"Had the same problem with my
"Had the same problem with my Bravo II leg on my 1996 Searay 270, it had sat in the marina (salt water) for well over 12 months unused before I purchased. The lip of the seal had rusted on to the swivel pin and when we operated the steering it ripped the centre of the seal out of the seal. I found that you do not have to remove the engine if you purchase a plug kit Mercury P/N28-88847A1, GLM16005 and I believe Sierra make one as well.
You basically use a hole saw and cut holes in either side of the upper gimbal housing using the template supplied. This allows access to the lock nut and clamp on top of the swivel pin and though the holes you have cut using a cold chisel and hammer you undo the top nut and with a socket and ring spanner loosen the steering arm clamp bolt.
After removing the bell housing, swivel pin and gimal ring you can access the swivel pin seal and bushings.
My swivel pin was a quite pitted and needed replacing however I took it to engineering shop to see it could be metal sprayed and then machined back. This could not be done as the pin is a hardened grade of steel and the heat process would have weakened the pin, they suggested fitting a Speed Sleeve, which is a approx 15 thou stainless steel sleeve that is stretched over the pin where the seal lip makes contact – the seal can handle the extra thickness at this point without any problems.
Note a new swivel pin cost almost $800 New Zealand dollars.
The two holes you have cut are tapped to take the screw in plugs supplied in the kit
The plug kit has a top lock nut that has notches in to tighten using the cold chisel and hammer.
Note the clearances and found in the bravo manual if needed, My boat has been in the water for the last twelve months without any problems, due to haul out in 2 weeks..
Hope this info is of some help."