www.iFourWinns.com

Already took the gear housing off and bolt holding the yoke. Very easy job. It stays pressed together with out the yoke bolt in, the gear housing allows this to happen. The Mercs fell apart with out the bolt. Assembly requires the 4 gaskets (all diff thickness) and one o-ring along with a tourqe wrench or tighten to same friction as the lower unit (by feel). Same friction/tightness from what I can see. I probably will not leave it to feel and will go get a low torque wrench and tighten to specs (9-14in/lbs)

Video of a Merc drive shaft seals replaced

http://youtu.be/c0SlzpJBhEM

Also here is a link to some photos of the boat (projects) along with the yoke gear housing removed.
http://flic.kr/s/aHsjPwC7g2

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REM9607

Black Pearl
2004 268 Vista
5.7L Gi-E
DP-SM 1.95

2010 6.4L F250
Dream boat- Catalina 28 MK II

What a great link and resource!!! Thank you for the link. will come in very handy.

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REM9607

Black Pearl
2004 268 Vista
5.7L Gi-E
DP-SM 1.95

2010 6.4L F250
Dream boat- Catalina 28 MK II

Interesting....I recall that being described on the I/O forum at iboats as a pretty critical measurement (like setting the crush sleeve on the pinion bearing of a truck differential).
Looking at the pix of the bellows installed, it looks like the person who installed it last did not get it far back enough on the gimble bearing tube and that may have caused it to bunch up and rub the clamp when you turned to the right. There is a groove on that tube that is supposed to line up with a ridge in the center of the sealing surface of the bellows (at least on the OE OMC ones there is).....

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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

I know the groove your talking about. Looking into a low profile clamp if the kit comes with the same basic clamp. Not sure what it's called, but I have seen some really nice clamps at the plumbing store that may do a better job. I guess also trailering with the trim up and turned all the way left would help also. The past year I been trailering turn right...every time.

On the gear housing, the crush sleeve is an issue, going to make sure I do it with a small torque wrench, and make sure I don't exceed the torque specs

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REM9607

Black Pearl
2004 268 Vista
5.7L Gi-E
DP-SM 1.95

2010 6.4L F250
Dream boat- Catalina 28 MK II

My bellows (on there since 2005) was installed by a local OMC shop with the normal clamp and it never leaked all these years. I bought a new OE one to put on the next time I take the gimble housing off and it also came with the same normal style stainless steel clamp. The OMC Cobra and Volvo SX use the same bellows same part # thats why I know about the groove in the tube and the ridge in the bellows sealing surface.

As others said thanks for the write up, very interesting to see the innards of a Volvo SX and to be able to work round their silly deletion of the replacable ujoints.
The one time I did have water in the bellows (end of 2004 season) the mechanic told me that he'd grease up the joints well and they should be fine. And they were. So there you go, it is worth having them. He replaced the bellows and gimble (salt water so you pretty much have to) and it's been fine for all this time.
When I can no longer get OMC Cobra parts I may convert it to a Volvo SX (if I can get a drive for the right price) so this will be of interest to me.

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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

Here's a video a forum member posted here a couple years ago of their trip to Bimini on a Four Winns 298. Not sure if he is still active on the forum or not? Either way it's a fun video:
http://www.youtube.com/watch?v=6pmNI4OuPB4

Here's one of my all time favorite Caribbean boating video's:
http://www.youtube.com/watch?v=NBSX3-Q1O3w

The video also reminded me of something to add to your list: A yellow quarantine flag to fly before you check in with customs

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Our Boating Blog: http://ben-dana.blogspot.com/

2005 268 Vista "Sea Pickle II"
1979 AMF Alcort Puffer
Previous:
2003 FW190 Horizon
1973 Startcraft 18ft "Sea Pickle"

You would like this new one with a quad copter.
http://www.youtube.com/watch?v=30HDdocM ... 6w&index=3

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REM9607

Black Pearl
2004 268 Vista
5.7L Gi-E
DP-SM 1.95

2010 6.4L F250
Dream boat- Catalina 28 MK II

Very cool and well done videos! Thanks for sharing. I'm kind of partial to the one with the 298 in it!

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2004 Four Winns 298 Vista
"Last Minute"

REM9607, this link to another site and forum has some info and links that may be helpful for your trip planning. It sounds like a great trip.

http://forums.iboats.com/boating-activi ... 29781.html

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Surface Interval: A scuba diving term for that time between dives to relax and prepare for life's next great adventure.

Current boat: '02 FW 268 Vista
Previous boat: '95 FW 190 Horizon