OMC parts 800 / Cobra outdrive drawings * How to videos

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800 outdrive repaired or lower unit replacement

400-800 series installation / lower unit repair steps 1 to 20

  • 400-800 repair photos
  • Co-manufacturer and distributor for GLM Products including aftermarket with 2 year warranty on parts

Sandblast outdrive parts

Sandblast outdrive parts

Lower unit is disassembled, and placed into the sandblast area

inside gearcase and out

inside gearcase and out

The outside and inside of the housing is sandblasted, removing all rust and corrosion

Sterndrive rebuild parts

Sterndrive rebuild parts

New parts are installed, with the exception of the bearing carrier and bearing retainers which are sandblasted and primed.

For repair jobs, if parts removed from customer unit can be re-used, they are sandblasted. Some are primed such as the bearing carrier.

New prop shaft installed

New prop shaft installed

For replacement rebuilt lower units, a new propeller shaft (GLM P/N 22414, 1-3/16") is installed.

For customer units, a dial indicator is used to determine if the propeller shaft is out of round (bent). This would not be visible to the eye when turning so the tool is required. The threshold we use to determine if it needs to be replaced is .004" out of round. Any more than that, and continued use of the bent unit would damage the oil seals and allow for water to enter the gear case and oil to leak out.

reverse gear

reverse gear

Reverse gear is installed

Pinion gear

Pinion gear

Pinion gear is installed

Forward gear set

Forward gear set

For rebuilt units, a new forward gear and pinion are installed.

For customer units, the forward and pinion are inspected for any chips or cracks on the teeth - or excessive pitting that would effect the integrity of the tooth on the gear. If found, a new forward/pinion set is installed.

forward bearing retainer

forward bearing retainer

The forward bearing housing assembly is installed (GLM P/N 27700, replaces 389455). This has the bearing pre-installed into the housing.

Clutch dog

Clutch dog

A new clutch dog is installed (GLM P/N 22625, replaces 337774).

For customer repair jobs, the teeth (corners) on the clutch are inspected - if there are signs of wear, in which the edges are beginning to or have rounded out, a new clutch is installed. Re-using a worn clutch would continue to cause problems with shifting, possibly loss of forward and reverse or shift cable damage.

Drive shaft

Drive shaft

The vertical drive shaft is installed.

For customer lower units, the unit is inspected for excessive wear or damage to the threaded area. In many instances, the parts can be repaired using a lathe. Shaft must be replaced if it is not repairable.

Drive shaft
 
Swivel bearing retainer

Swivel bearing retainer

The swivel housing is installed. It is sandblasted, primed and painted before installation and the face is machined to make sure it seats flush onto the lower unit / gasket.

Prop shaft bearing carrier

 bearing carrier

The bearing carrier is sandblasted and primed, and the bearing (P/N 11410, replaces 387247) and the reverse gear bearing are pressed in.

Upper bearing retainer

Upper bearing retainer

The upper bearing retainer is installed - cleaned and primed

Shims

Shims

All gears are shimmed to correct OEM specifications

Forward assembly

Forward assembly

Forward gear and clutch are assembled

New intake screen installed

New intake screen installed

The intake screen is installed and painted to match outside case color

Zinc chromate paint

Zinc chromate paint

Zinc chromate primer is used on the inside of the housing

1-4 inch holes re-tapped

1-4 inch holes re-tapped

 
Drive shaft inspected

 inspected

 

*800 series and Cobra lower unit repair photos.
Click here for steps 21-40 in the repair process