembly 25 Yoke gear end Bravo Drive Unit Components 26 Retainer nut 27 O ring 28 Oil seal 29 Preload washer 30 O ring 31 Sealing ring 32 U joint bearing assembly 33 Pinion gear 34 Washer 35 Nut 36 Anode plate 37 Screws 38 Washers 39 Shift shaft oil seal plug 40 Upper shift shaft bushing 41 Seal 42 Shim 43 Lower shift shaft bushing 44 Tapered roller bearing 45 Flanged bearing cup 46 Bearing cup 47 Tapered roller bearing 48 Grounding tab 49 Self tapping screw Page 8A 5 y Bravo Drive Unit Componen
39. and Above Driven Gear Thrust Race 364596 NIN WO o amp o OIO RTA O1 O1 O on Olo Q1 O1 NIN P 2 o OIO A gt OI O1 oO P gt OIO OIO O 1 57 mm 0 062 in 160mm o 063in Red NININ Wl ao Y o CO Oo OD AIAJ ae O1 O17 O1 o o0 Oo o2 or OloloO oO O Od AION i D gt O1 o OIO gt O1 NIN OO oO P gt OJO O oO on NO oO 00 oO gt O1 Co O O N General Information Improper gear adjustment can cause severe damage to the sterndrive Follow the gear adjustment procedure closely All Bravo drives with the starting Serial Number of OM198373 and above must be shimmed during reassembly of the driveshaft housing Assembly Changes U JOINT SHIM The U joint assembly is shimmed for gear depth and location NOTE The shim is between the shoulder of the U joint snout and the flanged bearing cup When the driveshaft housing is assembled the shim fits between the flanged bearing cup and the shoulder of the U joint snout Adding shim thickness positions the pinion drive gear farther away from the driven gear and removing shim thickness positions the pinion drive gear closer to the driven gear INSLESASSASS MY If A O TU ha ASSES MOO RSS Driveshaft housing cut showing shim and gear placeme
40. and flat washers 5 IMPORTANT On Bravo One Two and Three models the Trim In Limit Pin if equipped must be properly positioned before installing the trim cylinder anchor pin in the following steps 90 899907001 JULY 2006 Page 8F 13 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 15 Ensure that the Trim In Limit Pin is positioned as shown for the appropriate Bravo model Nae U lt SS Pa gt i _ C yA 7343 a Trim In Limit Pin for Bravo One and Two positioned forward b Trim In Limit Pin for Bravo Three positioned aft IMPORTANT The position of the Trim In Limit Pin on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested IMPORTANT To aid in installing rubber bushings use a water and soap solution Do not use oil or grease 16 Install trim cylinders on aft end of drive unit with hardware as shown Lubricate anchor pin threads with 2 4 C Marine Lubricant with Teflon and tighten nuts until they bottom Install plastic caps and tighten hand tight only O w N 7 wt L 5 P 7 iy J a Aft anchor pin d Small I D flat washers 2 b Large D flat washers 2 e Locknuts 2 c Rubber bushings 4 f Plastic caps 2 2 4 C with Teflon Anchor pin threads 92 802859A1 17 Raise drive to gain access to area between gimbal housing and sterndrive and locate the opening in the forward end of the anti ventilation plate
41. aring and race are now combined into one assembly CONE CLUTCH All Bravo 2000 models 90 899907001 JULY 2006 Page 7A 9 Bravo Drive Unit History e There will be a new cone clutch identified with a shallow groove machined on the top flat surface of the cone clutch UNIVERSAL JOINT ASSEMBLY Standard Bravo e The U joint assembly will remain the same as today L 15 15 tooth spline input yoke and use the present cross and bearing assemblies Bravo X XZ XR e There will be a new larger L 18 U joint assembly that will have an 18 tooth spline input stub yoke and use a larger cross and bearing assembly e There is a new retainer nut that has the stub yoke oil seal installed into it as well as the O ring groove in it for installing the O ring that seals the outside diameter of the retainer nut The new spanner wrench is required for removal and installation of the new retainer nut Spanner Wrench for L 18 U joint Bearing 91 862219A1 Retainer e There is also a new thrust washer in the U joint assembly behind the oil seal in the carrier retainer nut that is only used with the L 18 U joint assembly SPLINED COUPLER BETWEEN UPPER DRIVESHAFT AND LOWER DRIVESHAFT All Bravo 2000 models e There is a new splined coupler between the upper driveshaft and lower driveshaft The only difference is that the spline has had a small radius added to the bottom root of the spline Both the old coupler and the new coupler will work on old and
42. aring preload to drive shaft preload as outlined in the following example Setting Overall Gear Housing Preload IMPORTANT The overall preload includes both the driveshaft preload and the propshaft preload Propshaft new bearings 9 1 4 Nm 8 12 Ib in Propshaft used bearings 6 9 Nm 5 8 lb in Driveshaft 3 6 Nm 3 5 Ib in Bearing is considered used if spun under load with power applied Plus driveshaft preload 3 6 Nm 3 5 Ib in Example Driveshaft preload 45 Nm 4 Ib in Propshaft new bearing 1 1 Nm 10 Ib in preload 1 1 Nm 10 Ib in Over all preload 1 6 Nm 14 Ib in 90 899907001 JULY 2006 Page 8D 9 Bravo One Gear Housing Setup OVERALL GEARCASE PRELOAD TABLE Driveshaft preload 3 Nm 3 Ib in 45 Nm 4 Ib in 6 Nm 5 Ib in Ne E Tein Ne Ein Propeller shaft preload 6 Tighten the retainer nut to achieve the proper preload using the following procedure a Tighten the retainer nut in small increments a a om 20296 a Bearing Carrier Retainer Nut Wrench Bearing Carrier Retainer Nut Wrench 91 61069T Page 8D 10 90 899907001 JULY 2006 Bravo One Gear Housing Setup b After tightening retainer nut in small increments check overall gear housing bearing preload at propeller shaft each time until correct specification is reached 20302 a Dial type Ib in Torque Wrench c Rotate shaft in direction of normal b Pro
43. ative marks NOTE Timing marks on gears must be aligned in one of two ways The positive mark over the negative or the negative mark over the positive Never align two positive marks or two negative marks 8 Position the clutch and gear assembly timing marks on gears 18178 a Upper driven gear to the positive b Lower driven Gear to negative mark mark 90 899907001 JULY 2006 Page 8C 19 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 9 Lightly lubricate clutch and gear assembly 18179 a Clutch and gear assembly rugn PANAN eat Clutch and gear assembly 92 802854A1 Lubricant 10 Install the clutch and gear assembly into the driveshaft housing so that the timing marks on gears are easily visible through the back of the driveshaft housing 15793 a Clutch and gear assembly b Bottom face of lower gear 11 Position the clutch and gear assembly timing marks on the gears Page 8C 20 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above NOTE The timing marks on the gears must be aligned in one of two ways The positive mark over the negative or the negative mark over the positive Never align two positive marks or two negative marks 16557 Clutch and gear assembly properly installed in the driveshaft housing a Upper gear positive timing mark
44. ator Spline Backlash Tool 91 806192 Dial Indicator 91 58222A1 c Check total lash by lightly rotating outer propeller shaft back and forth Observe dial indicator and record reading d Subtract the gear shaft spline lash reading obtained from Propeller Shaft Spline Lash Check performed earlier from total backlash reading Actual gear backlash should be between 0 3 0 4 mm 012 016 in Example Total backlash reading 0 75 mm 030 in Minus Gear Shaft spline lash from propeller shaft spline lash check 0 4 mm 016 in Equals Actual gear backlash 0 35 mm 014 in e If backlash is not correct disassemble and proceed as follows If backlash is more than specified remove shims from in front of rear driven gear bearing cup If backlash is less than specified add shims in front of rear driven gear bearing cup f Recheck backlash reading after reassembly 3 Check propshaft end play 90 899907001 JULY 2006 Page 8E 5 Bravo Three Gear Housing Setup a Install Dial Indicator on propshaft as illustrated below Move inner shaft up and down while reading Dial Indicator ensure outer shaft is also being lifted by inner shaft If reading is outside of range the outer propeller shaft thrust race shims must be increased or decreased to bring the end play reading within range of specifications b Dial Indicator End Play Range 0 03 0 30 mm 001 012 in Dial Indicator 91 58222A1 4 Remove Driveshaft R
45. ave been upgraded from two back to back seals to a new one piece canister type design e The two individual seals for the inner shaft are now housed in a canister that is inserted into the outer propeller shaft assembly e The two seals for the outer propshaft are also housed in a canister that is installed in the bearing carrier 20431 20433 Bravo Three and BlackHawk outer prop shaft oil seal Bravo Three and BlackHawk inner prop shaft oil seal 26 861694 26 861695 90 899907001 JULY 2006 Page 7A 7 Bravo Drive Unit History The following drawings show the area and dimensions on the seal installation tools to be modified so that they can be used to install the new one piece canister type oil seals Present tools can be modified in the areas shown to allow them to work with the new and old seals 20434 20435 Inner seal installation tool 91 805358 modifications 0 39 Outer seal installation tool 91 805372 modifications 2000 Page 7A 8 x 0 22 cm 0 155 x 0 085 in 0 61 x 0 28 cm 0 240 x 0 110 in There were four new Bravo 2000 drive units S N OM100000 and above These units have had many changes made to enhance durability and most of the internal parts in these drives will not backfit older Bravo product Use Service Manual 28 for 2000 models Use Service Manual 11 for all older models Bravo 2000 Models Versions ProauctCnanges modets Effeced Bravo One all ratios Bravo Two all ratios B
46. b in Bearings are used if spun once under load 20280 a Torque wrench lb in with Dial b U joint shaft hanging straight down Indicator being used to check preload 90 899907001 JULY 2006 Page 8B 3 Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below 20281 a Stamped number The stamped number designates the thickness of the top and bottom thrust bearing races NOTE If using the original thrust bearing race install race so that side with original contact area faces bearing If the upper and lower thrust bearing races get mixed up they should be checked with a micrometer for thickness to correspond with the housing stamped numbers t DONN Oy 20282 a Micrometer b Thrust bearing race Page 8B 4 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below IMPORTANT Timing marks on clutch gears must be aligned in one of two ways The positive mark over the negative or the negative mark over the positive Never align two positive marks or two negative marks 20283 Align clutch gear timing marks with index marks on driveshaft housing as closely as possible 20284 a Timing marks b Index marks 90 899907001 JULY 2006 Page 8B 5 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Bravo Drive Unit Service Section 8C Bravo Driveshaft Ho
47. bricant 101 Threads of retainer nut 92 802865A1 IMPORTANT Ensure that the retainer nut is not cross threaded by turning the retainer nut COUNTERCLOCKWISE until thread engagement is felt then turn retainer nut clockwise Page 8C 12 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 8 Install the U joint retainer nut to driveshaft housing and torque 15814 a U joint retainer nut c Torque wrench b Bearing retainer wrench 9 Use the specified torque chart and torque wrench as outlined in this section under Torque Conversion Chart For U joint Retainer Nut Tool Typical Bravo retainer nut tool shown a Torque wrench length b U joint retainer nut tool measurement 30 5 cm 12 in Bearing retainer wrench 91 17256 NOTE For Bravo X Series and Bravo XR use the bearing retainer wrench tool to loosen and remove the retainer nut from the driveshaft housing Spanner wrench for L 18 U joint bearing 91 862219A1 retainer IMPORTANT Ensure that the number of driven gear teeth match the drive gear ratio NOTE Diesel sterndrives are listed as Bravo X series 90 899907001 JULY 2006 Page 8C 13 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Driveshaft Housing Gear Ratio and Gear Tooth Count Sterndrive model Pinion drive gear teeth Driven gear teeth Standard Bravo Three and Bravo Three X 2 43 1 23 30 series Standard Bravo Thr
48. cco auateinetaeciemessadeis T U joint Assembly Standard and X models 16 ZOO E E EN E E epic niennne 8 Bravo Shift Effort Noise Reduction 00 17 Bravo 2000 Models cccccecseeecseeeseeeeeeeeeeseeeees 8 Revised Shift Lever Detent ccccseeeeeees 17 Driveshaft Housing Changes cccccseeeeeeeeeeees 9 Cone Clutch Change ccccccseeeeeeseeeeeeeeeeens 17 Aluminum Bearing Chimney In Top Cover 9 Shift Switch Added cccccccseeeeseeeeeeeeeeeeeeeens 18 Drive Shaft Housing Bearing Chimney 9 Bravo Styling Change ccccssceeseeeeeseeeeeaeeeees 18 Driveshaft Housing Driven Geals 060608 9 Increased Bravo X durabllity c cccceseeeeeees 18 Driven Gear Needle Thrust Bearing6 9 Increased Bravo XR durability cccceseeeees 18 Driven Gear Thrust R amp CeS ccccseeeeeeeeeeees 9 All Bravo Models will now have Shimmable Needle Thrust Bearings Between The Garter Driveshaft Housing Gears for Increased Durability Spring And The Driven Geat c s0sceeseeeeeees acetate reacties ce ae oy see eee cea ep eas 19 Cone CIC icc ccscicvnssueictiwededecssertdsnateeatexetncsiadedens 9 Bravo Three Changes cccccseeceseeeseeeeeeeaeeees 20 Universal Joint ASSeEMbDIy cccceeeeeeeeeeees 10 Additional Corrosion Protection 000 20 Splined Coupler Between Upper
49. cer between bearing cups must be free to move Do not over press as damage to both bearings could occur Secure pinion gear assembly to shaft with washer and new nut Tighten nut to the point where washer just touches gear 20276 a Nut c Pinion gear assembly b Washer Set the preload on bearing package as follows two assembly holding methods shown Method 1 Mount upper driveshaft housing in bench holding fixture Install U joint assembly into housing and secure with retainer nut 20277 a Torque wrench Ib in Dial b Driveshaft housing U joint shaft Indicator hanging straight down Method 2 Mount retainer nut wrench in vise to support U joint assembly Page 8B 2 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below Install U joint assembly into wrench with shaft pointing straight down 20280 a Torque wrench lb in b U joint shaft hanging straight down Set preload by tightening nut 1 16 of a turn at a time After each tightening check for proper preload by turning pinion gear using an appropriate socket and torque wrench lb in with Dial Indicator until acceptable torque is obtained If nut becomes over tightened causing excessive preload loosen nut a number of turns and gently strike pinion end of U joint shaft using a soft hammer Repeat adjustment procedure U joint Bearing Preload 0 7 1 0 Nm 6 10 Ib in 0 3 0 8 Nm 3 7 I
50. daoonintemmnding nasnnwndieleudentaremdseonnctecaaaele 6 U joint Pinion Gear and Bearing Assembly Preload U joint Pinion Gear and Bearing Assembly Preload na eeceeeeccececceeceseeeeeeeeeeeeeeeseeeeeseeeeseaeeesaeeeessaeeeesaaes 36 Soran E E ete atte eee tiie eae E E debe 6 Setting Preload Using A ViSE ceeceeeee 36 Setting Preload Using A VISE ccsecccseeeeeees 6 Setting Preload In The Driveshaft Housing 39 90 899907001 JULY 2006 Page 8C 1 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Bravo Driveshaft Housing Activity The object of the activity is to review and or perform the subjects in the Service Manual 28 and the Supplement and be able to answer the related questions on the Bravo Shimmable Driveshaft Housing activity sheet Specifications Starting Shim Specification U joint pinion gear shim Gear Tooth Count and Gear Lash 0 28 0 41 mm 0 011 0 016 in 0 33 0 46 mm 0 013 0 018 in 0 28 0 41 mm 0 011 0 016 in 0 23 0 38 mm 0 009 0 015 in U joint Pinion Gear Shim C 15 888927 028 0 71 0 028 15 888927 029 15 888927 030 15 888927 031 15 888927 032 15 888927 033 15 888927 034 15 888927 035 joint pinion gear shim om m 15 888927 037 15 888927 038 15 888927 039 099 0 039 15 888927 040 15 888927 036 0 036 Page 8C 2 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373
51. e 3 mm 1 8 in The casting numbers that you now identify the cylinders with 98704 and 98703 will be changing to new casting numbers 98719 and 98718 for the cylinders with the tilt limit spacer installed All diesel transoms and service parts Magnum and Hi Performance transoms will be built with the tilt limit spacer installed in the cylinders Additional Information INSTALLING A BRAVO X MODEL ON AN OLDER TRANSOM ASSEMBLY see MerCruiser Service Bulletin 2000 8 for information on installing a Bravo X model on an older transom assembly BRAVO THREE DRIVESHAFT HOLDING TOOL MODIFICATIONS The new Bravo Three lower driveshaft requires a larger opening in the driveshaft holding tool to accommodate the larger shaft used on Bravo 2000 models You can order a new holding tool or modify an older version In order to use an older Bravo Three Driveshaft Retaining Tool on a Bravo Three 2000 Standard or X drive you will need to modify the tool to the 29 7 29 8 mm 1 170 1 175 in dimension to make it work This modification will change the tool so that it will not work with the older Bravo Three with the smaller diameter driveshaft Therefore you will need to retain an original tool to work with the older Bravo Three The following artwork will illustrate the change to the lower driveshaft retaining tool 4 012 1 175 iT rrtrtrtrLILLILiLtitititittititititit 20444 20446 Old tool for Pre 2000 Bravo Three models 91 805381
52. e 19 Tapered roller bearing assembly 20 Tab washer 21 Shim kit 22 Spacer 23 O ring 24 Coupling assembly 25 Retaining ring 26 Shim kit 27 Tapered roller bearing assembly 28 Inner propeller shaft Bravo Drive Unit Components 29 Thrust bearing 30 Bushing 31 Shim assembly 32 Retaining ring 33 Shim assembly 34 Tapered roller bearing assembly 35 Outer propeller shaft 36 Roller bearing 37 Oil seal 38 Retainer 39 Bearing carrier assembly 40 O ring 41 Roller bearing 42 Oil seal 43 Front thrust hub 44 Front propeller nut 45 Rear thrust hub 46 Rear propeller nut 47 Screw 48 Washer 49 Nut 50 Propeller shaft anode kit 51 Flat washer 52 Internal tooth lockwasher 53 Screw 54 Anode 55 Screw Page 8A 17 Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below Bravo Drive Unit Service Section 8B Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below Table of Contents Bravo Driveshaft Housing Shimming Setup Method 1 ccccccccceseccceeeecceeeecsaeeeseeeessaueessees 2 FOC CCU OS spicata cnet ieee ean dinaneieeeonnnt 2 Wileh plete IE AN 2 90 899907001 JULY 2006 Page 8B 1 Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below Bravo Driveshaft Housing Shimming Setup Procedures Assemble U joint bearings as instructed NOTE Spa
53. e Needle Bearing Removal Tool The old Bravo gearcase needle bearing located above the pinion gear on the driveshaft removal tool too large in diameter at the top end for the newer gearcase bore There is a new tool available Following will indicate the proper dimensions for the old and new tool Dealers can order a new tool or the old tool can be machined down 63638 ates a Lo a T pi 614 J 611 990 a Older Tool 91 63638T 40 92 41 0 mm 1 611 1 614 in b Tool identification mark 63638 c Newer Tool 91 63638 1 40 39 40 46 mm 1 590 1 593 in d Tool identification mark 63638 1 20884 Page 7A 28 90 899907001 JULY 2006 Manual Outline Section 8 Bravo Drive Unit Service A Bravo Drive Unit Components B Bravo Driveshaft Housing Set Up Earlier Models Serial Number 0M198372 and Below C Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above D Bravo One Gear Housing Setup E Bravo Three Gear Housing Setup F Bravo Shift Cable Installation Drive Unit Installation and Shift Setup Bravo Drive Unit Components Bravo Drive Unit Service Section 8A Bravo Drive Unit Components Table of Contents Exploded VICWG cccccsccecsecceeeeceeeeseeeeeeeeseseeneneeaes 2 Driveshaft Housing and Gears for XR Models 8 Driveshaft Housing and Gears for Standard and X Driveshaft Housing U Joint and Shift Components Series MOAEIS cccsscccss
54. eal washer hidden by nut f Core wire is in later model cable only at this step of reinstallation Description Outer retaining nut 3 Install shift cable wrapping 21270 a Shift cable wrapping Water leakage into the bilge may result if the shift cable bellows crimp clamp is not installed properly Check that bellows end is not flattened out when crimping Installation tool information is found in drive unit service manual 90 899907001 JULY 2006 Page 8F 5 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 4 Install and compress shift cable bellows crimp clamp maintaining a 12 7 mm 1 2 in diameter round O D Ensure that clamp is crimped evenly so that a good seal is maintained between bellows and shift cable Do not allow bellows to flatten 21272 a Crimp clamp 5 Models with earlier shift cable install inner core wire eee mm N SN LUOZ SY 6 Install Core Wire Locating Tool on face of bell housing a Inner core wire a Bell housing b Core Wire Locating Tool Shift Cable Anchor Adjustment Tool 91 17262A1 Page 8F 6 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup 7 Install threaded tube until it bottoms out Tighten finger tight Tighten jam nut securely a Threaded tube b Jam nut 8 Earlier shift cables with support tubes discard support tube do not reinstall 9
55. ee and Bravo Three X series 2 20 1 23 30 i 1 81 1 27 29 Standard Bravo Two and Bravo Two X series Standard Bravo Three and Bravo Three X series 27 32 Standard Bravo Two 1 65 1 and Bravo Two X series Standard Bravo Two and Bravo Two X series Standard Bravo Three and Bravo Three X series Standard Bravo Two and Bravo Two X series Standard Bravo Three and Bravo Three X series Standard Bravo One and Bravo One X series Standard Bravo Three and Bravo Three X series 27 32 Standard Bravo One 1 50 1 and Bravo One X series aa of and Bravo Three X series 1 36 1 27 29 and Bravo One X series Bravo One XR 16 19 90 899907001 JULY 2006 Page 8C 14 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 10 Insert the pinion gear shimming tool in the top of the driveshaft housing Position the matching gear teeth count access hole to the pinion gear 27 32 23 30 NG Ae 15815 a Pinion gear shimming tool c Access holes for gear tooth counts b Access holes for gear tooth counts 27 29 27 32 23 30 16 19 Pinion gear shimming tool 91 865114 NOTE Refer to Feeler Gauge Measurement for further assistance 11 Insert the feeler gauge and measure the clearance of the pinion gear shimming tool to the pinion gear teeth SSS KA is 15816 a Feeler gauge c Pinion gear shimming tool b Access hole d Pinion gear il Specification
56. eeccesecceeeeecseeeeceeeeseeeees 2 for XR MOdEIS ccccccseeeeceseeceeeeceeseesseeeesenees 10 Driveshaft Housing U Joint and Shift Components Bravo One Gear Housing Exploded View 12 for Standard Bravo Models cccccseeeeeneeeees 4 Bravo Two Gear Housing Exploded View 14 Driveshaft Housing U Joint and Shift Components Bravo Three Gear HOUSING cccseeeeeeeeeeeenees 16 for X Series MOdEeIsS ccccceceeeeeceeeeeeeeeseeeesaeeees 6 90 899907001 JULY 2006 Page 8A 1 P Bravo Drive Unit Components Exploded Views Driveshaft Housing and Gears for Standard and X Series Models Ae 5 LTP 18217 Page 8A 2 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Driveshaft housing 2 Stud 4 3 Water passage seal 4 O ring 5 Bearing race 6 Needle bearing 7 Shift shaft oil seal plug 8 Upper shift shaft bushing 9 Shift shaft seal 10 Vent plug 11 Vent plug seal 12 Top cover standard 13 Bearing sleeve 14 Needle bearing 15 Top cover O ring 16 Top cover screws 4 standard 17 Thrust race 18 Ball check assembly Bravo Drive Unit Components 19 Thrust bearing 20 Upper driven gear 21 Garter spring thrust bearing 22 Clutch 23 Garter spring 24
57. eeeseaaeeesaeeeeas 27 PRS SOIMIONY etaseectere sane anecr ina tionaeouiedeandtyumonnnduaenesines 13 Bravo Bell Housing to Gimbal Housing Alignment Bravo Three Driveshaft Holding Tool Modifications TOOL cores tenet ove sec cuaened seas asnve neue vaaeeteens ean tadctemn teenie 27 r A E A 13 Bravo One Two Three Gearcase Needle Bearing New Tools For Bravo 2000 Models 13 Removal TOOI c cccceeccseeceseeeseceeseeeseeeseensaess 28 Page 7A 1 Bravo Drive Unit History 1988 1989 1990 1991 Page A 2 Bravo One introduced on Big Block Magnum and 7 4L models Due to their straight cut gears it is a true bi rotational drive Propshaft rotation changed by changing shift cable output at remote control box and changing propeller Propshaft bearing carrier was shimmed to set propshaft rolling torque No gear lube monitor and no lube passages in driveshaft housing or bell housing Dipstick was in the top cover Drain plug at front of torpedo Had to tilt drive unit approximately 45 to allow full drain Fill in vertical position until oil flows out vent plug and verify with dipstick Bravo Two introduced Designed for large heavy boats with 45 MPH maximum speed Same driveshaft housing as Bravo One but much larger gear housing Swings a 50 8 cm 20 in diameter propeller Uses TR style prop mounting hardware Load ring on propshaft carrier is used to maintain rolling torque instead of shims Bravo One rec
58. eived streamlined gearcase The strut was moved forward 5 cm 2 in Bravo One drain plug is now at the rear of the propshaft carrier C2 carrier Bravo One must trim in fully to drain Fill in vertical position until oil flows out vent plug Gear lube monitor added to all driveshaft housings and transom assemblies Dipstick removed from top cover Oil recirculation added Lower gearcase pumps lubricant to the U joint shaft bearings and it returns to the lower gearcase through cast in passages Required new driveshaft and gear housings Service Bulletin 91 20 90 899907001 JULY 2006 Bravo Drive Unit History Bravo Oil Circulation System 1991 and Newer Oil movement starts in the gearcase a high pressure area is created by gear rotation Using passages cast into the housings this high pressure is directed to the U joint bearings and seal Oil cooled by water flowing past the gearcase lowers the U joint bearing and seal temperature Another passage directs oil from above the U joint gear to the needle bearing inside the top cover Oil returns to the gearcase through a passage aft of the driveshaft Oil enters this return cavity from under the driven gear A small amount of oil will pass through the bearings under the lower driven gear and around the needle bearing on the upper driveshaft Oil exits the driveshaft housing and reenters the gearcase through the driveshaft bore 20452 NOTE Gearcase and driveshaft housings with the o
59. et Up Later Models Serial Number 0M198373 and Above NOTE For Bravo XZ XR and Diesel Bravo drives use the bearing retainer wrench for Bravo X series tool to loosen and remove the retainer nut from the driveshaft housing Spanner wrench for L 18 U joint bearing 91 862219A1 retainer ROTE The shift shaft upper seal must be installed on the driveshaft housing before you can install the top cover 25 Insert the shift shaft seal into the driveshaft housing 15330 a Shift shaft seal NOTE Ensure that the top cover O ring is positioned correctly 26 Apply lubricant to the top cover O ring and install to the top cover a Top cover O ring High Performance Gear Top cover O ring 92 802854A1 Lubricant 2 Install the top cover and torque the screws P 16430 a Top cover b Bolts 90 899907001 JULY 2006 Page 8C 25 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Driveshaft housing top cover screws a Adapter rod tool b Nut 91 865086 Adaptor rod tool 29 Install the gear lash flag onto the stub shaft tool Ensure that the drive tooth count matches the numbers on the flag 30 Align the indicator mark of the gear lash flag toward the stub shaft tool 15798 a Stub shaft tool b Gear lash flag 91 865080 91 865082 91 865116 Gear lash flag 27 29 91 865081 Page 8C 26 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up
60. etaining Tool and reinstall shim s spacer and O ring Page 8E 6 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup Bravo Drive Unit Service Section 8F Bravo Shift Cable Installation Drive Unit Installation and Shift Setup Table of Contents Replacing Earlier Model Bravo Shift Cables with Later Bravo Drive Unit Remote Control and Drive Unit Shift Model Shift Cables cccccccccesececeeeeeeeeseeeeeeeeesees 2 Cable AdjuStment cccccsecccsseecseeesseeesseeesaaees 15 Bravo Drive Unit Shift Cable Installation 4 Changes to Shift Plate Assembly 2003 19 Bravo Sterndrive Unit Installation cccccceceeee 8 90 899907001 JULY 2006 Page 8F 1 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup Replacing Earlier Model Bravo Shift Cables with Later Model Shift Cables Models with earlier style shift cable identified by small nut which will not pass over cable anchor core wire must be pulled from shift cable to remove cable assembly from bell housing 21258 Models with later style shift cable identified by larger nut which fits over core wire anchor it is unnecessary to remove core wire to remove shift cable assembly 21261 a Shift cable retaining nut c Inside nut b Washer To install the later model shift cable on all Bravo transom assemblies with serial number OD542204 and l
61. etting Preload Using a Vise Setting Preload In The Driveshaft Housing SETTING PRELOAD USING A VISE 1 Set the preload on bearing package as follows a Mount the retainer nut wrench tool in a vise to support the U joint assembly b Position the U joint assembly with its shaft facing down as shown Standard Bravo a U joint pinion gear and bearing d Vise assembly e Screwdriver b Bearing retainer wrench c U joint shaft facing down Bearing retainer wrench 91 17256 16408 Bravo X series a U joint pinion gear and bearing d Vise assembly e Screwdriver b Bearing retainer wrench c U joint shaft facing down Spanner wrench for L 18 U joint bearing 91 862219A1 retainer c Apply a light coat of lubricant to bearings Page 8C 6 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above lg PENONNANCE GEAL Bearings 92 802854A1 Lubricant d Set preload by tightening the nut 1 16 of a turn at a time e Check for proper preload by turning the pinion gear using an extension appropriate socket and a dial torque wrench Ib in until you reach the specified torque Avoid premature bearing failure Do not overtighten the U joint pinion gear nut 16409 Standard Bravo shown Bravo X series similar a Dial type torque wrench lb in NOTE Bearings are used if spun once under load Description po Now set U joint bearing preload 0 7 1 0 Nm
62. ever stud and slide stud up or down until slot in tool fits over stud When adjustment is correct retighten stud 16 Lift the adjustment tool so that the slot is above the stud 17 Shift the remote control into reverse and repeat the adjustment process a RH rotation Bravo One Two Three forward LH rotation Bravo One and Two reverse slot b LH rotation Bravo One and Two forward RH rotation Bravo One Two and Three reverse slot 18 Remove adjustment tool 19 Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180 degrees 20 Lubricate shift cable pivot points with 30W oil Page 8F 18 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup Changes to Shift Plate Assembly 2003 Switch guide bosses added to hold switches in place when tightening mounting screws switches have elongated screw slots for moving them to make the adjustment studs and cotter pins replace threaded studs and nuts and shift levers modified 21494 Alpha shift plate assembly Bravo similar a Clevis pin e Shift interrupt switch Alpha only b Cotter pin f Gear indicator switch Alpha and c Shift lever with dual detents Bravo d Cast in switch guide bosses g Shift assist assembly Alpha only Dual gear indicator switch detents added so that lever can be moved from run position to set position for adjusting switch lever moves out of the way of the adj
63. ge Allows easier end play movement checking 2005 Oil Leak When Using the Current Magnetic Drain Plug in the XR or XZ Heavy Duty Blue Billet Bearing Carrier The current 22 67892 A05 magnetic drain plug when installed in the XR or XZ Heavy Duty Blue Billet bearing carrier only is making contact at the starter pilot on the end of the plug when it bottoms in the fill drain hole of the carrier This prevents the gasket from seating and sealing allowing the oil in the drive to leak out at that area To correct the problem use the old style fill drain plug P N 22 67892 A1 All current production XR XZ drive units have been corrected using the old style fill drain plug 22 67892 A1 This plug will be used for a short term until a revised plug is available There will be a new shorter version of the 22 67892 A065 fill drain plug which will have a new part number 22 67892 A06 The current 22 67892 A05 plug works with all other drive product with no interference Alpha Bravo Standard Bravo X They will be used on these models until the stock is used up Then they will be switched to the new shorter drain plug 90 899907001 JULY 2006 Page 7A 21 7 Bravo Drive Unit History Following are drawings illustrating the types of plugs including the shortened pilot dimension 1 65 mm 0 065 in less version that will be going into production Overall dimension of the new plug is the same as the A05 version V5 d 180
64. h the new Hi Performance propeller shaft assembly The assembly includes a new heavy duty bearing carrier with a larger bearing and piloted gear and a larger diameter propshaft Transom Assembly Changes for Bravo 2000 Models INTERMEDIATE SHIFT CABLE GUIDE EXTENSION The Gimbal Housing for both Alpha One and all Bravo product now has a new intermediate shift cable guide extension cast into the housing There is also a new plastic cable guide insert for the extension in the housing This extension will help when installing a new intermediate shift cable It now extends out over the flange of the exhaust pipe It will help prevent the shift cable from being pushed into the engine coupler area 90 899907001 JULY 2006 Page 7A 11 Bravo Drive Unit History NEW GIMBAL BEARING There will be a new gimbal bearing installed in the gimbal housing for Bravo 2000 product only The new bearing and cartridge will look just like the current gimbal bearing and cartridge The only difference will be at the center race of the bearing If you look at the new bearing from the side the center race will look like it is offset towards the notched side of the bearing cartridge The center race has been machined down on one side to provide extra clearance for the L 18 U joint assembly The new bearing will also be identified with a red paint dot on the aluminum cartridge of the assembly This new gimbal bearing will be the only gimbal bearing used in all Bravo transo
65. ight coat of lubricant to bearings b Install the U joint and pinion gear assembly into the driveshaft housing ING Oiny 3 Ss NS SSO TTA ANAAAN AAAA ASASAN 16414 Standard Bravo shown Bravo X series similar a U joint and pinion gear assembly b Retaining nut c Position the driveshaft housing so that the U joint coupling shaft is pointing straight down d Set the preload by tightening the nut 1 16 of a turn at a time Check for proper preload by turning the pinion gear using an extension appropriate socket and dial torque wrench until you reach an acceptable torque Premature bearing failure can result if U joint pinion gear nut becomes overtightened causing excessive preload eas 1 IRE NND l ISSS SSS TTT TAN AAN 16415 Standard Bravo shown Bravo X series similar a Dial torque wrench Ib in b Driveshaft housing U joint shaft facing down 90 899907001 JULY 2006 Page 8C 39 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above NOTE Bearings are used if spun once under load Descipion a a U joint bearing preload 0 7 1 0 Nm 6 10 Ib in 0 3 0 8 Nm 3 7 Ib in Torque wrench Ib in 91 66274 2 Remove U joint and pinion gear assembly from driveshaft housing 3 If nut becomes overtightened causing excessive preload release the pinion gear and bearing assembly preload a Remove
66. il circulation system will not interchange with housings from older Bravo units without oil circulation If housings are intermixed gear oil will drain out of the drive unit through the interconnecting oil passage Refer to Service Bulletin 91 20 90 899907001 JULY 2006 Page 7A 3 Bravo Drive Unit History Bravo Driveshaft Housing Gear Housing Compatibility Diagrams NOTE All diagrams are of the mating surfaces at the driveshaft bore and forward water cavity areas Arrows connecting diagrams mean that units are compatible 1 2 Gj V T pg N n 20679 a Oil hole b No oil hole 1 Bravo driveshaft housing old style 4 Bravo gear housing intermediate style 2 Bravo gear housing old style 5 Bravo driveshaft housing new style 3 Bravo driveshaft housing intermediate style 6 Bravo gear housing new style NOTE Remove and discard any oil passage plugs found in housing mating surface before assembling unit 1993 e Bravo Three introduced Page 7A 4 90 899907001 JULY 2006 1995 1996 1 2 1997 1 2 Bravo Drive Unit History Uses two counter rotating propellers to reduce propeller torque improve tracking and handling Used two piece gearcase housing Extension held in place with trim tab bolt Negative trim must be limited by to 2 54 cm 1 in Exhaust tube must be used instead of exhaust bellows Bravo One propshaft bearing carrier changed to load ring design C3 carrier
67. ing a Remove clamp plate O ring spacer and shim s and place drive shaft retaining tool on tab washer as shown Do not tighten locking bolt at this time t gt j E mam SN a aa his LA 20312 a Driveshaft Retaining Tool 1999 and prior 91 805381 2000 and Newer 91 863738 b Locking bolt c Tab washer Driveshaft Retaining Tool 91 805381 Driveshaft Retaining Tool 91 863738 b Position gear housing so that propeller shafts are facing up in the vertical position Rotate propeller shafts several times to seat bearings prior to making checks c Lightly press down on Driveshaft Retaining Tool while simultaneously turning shaft to ensure bearings are seated in bearing cups then tighten locking bolt to retain drive shaft 90 899907001 JULY 2006 Page 8E 3 Bravo Three Gear Housing Setup d Install Backlash Indicator Rod to inner propeller shaft as shown Mount Dial Indicator to bearing carrier and position probe on mark stamped in Indicator Rod 20313 a Dial Indicator c Inner propeller shaft b Spline Backlash Tool NOTE Dial Indicator Rod and Backlash Indicator Rod should be at exactly 90 degrees to each other Dial Indicator 91 58222A1 Spline Backlash Tool 91 806192 NOTE For a more definite feel of the gear lash channel lock pliers can be used to grip the drive Shaft splines while rotating shaft to determine amount of play e Check total backlash by lightly rotating inner propeller shaf
68. kness at upper bearing a O ring d Tab washer b Spacer e Bearing cup lower c Shims upper f Shims lower 3 Recheck clearance after changing shim s in previous step SS _ ame a 8 a ee 4 fee ae a a a a a aa _ AA 20293 a Driveshaft Pinion Gear Shimming Tool b Feeler gauge 4 Recheck rolling torque preload before proceeding to setting propeller shaft preload Adjust if necessary to attain proper reading Driven Gear Lash Shimming Setup Procedure NOTE Models with shims in front of the bearing carrier can be upgraded to a load ring per Service Bulletin 93 10 Page 8D 6 90 899907001 JULY 2006 Bravo One Gear Housing Setup NOTE When switching to a load ring in an older gear housing that was using shims some housings will cause the tab on the tab washer to bend as the bearing carrier retainer nut is tightened to get the proper rolling torque preload The round tab hole in the older cases may not have enough clearance to allow some forward movement of the tab as the bearing carrier retainer nut is tightened Newer cases have an elongated tab hole to permit this forward movement without bending the tab If you find that excess torque is required to get the proper rolling torque preload more than 339 Nm 250 Ib ft or if there are signs of the tab being deformed then order a Tabless Spacer Washer 14 863195 and place it under the tab washer This spacer washer may also be re
69. ll be a new steel lower bearing chimney that threads into the driveshaft housing similar to the one that was used in the BlackHawk drive DRIVESHAFT HOUSING DRIVEN GEARS Standard Bravo e There will be new driven gears spiral bevel with the new thick web floor and narrower needle bearing Bravo X XZ e The Bravo X and XZ will have spiral bevel Near Net Forged gears including both driven gears with the new thick web floor and narrower needle bearing as well as a new Near Net Forged U joint pinion gear with an 18 tooth internal spline for all ratios Bravo XR e The Bravo XR will have straight tooth Net Forged gears including both driven gears with the new thick web floor and narrower needle bearing as well as a new Net Forged U joint pinion gear with an 18 tooth internal spline for all ratios DRIVEN GEAR NEEDLE THRUST BEARINGS All Bravo 2000 models e There will be new larger needle radial thrust bearings for the driven gears DRIVEN GEAR THRUST RACES All Bravo 2000 models e Because of the change to new larger needle radial thrust bearings there will also be a change to the driven gear radial thrust bearing race from the old thickness of 2 3 2 4 mm 0 091 0 094 in to the new thickness of 1 5 1 6 mm 0 061 0 064 in NEEDLE THRUST BEARINGS BETWEEN THE GARTER SPRING AND THE DRIVEN GEAR All Bravo 2000 models e There will be a new larger needle radial thrust bearing between the garter spring and the driven gear The be
70. m assemblies MG NMI SS 20440 a Current bearing 30 60794A4 center race thickness even on both ends b New bearing 30 862540A3 center race machined down on the side that arrow is pointing towards c New bearing 30 862540A3 identifying red dot shown on side of aluminum cartridge NEW UNIVERSAL JOINT BELLOWS ALUMINUM RETENTION SLEEVE There will be a new U joint bellows aluminum retention sleeve retainer ring The retention sleeve will have a larger inside dimension and will be narrower than the current retention sleeve This change was required to allow clearance for the new larger L 18 U joint assembly The change will be made on all Bravo transom assemblies Blin 43 69 in 3 7 Jin 20441 20442 Original U joint bellows retention sleeve New U joint bellows retention sleeve Page 7A 12 90 899907001 JULY 2006 Bravo Drive Unit History TRIM CYLINDER TILT LIMIT SPACERS New trim cylinders with the tilt limit soacer installed by the factory will be shipped on all Bravo Transoms The spacer limits the total amount of trailer limit travel by 16 mm 5 8 in when the unit is raised to the trailering position The overall total travel of the trim cylinder with the tilt limit spacer factory installed will be 672 mm 26 7 16 in from anchor pin hole to anchor pin hole Current trim cylinders without the tilt limit spacer have an overall total travel of 687 mm 27 1 16 in from anchor pin hole to anchor pin hol
71. m the upper driven gear 90 899907001 JULY 2006 Page 8C 29 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 42 Reposition the clutch carefully pushing the clutch down with a screwdriver to gain access to the lower driven gear a Clutch c Lower driven gear b Upper driven gear d Screwdriver 43 Install the driven gear clamping tool to the lower driven gear of the clutch and gear assembly NOTE The driven gear clamping tool clamps to the lower torus ring 15817 a Lower gear torus ring c Clutch b Driven gear clamping tool Driven gear clamping tool 91 865115 Page 8C 30 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above 44 Hold the driven gear in locked position with the driven gear clamping tool Slightly rotate the clamp block and handle tool back and forth to move the U joint pinion gear to feel the gear lash oe 15807 a Clamp block and handle tool c Dial indicator b Driven gear clamping tool 45 Observe the dial gauge while rotating the pinion gear back and forth to feel the gear lash Record measurement as a lower driven gear measurement NOTE The upper driven gear and lower driven gear have the same gear lash specification Drive gear tooth Driven gear tooth Gear lash specification 0 279 mm 0 406 mm 0 011 in 0 016 in 0 330 mm 0 457 mm 0 013 in 0 018 in 0 279 mm
72. new product The reason that the radius was added to the bottom root of the spline groove was to give added strength in that area of the coupler 20438 Old Style Spline New Style Spline Lower Unit Changes BRAVO ONE AND THREE LOWER DRIVESHAFT All 2000 Bravo One and Three lower units Page 7A 10 90 899907001 JULY 2006 Bravo Drive Unit History e There will be a new driveshaft only in the Bravo One and Three with induction hardened splines on both ends of the shaft There will be a larger mid section on the shaft as well The Bravo One will use the same drive shaft assembly as the Bravo Three A screw and washer will be used to retain the pinion gear to the shaft in place of the pinion nut and washer used on older Bravo One product WATER PICKUPS Bravo standard and X models e The Bravo One will be offered with the new Dual Water pickup style gearcase This unit draws water from the side water inlets and from four inlet holes in the front of the torpedo area The front pickups provide a ram effect and will allow a slightly higher X dimension for the drive unit If they become plugged from beaching the boat they will self clean when under way again Bravo XZ XR models e The Bravo One will be offered in both the dual water pickup and the Hi Performance low water pickup style gear housing New Bravo One dual water pickup style gear housing HI PERFORMANCE PROPELLER SHAFT ASSEMBLY Bravo One XZ XR e These drives are equipped wit
73. ng cup has been changed to a new flanged style which uses shims for setting clearances Separate bearing spacer ring no longer used Selection of shims available Gs 20800 a Eight semi circular oil slots equally spaced on face of new bearing cup b Flanged edge on bearing cup 20802 a Original bearing cup c New flanged bearing cup b Bearing spacer ring d Shim location Driven gear thrust bearing races now available in different sizes for setting clearances New special tools and a shimming procedure used for setting driveshaft housing clearances to be covered later in the course 90 899907001 JULY 2006 Page 7A 19 r Bravo Drive Unit History Bravo Three Changes ADDITIONAL CORROSION PROTECTION A second anode has been added to the underside of the anti ventilation plate and a propshaft anode was also added 20803 IMPROVED DURABILITY New outer propshaft thrust bearing design changed for increased load carrying capacity durability increased roller diameters 20816 Original thrust bearing New thrust bearing Page 7A 20 90 899907001 JULY 2006 Bravo Drive Unit History New outer propshaft shorter to allow clearance for new larger thrust bearing B5 H5 G5 55 W41 44 865315402 RIRI ser 44 805074 AZ a Older outer propshaft b Newer outer propshaft NEW IMPROVED PROPSHAFT SEALS New lip design material and spring tension Greatly reduces potential for leaka
74. nt a Shims position on the flanged d U joint retainer nut Standard Bravo bearing cup e Pinion drive gear b Shoulder of the U joint snout c Shoulder of the flanged bearing cup 90 899907001 JULY 2006 Page 8C 3 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above The flanged bearing cup replaces the smaller outside diameter bearing cup and spacer of the pinion drive gear and bearing assembly ss 0 Sp 17584 a Flanged bearing cup c Shim b Shoulder During reassembly of the driveshaft housing use the original shim thickness that came out of the drive or use the shim thickness listed in the starting point specification chart below Starting shim specification U joint pinion gear shim Shims graduate in 0 025 mm 0 001 in thickness U joint pinion gear shim 15 888927 028 0 028 DRIVEN GEAR SHIM The driven gears are set by measuring the gear lash of the pinion drive gear to each driven gear Driven gears in the driveshaft housing are shimmed into position by using the correct upper and lower thrust race thickness Therefore adding upper thrust race thickness positions the upper driven gear closer to the pinion gear thereby reducing gear lash Consequently removing upper thrust race thickness positions the upper driven gear farther away from the pinion gear increasing gear lash Page 8C 4 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models
75. ower you must enlarge the bell housing shift cable retainer hole from 9 53 mm 3 8 in to 11 11 mm 7 16 in Use the Bravo Shift Cable Replacement Kit 815471A3 All Bravo Transom Assemblies serial number OD542205 and above already have the latest style shift cable Shift Cable Inspection and Upgrade 1 Remove the sterndrive unit 2 Compare the shift cable that was removed from the unit with the replacement shift cable a If cable diameter a is equal on both the removed cable and the replacement cable then both cables are the later model Install the replacement cable skip Steps 3 8 and go to Bravo Drive Unit Shift Cable Installation Page 8F 2 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup b If cable diameter a is larger on the replacement shift cable than on the removed shift cable proceed with the following instructions 21263 a Cable diameter 3 Slide the slotted hole of the Drill Bushing Tool over the lowest stud closest to the bell housing shift cable bore 4 Install the alignment rod through the round 11 11 mm 7 16 in hole of the bushing tool and into the bell housing shift cable bore Make sure that it is seated fully into the bore 5 Clamp the drill bushing tool into place using one of the nuts and washers that hold the sterndrive unit to the bell housing 21264 a Alignment rod d Drill Bushing Tool b Nut e Bell housing stud c Washer f
76. parately Splined yoke engine coupler end 866133 not sold separately ITS splined yoke engine coupler 866135 not sold separately Cross and bearing assembly 866136 not sold separately Bravo Bell Housing to Gimbal Housing Alignment Tool If there is a vibration problem when running an engine an engine alignment procedure should be performed If a vibration issue still exists after the alignment then following steps need to be done 1 Install the Engine Alignment Shaft Tool through the gimbal bearing and into the engine coupler similar to performing an engine alignment Alignment Tool Assembly 91 805475A 1 90 899907001 JULY 2006 Page A 27 T Bravo Drive Unit History 2 Slide the Bell Housing to Gimbal Housing Alignment Tool over the end of the alignment shaft smaller tool step towards bell housing and up to the housing The smaller step should be inside of the bell housing case m ii 20883 Bell Housing Alignment Tool 91 863372 3 Check the gap between the alignment tool larger step and the bell housing case at 90 degress and at 270 degrees The gaps should be even 4 If they are not then the front engine mounts should be checked for being properly attached angled lag screws etc They can be loosened up to see if the engine re aligns itself side to side 5 If a difference in the 90 degree and 270 degree gaps still exists there may be a transom thickness issue that should be checked Bravo One Two Three Gearcas
77. peller nut under socket rotation using a smooth steady motion c Ifyou tighten the retainer past the overall preload replace the load ring and start again at Step 2 7 When proper overall preload is reached bend the tab washer up into the retainer nut to secure it Major Differences Between The Bravo One And Bravo Two Gear Housing e A larger bearing carrier retainer wrench tool is used 91 17257 e The propshaft bearing carrier uses a locating key like the older Alpha drives e The propshaft bearing carrier has a tapered roller bearing race like a Bravo One and a caged needle bearing like the Alpha series The bearings are serviced separately but the roller bearing race is used to set the propshaft bearing preload and the caged needle bearing absorbs axial thrust loads A Driver 91 55919 is used to press the needle bearing from the carrier like an Alpha and a different Driver 91 55918 is used to install the bearing The tapered roller bearing race is removed with a slide hammer and installed with a Driver 91 63626 which is the same tool used to install the driven gear race e All Bravo Two units use a load ring There are no shimmed bearing carriers Propshaft rolling torque is still measured at the propshaft and must be 9 1 4 Nm 8 12 Ib in new bearings or 6 9 Nm 5 8 Ib in used bearings above the driveshaft rolling torque of 3 6 Nm 3 5 Ib in just like a Bravo One e A larger seal installer 91 559
78. quired on some early load ring gearcases 1 Install the original load ring thrust ring and O ring into the gear housing a Load ring c O ring b Thrust ring 105 in thickness d Propeller shaft 2 Install the bearing carrier and tab washer in the gear housing 3 Lubricate threads on bearing carrier retainer with Special Lubricant 101 and then install and tighten bearing carrier retaining nut until no more end play can be felt to preload bearings Then tighten bearing carrier retainer nut enough to make propshaft hard to turn to assist when making gear lash check Do not over torque 20296 a Bearing Carrier Retainer Nut Wrench Bearing Carrier Retainer Nut Wrench 91 61069T 4 Driven gear shimming 90 899907001 JULY 2006 Page 8D 7 Bravo One Gear Housing Setup a Install the following special tools Dial Indicator Adapter Backlash Indicator Rod and Dial Indicator as shown Ensure dial rod is aligned with II on indicator rod and that dial rod and indicator rod are at exactly 90 degrees to each other om 1l SSeS ee a Dial Indicator Adapter b Dial Indicator positioned at 90 degrees to indicator rod c Backlash Indicator Rod Dial Indicator Adapter 91 83155 Backlash Indicator Rod 91 53459 Dial Indicator 91 58222A1 b Check gear backlash by lightly rotating drive shaft back and forth Do not allow propeller shaft to turn Observe dial indicator and record the reading
79. ravo Three all ratios Bravo One X all ratios Bravo Two X all ratios Bravo Three X all ratios Bravo Standard Bravo X Bravo One XZ 1 36 Bravo XZ ratio Bravo One XZ 1 50 ratio Bravo One XR Bravo XR 1 26 1 35 1 50 ratio Improved bearings and clutch new style cut gears Standard on all gasoline engines aluminum lower bearing 4 3L 5 0L 5 7L 6 2L 496 chimney Improved bearings and clutch larger U joint Standard on all diesel engines and near net forged gears steel 496 H O lower bearing chimney Improved bearings and clutch larger U joint near net forged gears steel Standard on all SOOHP engines lower bearing chimney Optional on 496 H O Hi Performance propshaft kit Improved bearings and clutch larger U joint straight tooth net forged gears steel lower bearing chimney Hi Performance propshaft kit Standard 575HP Hi Performance engines Optional 500HP Optional on 496 H O 90 899907001 JULY 2006 Bravo Drive Unit History Driveshaft Housing Changes ALUMINUM BEARING CHIMNEY IN TOP COVER All Bravo 2000 models e The Aluminum bearing chimney in the top cover is machined to a shorter height to allow for the new narrower needle bearing race DRIVE SHAFT HOUSING BEARING CHIMNEY Standard Bravo e The aluminum bearing chimney in the driveshaft housing is machined to a shorter height to allow for the new narrower needle bearing races Bravo X XZ XR e There wi
80. reasing gear lash 1 52 mm 0 060 in 1 55 mm 0 061 in N P Go O D gt O ri OI Go NO oO 00 O Bas O1 Co O O1 Co NINININ G1 S11 2 o CO CO O at Oo RPA RY aR O11 O17 G1 O1 o1 01011 PIPPIP oOlololoO Oo GO GD OD OINI gt O omom a C imene N Q 00 O Bas O1 Co O O O gt 1 63 mm 0 064 in Light Blue 1 65 mm 0 065 in 1 68 mm 0 066 in 1 70 mm 0 067 in NO MT NM Wl oO oe o CO oO DI KR BRYA O J O17 O1 o o0 Oo QIQ D OloloO Oo D amp NIOJ Driveshaft Housing Reassembly Reset U joint Pinion Gear and Bearing Preload IMPORTANT Reset the U joint pinion gear and bearing assembly preload after the shimming procedure and before it is reinstalled into the driveshaft housing 1 Carefully remove the shim from the pinion gear and bearing assembly 2 Release the pinion gear and bearing assembly preload a Place the universal puller plate tool under the shoulder of the flanged bearing cup b Press end of pinion gear with a suitable mandrel just until the bearing cups rotate easily Failure to do this can result in premature bearing failure 16412 a Universal puller plate tool e Pinion gear b Flanged bearing cup shoulder f Mandrel on pinion gear c Flanged bearing cup g Press on mandrel d Top roller bearing and bearing cup 91 37241 Universal puller plate 90 8999
81. rs and kits to the new gear sets and gear kits Also listed is a cross reference chart of the large thrust bearing shim race that will be required to install the new gear sets and gear kits NEW GEAR SETS AND GEAR KITS Gear Set _ 43 883473A3 43 807436A6 43 807436A7 and 43 856184A1 Gear Set 43 883476A3 43 807438A5 43 807438A6 and 43 856186A1 Gear Set 43 883479A3 43 807437A5 43 807437A6 and 43 856188A11 Shift Upgrade Gear Kit 43 883473A4 replaces Shift Upgrade Kit 43 807436A1 Shift Upgrade Gear Kit 43 883476A4 replaces Shift Upgrade Kit 43 807438A1 Shift Upgrade Gear Kit 43 883479A4 replaces Shift Upgrade Kit 43 807437A1 REQUIRED NEW THRUST BEARING SHIM RACES NOTE The number stamped on the housing will now correspond to thinner shims Refer to the table below for specific information Thrust Bearing Shim Race used with Old Gear Set Thrust Bearing Shim Race Required with new Replacement Gear Set Part Number Shim Race Size Part Number Shim Race Size 23 87560091 2 31 mm 0 091 in 23 861782051 1 30 mm 0 051 in in in 23 87560094 2 39 mm 0 094 in 23 861782054 1 37 mm 0 054 in 23 87560097 2 46 mm 0 097 in 23 861782057 1 45 mm 0 057 in Page 7A 14 90 899907001 JULY 2006 Bravo Drive Unit History SLEEVE BEARING RACE DRIVERS The following illustrations will show the proper installation tools and positioning of the sleeve bearing races on the bearing chimney in the driveshaft housing and top co
82. rsion is No Longer Available NLA GKN now makes this assembly for MerCruiser i 20793 a Rockwell U joint assembly b GKN U joint assembly e The Rockwell assembly is gray in color where as the GKN assembly is black in color e The Rockwell assembly has the cross and bearing end caps retained with clips at the bottom of the cap inside of the yoke ear e The GKN assembly has the cross and bearing end caps retained with the clips above the cap on the outside of the yoke ear for standard Bravo and Alpha e The Rockwell U joint assembly was a greaseable assembly The GKN is a permalube style like the Alpha U joint assembly and cannot be greased Page 7A 16 90 899907001 JULY 2006 Bravo Drive Unit History e The GKN Bravo X assembly is black in color and has the cross and bearing end caps retained with clips at the bottom of the cap inside of the yoke ear as did the Rockwell style Bachman U joint assembly Bravo Shift Effort Noise Reduction REVISED SHIFT LEVER DETENT All standard Bravo drives not on X models received a revised shift lever detent design to reduce shift effort in rear cover area e Shape change e Smooth detent transition when shifting for reduced effort 20795 Standard Bravo Shift Lever 861175A03 Used in all standard Bravo sterndrives with low bump brass sleeves 20796 X and XR Bravo Shift Lever 861175A2 Used in all X and XR Bravo sterndrives with high bump brass sleeves CONE CL
83. rting thrust race specification om m Driven gear thrust race 0 064 4 Lightly lubricate the lower thrust race oo Gear Lower thrust race 92 802854A1 NOTE If using the original thrust race race should be installed so that the side of original contact area is in the same position as removed 5 Position the lower thrust race in the center of the driveshaft housing 15384 a Lower thrust race 6 Lightly lubricate the lower thrust bearing High AONANE Gear Lower thrust bearing 92 802854A1 Lubricant NOTE The thrust bearing is always positioned to the gear and the thrust race shim is positioned to the driveshaft housing 7 Position the lower thrust bearing on top of the lower thrust race in the center of the driveshaft housing 15383 a Lower thrust bearing Page 8C 18 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above NOTE The clutch and gear assembly and the top cover assembly can not be properly installed if the lower thrust race and lower thrust bearing are positioned incorrectly 16444 Positioned correctly Positioned incorrectly a Driveshaft housing b Lower thrust bearing Mistiming of the clutch and gear assembly will cause the sterndrive not to shift out of gear properly and can cause damage and failure of the gear assembly Always time the assembly as specified IMPORTANT Do not align two positive marks or two neg
84. s shown below on the assembly Shift Cam Assembly 806552A1 d The shift yoke has been made 0 01 cm 004 in thicker The yoke will be identified by a yellow paint stripe illustrated on the drawing below 20269 Shift Yoke 806552 2 Following is a list of the kits that are available to back fit the new shift components into every Bravo unit from the first one built a Yoke and cam assembly for units starting with serial number OKO91000 and above b Clutch kit assembly 52 807375A1 which includes the new cone clutch and springs as well as the yoke and cam assembly and two new socket head Allen screws for use on units starting with serial number 0F 345868 through OKO90999 c Shift upgrade kits for use in units with serial number 0F 345867 and prior back to the first Bravo unit built Each kit will be preassembled and consist of the following parts Page 7A 6 90 899907001 JULY 2006 Bravo Drive Unit History 2 new driven gears 1 new cone clutch 2 new garter springs 1 upper drive shaft 2 thrust bearings 2 thrust bearing races 1 new shift yoke 2 shift cams and the miscellaneous bolts and spacers required to assemble the kits me OO OL M A The Shift Upgrade kit part numbers are as follows 32 TEETH 43 807436A1 30 TEETH 43 807437A1 29 TEETH 43 807438A1 1999 1 2 e The propshaft oil seals used in the Bravo Three and BlackHawk bearing carrier and the outer propeller shaft assembly h
85. shift cable must be closely checked to make sure cable enters the jaws of shift linkage assembly in the sterndrive 12 Place remote control in neutral position NOTE As bell housing shift cable enters the shift linkage assembly it pushes the assembly back into the sterndrive housing and the jaw closes securing the cable as shown in steps A B and gS Page 8F 12 90 899907001 JULY 2006 Bravo Shift Cable Installation Drive Unit Installation and Shift Setup IMPORTANT If bell housing shift cable b does not line up to properly enter jaws of shift linkage assembly a cable will have to be aligned manually of G Sa 21406 a Shift linkage assembly b Shift cable 13 Place driveshaft housing in position on bell housing and install drive unit as follows a Position trim cylinders so they point straight backwards b Position drive unit so that U joint shaft aligns with bell housing bore c Guide U joint shaft through bearing in gimbal housing and into engine coupler Make sure that shift linkage jaws engage the bell housing shift cable assembly d If necessary rotate propeller shaft counter clockwise slightly using a propeller to align U joint shaft splines with splines in engine coupling then slide drive unit all the way into bell housing 14 Secure drive unit to bell housing with 5 flat washers and 6 locknuts Torque to specification a Do not install flat washer here b Elastic stop nuts 6
86. sing so that the U joint coupling shaft is pointing straight down Set the preload by tightening the nut 1 16 of a turn at a time Check for proper preload by turning the pinion gear using an extension appropriate socket and dial torque wrench until you reach an acceptable torque Page 8C 8 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above Premature bearing failure can result if U joint pinion gear nut becomes overtightened causing excessive preload TR TAE i ON MOASATAYS KN LSS jee ARUBA NANA BBB RRRRY 16415 Standard Bravo shown Bravo X series similar a Dial torque wrench Ib in b Driveshaft housing U joint shaft facing down NOTE Bearings are used if spun once under load e a a e U joint bearing preload 0 7 1 0 Nm 6 10 Ib in 0 3 0 8 Nm 3 7 Ib in Torque wrench Ib in 91 66274 2 Remove U joint and pinion gear assembly from driveshaft housing 3 If nut becomes overtightened causing excessive preload release the pinion gear and bearing assembly preload a Remove the pinion gear and bearing assembly from the U joint b Place the universal puller plate under the shoulder of the flanged bearing cup 90 899907001 JULY 2006 Page 8C 9 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above c Press end of pinion gear with a suitable mandrel just un
87. t back and forth Observe dial indicator and record reading f Subtract the gear shaft spline lash reading obtained from Propeller Shaft Spline Lash Check performed earlier from total backlash reading Actual gear backlash should be between 0 3 0 4 mm 012 016 in Example Total backlash reading 0 75 mm 030 in Minus Gear Shaft spline lash from propeller shaft spline lash check 0 4 mm 016 in Equals Actual gear backlash 0 35 mm 014 in g If backlash is not correct disassemble and proceed as follows If backlash is more than specified add shims behind front driven gear bearing cup If backlash is less than specified remove shims from behind front driven gear bearing cup h Recheck backlash reading after reassembly 2 Rear driven gear shimming a Position gear housing so that propeller shafts are facing down in the vertical position Loosen locking bolt on drive shaft retaining tool and rotate propeller shafts several times to seat bearings prior to making checks Lightly press down on drive shaft retaining tool to ensure bearings are seated in bearing cups then tighten locking bolt to retain drive shaft 90 899907001 JULY 2006 Page 8E 4 Bravo Three Gear Housing Setup b Install Spline Backlash Tool to outer propeller shaft as shown Mount Dial Indicator to bearing carrier and position probe on mark stamped in Indicator Rod a Spline Backlash Tool c Outer propeller shaft b Dial Indic
88. t plug 11 Vent plug seal 12 Top cover standard 13 Bearing sleeve 14 Needle bearing 15 Top cover O ring 16 Top cover screws 4 17 Thrust race Bravo Drive Unit Components 18 Ball check assembly 19 Thrust bearing 20 Upper driven gear assembly 21 Thrust bearing 22 Clutch 23 Garter spring 24 Upper driveshaft 25 Thrust collar 26 Keepers 27 Washer 28 Plug 29 Nut 30 Trim in insert 31 Lower shift shaft bushing 32 Washers 33 Grounding tab 34 Self tapping screw Page 8A 9 Bravo Drive Unit Components Driveshaft Housing U Joint and Shift Components for XR Models 18216 Page 8A 10 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Back cover 2 Back cover seal 3 Detent assembly 4 Back cover short bolt 5 Back cover long bolt 6 Wear pad 7 Shift shaft 8 Cam 9 Yoke 10 Cam screws 11 Spacer 12 Nut 13 Shift shaft screw 14 Link bar 15 Shift lever 16 Washer 17 Cotter pin 18 Latch 19 U joint assembly 20 Yoke coupler end 21 O rings 22 O ring 23 Socket 24 Cross and bearing assembly Bravo Drive Unit Components 25 Yoke gear end 26 Retainer nut 27 O ring 28 Oil seal 29 Preload washer 30 U joint bearing assembly 31 Pinion gear 32 Washer 33 Nut 34 Anode plate 35 Screws 36 Washers 37 Shift shaft oil seal plug 38 Upper shift shaft bushing 3
89. til the bearing cups rotate easily Failure to do this can result in premature bearing failure 16412 a Universal puller plate tool e Pinion gear b Flanged bearing cup shoulder f Mandrel on pinion gear c Flanged bearing cup g Press on mandrel d Top roller bearing and bearing cup 91 37241 Universal puller plate d Reassemble components to the U joint and repeat preload procedures Driveshaft Housing Shimming Preparation For Assembly U joint Pinion Gear Shimming Avoid injury Heavy sterndrive components may come apart suddenly and forcefully possibly resulting in injury Properly support the U joint yoke assembly while removing the pinion gear nut 1 Ensure that the U joint pinion gear and bearing assembly preload is set and ready to install 2 Disassemble U joint from pinion gear and bearing assembly a Mount the retainer nut wrench tool in a vise to support the U joint assembly b Position the U joint assembly with shaft pointing straight down c Use a long screwdriver to secure the U joint so that it will not rotate while loosing the nut d Remove screwdriver Page 8C 10 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above e The U joint will fall when nut is removed Hold the U joint and remove the nut and washer 15754 a Retainer nut and washer d U joint shaft b U joint pinion gear and bearing e Vise assembly
90. ting the preload 16402 a Screwdriver b Ratchet and socket NOTE Complete the U joint and pinion gear preload procedure before installing the assembly to the driveshaft housing U joint Pinion Gear and Bearing Assembly Preload Follow only one of the procedures Setting Preload Using a Vise Setting Preload In The Driveshaft Housing SETTING PRELOAD USING A VISE 1 Set the preload on bearing package as follows a Mount the retainer nut wrench tool in a vise to support the U joint assembly Page 8C 36 90 899907001 JULY 2006 Bravo Driveshaft Housing Set Up Later Models Serial Number 0M198373 and Above b Position the U joint assembly with its shaft facing down as shown Standard Bravo a U joint pinion gear and bearing d Vise assembly e Screwdriver b Bearing retainer wrench c U joint shaft facing down Bearing retainer wrench 91 17256 16408 Bravo X series a U joint pinion gear and bearing d Vise assembly e Screwdriver b Bearing retainer wrench c U joint shaft facing down Spanner wrench for L 18 U joint bearing 91 862219A1 retainer c Apply a light coat of lubricant to bearings ele erormance Sear Bearings 92 802854A1 Lubricant d Set preload by tightening the nut 1 16 of a turn at a time e Check for proper preload by turning the pinion gear using an extension appropriate socket and a dial torque wrench lb in until you reach the specified torque 90 899907001
91. ts Driveshaft Housing U Joint and Shift Components for X Series Models 5 1 a 10808 Page 8A 6 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Back cover 2 Back cover seal 3 Detent assembly 4 Back cover short bolt 5 Back cover long bolt 6 Wear pad 7 Shift shaft 8 Cam 9 Yoke 10 Cam screws 11 Spacer 12 Nut 13 Screw 14 Link bar 15 Shift lever 16 Washer 17 Cotter pin 18 Latch 19 U joint assembly 20 Yoke coupler end 21 O rings 22 O ring 23 Socket 24 Cross and bearing assembly Bravo Drive Unit Components 25 Yoke gear end 26 Retainer nut and oil seal carrier 27 O ring 28 Oil seal 29 Preload washer 30 U joint bearing assembly 31 Pinion gear 32 Washer 33 Nut 34 Anode plate 35 Screw 36 Washer 37 Shift shaft oil seal plug 38 Upper shift shaft bushing 39 Seal 40 Shim 41 Lower shift shaft bushing 42 Tapered roller bearing 43 Flanged bearing cup 44 Bearing cup 45 Tapered roller bearing 46 Grounding tab 47 Self tapping screw Page 8A 7 Bravo Drive Unit Components Driveshaft Housing and Gears for XR Models Page 8A 8 18215 90 899907001 JULY 2006 90 899907001 JULY 2006 1 Driveshaft housing 2 Stud 4 3 Water passage seal 4 O ring 5 Bearing sleeve 6 Needle bearing 7 Shift shaft oil seal plug 8 Upper shift shaft bushing 9 Shift shaft seal 10 Ven
92. using Set Up Later Models Serial Number 0M198373 and Above Table of Contents Bravo Driveshaft Housing ACctivity c ccscceseeee es 2 Setting Preload In The Driveshaft Housing 8 SPECIN COONS sses nra Ea ES 2 Driveshaft Housing Shimming Preparation For Starting Shim Specification ccccseeeeeseeeeeeeees 2 eSO1S 411 8 eee ae eee Dee ere een ere 10 Gear Tooth Count and Gear LashN 00c00 2 U joint Pinion Gear Shimming c cccceeeeeees 10 U joint Pinion Gear Location 0 cccsseeeeeseeeeees 2 Feeler Gauge Measurement ccccceeeeeeees 17 U joint Pinion Gear SHIM ccceceeseeeeeeeeeeeeeees 2 Measuring Driven Gear LaShN cccsseceeeneeees 17 Driven Gear Thrust RACE c ccccceeeeeeeeeeeeeeees 3 Calculation Method For Specified Gear Lash 32 General INformatiOn ccccccccceeeeeeeeeeeeseeeeeseeeeeeeees 3 Driveshaft Housing Reassembly ccccseceeees 33 Assembly Chang s cccccccccseeeeeeeeeeeeeeeeeaeeeens 3 Reset U joint Pinion Gear and Bearing Preload U Joint STN pathateicciac toacacsuscecretedeenesasedeamccssteonen eects ae ste se feo E E NE A 33 Driven Gear SNIM ccccscccsseceseseeeeeesenseeeenees 4 U joint Pinion Gear and Bearing Assembly Driveshaft Housing Assembly Teardown Inspection REASSOMDI Y cccccceecceseceseceeeceeeceeeeceeeaueeeeeeees 34 and TRE DA cate eiresssinsientda
93. usting screws and switch plunger can also be viewed ALPHA and BRAVO stamped on individual levers for identification 21499 New shift levers for Alpha and Bravo 90 899907001 JULY 2006 Page 8F 19
94. ver for all Bravo product BEARING DRIVER AND CHIMNEY FOR 1999 AND PRIOR UNITS WITH OLDER BEARINGS AND GEARS AE z 1 p Bearing Driver 91 90773T BEARING DRIVER AND CHIMNEY FOR THE NEW DESIGNED BRAVO GEARS AND BEARINGS WHEN USED IN 1999 AND PRIOR UNITS A new bearing driver is required to install and properly place the sleeve bearing race in all 1999 and prior Bravo drive units when installing any of these new gear sets or shift upgrade gear kits The tool has a step that places the sleeve bearing race down further on the bearing chimney in the driveshaft housing and top cover at the correct location for this new gear set This is to allow clearance between the gear and bearing Sleeve placement is critical for proper operation A 20450 20447 Bearing Driver 91 864220 90 899907001 JULY 2006 Page 7A 15 Bravo Drive Unit History BEARING DRIVER AND CHIMNEY FOR BRAVO 2000 AND NEWER MODELS A different bearing driver different from the one used for replacement gear sets used on 1999 and prior units and the tool used on the original bravo units is used for installing the sleeve bearing used on all Bravo 2000 series and later drive units 7 E Y Wp STV ST 20449 Bearing Driver 91 862530 NOTE Information on the new gear sets new thrust bearing shim races and sleeve bearing drivers can be found in MerCruiser Service Bulletin 2001 17 2004 U joint Assembly Standard and X models Rockwell ve
95. vert 1 50 1 Bravo One XR drives to either a 1 26 1 or 1 35 1 overall gear ratio for boats that require a gear ratio change to improve performance The gear sets are available from the parts department Complete Bravo One XR drive units are also now available in both low water pickup and dual water pickup gearcase versions in 1 26 and 1 35 1 gear ratios BRAVO 2000 STYLE SERVICE REPLACEMENT GEAR SETS FOR ALL BRAVO DRIVE UNITS The Bravo driveshaft housing gears and kits available from Mercury Precision Parts Quicksilver are being replaced by the current production gear sets used in the Bravo 2000 series drive units They will be supplied in complete installation kits that include the pinion gear both driven gears the cone clutch and other required parts Some of the kits also include the Shift Upgrade Kit depending on the drive unit serial number All of the parts from the kits must be used to properly complete the installation of the new gear kit New thinner thrust bearing shim races must also be ordered These new gears have a thicker floor for improved strength This is where the collet on the upper driveshaft contacts the gear They are also double shot peened for greater durability The bearings in the kits have increased load capacity The thrust bearings are larger and the garter spring bearings are now incorporated into a single assembly previous bearing was two pieces The following charts will show the supersession from the old gea

Bravo Drive History Section 7A - Bravo Drive Unit History

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