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Gear shimming

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kite2

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I have a 1998 searay 3.0 engine alpha 1gen 2 outdrive 2:1 ratio and im trying to set the driven gear in the upper housing . Im using tool 91-60526 in hole position "Y" aiming for .025 and it's way off. I probably have 1/4 inch gap. The other thing that's odd is the manual shows the tool shoulder going all the way to the gear and mine doesn't but the tool is seated in the housing. Has anyone ever seen this before. Thank you for your input.
 
what's the serial number on the outdrive? just going by the year given, you are real close to a break point in configuration...
 
Possibly you may have the incorrect tool part number for your serial number range/year.
The following information may help,

Shimming tool A B C. Not X Y Z

I bought a shimming tool and its marked ABC What hole would I use alpha 1 with 1:50 gears? My manual say the holes should be marked XYZ and use the Z hole with .025
forums.iboats.com forums.iboats.com

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Also what service manual number at the front of the book, part number and year is written in the book (bottom pages) you’re using as it could have an effect too.
 
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I received the new tool part number 854377 and it definitely fits better. I have oem number 853040 gearset with 24 teeth on each gear that is coming up as letter "B" for measurements. The original shims are in and I'm getting over 0.100 measurement which would be about 0.075 shims plus the original. Seems like a lot to me. This is my first time doing a outdrive but I've done hundreds of differentials and was ever this far off. Any suggestions would be greatly appreciated.
 
853040 isn't a Mercury part number
0L225844 is the serial number for a transom plate not a drive
tool position A for 2.0:1 gears in a drive S/N 0L100009 and above
 
kite2 said:
Thank you for the feedback. Hopefully i can get this one done and learned a lot do so.
Click to expand...
Do you have manual #14 which is for the alpha gen 2 outdrives? It has all of this laid out and the procedure for doing the shimming. Would recomend getting one if you dont have it. I think I paid less than $50 on ebay for a lightly used copy
 
Yes I have a download copy but my printer is shot so I've been viewing it on my phone. It challenging so im going to buy a new printer to make it easier to read. Thank you for your help.
 
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