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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-1
ALPHA DRIVE UNIT TOOLS
73658
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ALPHA DRIVE UNIT
Page 1-2 90-806737--2 SEPTEMBER 2001
Alpha Drive Unit Tool Application Chart
Part Number Page DescriptionAlphaOne
Gen II
MC-1,R-MRAlphaOne
91-805475A1 1-5 Alignment Tool Assembly • •
91-78473 1-5 Backlash Indicator • •
91-53459 1-5 Backlash Indicator Rod • •
91-18605A2 1-5 Bearing Adaptor Installation Tool • •
91-61069T 1-6 Bearing Carrier Retainer NutWrench
• •
91-33493T 1-6 Bearing Cup Driver •
91-34379T 1-6 Bearing Cup Driver •
91-36577T 1-6 Bearing Cup Driver •
91-38918T 1-7 Bearing Cup Driver •
91-808053T 1-7 Bearing Cup Driver •
91-33489 1-7 Bearing Driver • •
91–32325T 1-7 Bearing Driver Head • •
91-38628T 1-8 Bearing Installation Tool •
91-31229A7 1-8 Bearing Removal and InstallationTool Assembly
• •
91-17256 1-8 Bearing Retainer Wrench • •
12-54048 1-8 Belleville Washer • •
91-45497A1 1-9 Bellows Expander Tool •
91-805057A2 1-9 Bushing Installation Tool • •
91-58222A1 1-9 Dial Indicator • •
91-83155 1-9 Dial Indicator Adaptor Kit •
91-89897 1-10 Dial Indicator Holding Tool •
91-56775T 1-10 Drive Shaft Adaptor • •
91-43506T 1-10 Drive Shaft Bearing RetainerWrench
• •
91-14311A2 1-11 Drive Shaft Bearing Preload Tool • •
91-36569T 1-11 Driver Head •
91-37323 1-11 Driver Rod • •
91-44357Q2 1-11 Flushing Device • •
91-815850 1-12 Forward Gear Assembly Tube • •
91-31229 1-12 Forward Gear Bearing Cup Puller Shaft
• •
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-3
Alpha Drive Unit Tool Application Chart
Part Number Page DescriptionAlphaOne
Gen II
MC-1,R-MRAlphaOne
91-30366T1 1-12 Gimbal Bearing Installation CollarNumber 3
• •
91-816243 1-12 Guide Plate • •
91-90774 1-13 Guide / Puller Tool •
11-24156 1-13 Hex Nut • •
91-78310 1-13 Hinge Pin Tool • •
91-37299Q2 1-14 Lube Gun •
91-877528-1 1-14 MCM Tool Overlay Kit • •
91-15755T 1-14 Needle Bearing Driver • •
91-33491 1-14 Needle Bearing Driver •
91-33492T 1-15 Needle Bearing Driver •
91-37324T 1-15 Needle Bearing Driver, PilotWasher
•
91-807944T 1-15 Needle Bearing Installation Tool,Reverse Gear
•
91-816245 1-15 Needle Bearing Removal Tool • •
91-31108T 1-16 Oil Seal Driver • •
91-817569T 1-16 Oil Seal Driver •
91-36571T 1-16 Pilot Washer •
91-37350T 1-16 Pilot Washer • •
91-56048T 1-17 Pinion Gear Shimming Tool • •
91-61067A3 1-17 Pinion Nut Adaptor •
91-95639 1-17 Pipe Tap •
91-29310 1-17 Plate Puller • •
91-806908A1 1-18 Power Steering Adaptor Kit •
91-38053A4 1-18 Power Steering Test Gauge Kit • •
91-61077T 1-18 Propeller Shaft Adaptor • •
91-38919 1-18 Puller Head •
91-63616T 1-19 Puller Head • •
91-34570 1-19 Puller Jaws • •
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ALPHA DRIVE UNIT
Page 1-4 90-806737--2 SEPTEMBER 2001
Alpha Drive Unit Tool Application Chart
Part Number Page DescriptionAlphaOne
Gen II
MC-1,R-MRAlphaOne
91-816242 1-19 Puller Jaws • •
91-85716
91-46086A11-19 Puller Jaw Assembly
Puller Bolt• •
816244 1-20 Reverse Gear Needle BearingDriver
• •
91-37292 1-20 Roller Bearing Removal andInstallation Tool
• •
91-806928A1 1-20 Seal and Bushing Installation Tool •
91-43591T 1-20 Seal Driver • •
91-44110T 1-21 Seal Driver • •
91-12037 1-21 Shift Cable Tool • •
91-31107T 1-21 Shift Shaft Bushing Tool •
91-809815A1 1-21 Shift Shaft Slide Stabilizer • •
75104A7 1-22 Shift Shaft Tool •
91-60523 1-22 Shimming Tool, Drive Gear • •
91-60526T 1-22 Shimming Tool, Driven Gear • •
91-854377 1-22 Shimming Tool, Driven Gear •
91-818162 1-23 Sleeve Installation Tool •
91-818169T 1-23 Sleeve Removal Tool •
91-34569A1 1-23 Slide Hammer Puller • •
91-37240A1 1-23 Snap Ring Pliers •
91-821709T 1-24 Spanner Wrench • •
91-38277A2 1-24 Tab Washer Pliers •
91-63209 1-24 Torch Lamp • •
91-66274 1-24 Torque Wrench, lb-in. • •
91-43693A2 1-24 Transom Cutout and Drill Fixture • •
91-52915A6 1-25 Trim Pump Test Gauge Kit • •
91-38756 1-25 U-joint Adaptor • •
91-37241 1-25 Universal Puller Plate • •
91-817570T 1-25 Upper Drive Shaft Housing SealDriver
•
91-34961 1-26 Washer • •
91-821571A1 1-26 Water Pump Alignment Pins •
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-5
Alignment Tool Assembly 91-805475A1
Description: Aligns the engine and driveunit during installation.
73699
Backlash Indicator 91-78473
Description: Checks the gear backlash onthe Alpha drive units using 14/28 tooth countand gear housing.
75943
Backlash Indicator Rod 91-53459
Description: Checks the gear backlash onthe TR, TRS, MC-1, R-MR, Alpha One andAlpha One Gen II drive units.
73455
Bearing Adaptor InstallationTool 91-18605A2
Description: Presses the reverse gearbearing adaptor into the gear housing of theAlpha One and Alpha One Gen II counterrotating gear cases.
73816
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ALPHA DRIVE UNIT
Page 1-6 90-806737--2 SEPTEMBER 2001
Bearing Carrier Retainer Nut Wrench 91-61069T
Description: Removes and installs thebearing carrier retainer nuts on the MC-1,R-MR, Alpha One and Alpha One Gen IIdrive units.
73605
Bearing Cup Driver 91-33493T
Description: Installs the upper drive shaftbearing cup in the drive shaft housing of theMC-1, R-MR and Alpha One drive units.
73491
Bearing Cup Driver 91-34379T
Description: Installs the drive shaft bearingcup in gear the housing of the MC-1, R-MRand Alpha One drive units.
73659
Bearing Cup Driver 91-36577T
Description: Installs the forward gearbearing cup in the gear housing of the MC-1,R-MR, Alpha One and Alpha One Gen II withbearing cup diameter of 3.500 in. 89 outsidediameter (O.D.).
73492
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-7
Bearing Cup Driver 91-38918T
Description: Installs the bearing cup in thetop cover of the drive shaft housing of theMC-1, R-MR and Alpha One drive units.
73490
Bearing Cup Driver 91-808053T
Description: Use to install a new smalleroutside diameter top cover bearing on theAlpha One Gen II drive units.
75945
Bearing Driver 91-33489
Description: Installs the small rollerbearing in the gimbal housing of the MC-1,R-MR and Alpha One drive units.
73468
Bearing Driver Head 91-32325T
Description: Installs the gimbal bearing inthe MC-1, R-MR, Alpha One and Alpha OneGen II drive units. Use with 91-30366T1Gimbal Bearing Installation Collar Number3.
73818
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ALPHA DRIVE UNIT
Page 1-8 90-806737--2 SEPTEMBER 2001
Bearing Installation Tool 91-38628T
Description: Installs the pinion bearing onthe MC-1, R-MR and Alpha One drive units.
74193
Bearing Removal andInstallation Tool Assembly 91-31229A7
Description: Removes and installs thebearings in the MC-1, R-MR, Alpha One andAlpha One Gen II gear cases. Includes:
91-36569T Driver Head91-37323 Driver Head Rod11-24156 Nut91-36571T Pilot Washer91-29610 Pilot Plate91-38628T Puller/Driver Head91-30366T1 Mandrel91-29310 Plate 91-32325T Driver Head91-31229 Puller Shaft12-34961 Washer
70615
Bearing Retainer Wrench 91-17256
Description: Removes and installs thedrive shaft bearing retainer on the MC-1,R-MR and all Alpha drive units.
73482
Belleville Washer 12-54048
Description: Use with the 91-61067A3Pinion Nut Adapter and a propeller nut tocheck the reverse gear lash on the MC-1,R-MR, Alpha One and Alpha One Gen IIdrive units.
75940
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-9
Bellows Expander Tool 91-45497A1
Description: Installs the exhaust bellowson the MC-1, R-MR and Alpha One driveunits.
73430
Bushing Installation Tool 91-805057A2
Description: Installs the shift shaft upperbushings in the R-MR, Alpha One andearlier models of the Alpha One Gen IItransom assembly.
73821
Dial Indicator 91-58222A1
Description: Measures gear the backlashon all drive units.
73429
Dial Indicator Adaptor Kit 91-83155
Description: Attaches the dial indicator tothe gear case when checking backlash onMC-1, R-MR and Alpha One Gen II driveunits.
73643
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ALPHA DRIVE UNIT
Page 1-10 90-806737--2 SEPTEMBER 2001
Dial Indicator Holding Tool 91-89897
Description: Secures the dial indicator togear housing when checking backlash onthe MC-1, R-MR and Alpha One drive units.
73648
Drive Shaft Adaptor 91-56775T
Description: Provides a wrench surface toturn the drive shaft on the MC-1, R-MR,Alpha One and Alpha One Gen II drive units.
73640
Drive Shaft Bearing RetainerWrench 91-43506T
Description: Removes and installs thethreaded bearing retainer on all Alpha driveunits.
73608
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-11
Drive Shaft Bearing PreloadTool 91-14311A2
Description: Preloads the drive shaftbearing when checking pinion height andbacklash on the MC-1, R-MR, Alpha Oneand Alpha One Gen II drive units.
NOTE: This tool is also used on the Mercu-ry and Mariner V-6 gear cases. Check yourinventory before purchasing.
73885
Driver Head 91-36569T
Description: Removes the pinion bearingfrom the MC-I, R, MR, Alpha One, and AlphaOne Gen II drive units.
74185
Driver Rod 91-37323
Description: Use with various drivers toinstall bearings on the Alpha One Gen IIgear cases.
74184
Flushing Device 91-44357Q2
Description: Attaches to the drive unitwater intake, to provide a fresh waterconnection when flushing the coolingsystem or operating the engine with thepower package out of the water.
73440
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ALPHA DRIVE UNIT
Page 1-12 90-806737--2 SEPTEMBER 2001
Forward Gear Assembly Tube 91-815850
Description: Installs and removes theforward gear of the Alpha One and AlphaOne Gen II counter rotating gear cases.
73486
Forward Gear Bearing CupPuller Shaft 91-31229
Description: 5/8 in. x 18 in (15.875 mm)long threaded rod.
75928
Gimbal Bearing InstallationCollar Number 3 91-30366T1
Description: Use with 91-29310 PlatePuller, 91-37323 Driver Rod and 91-32335TBearing Head to install the gimbal bearing inAlpha and MC-1 drive units.
75931
Guide Plate 91-816243
Description: Centers the rod used to drivein the front bearing on the Alpha One Gen IIcounter rotating gear case.
73483
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-13
Guide \ Puller Tool 91-90774
Description: Presses the bearing coneonto the Alpha One Gen II drive shafthousing pinion gear.
73823
Hex Nut 11-24156
Description: Use with 91-31229 ForwardGear Bearing Cup Puller Shaft to pull thebearing assembly.
75930
Hinge Pin Tool 91-78310
Description: Removes and installs thehinge pins from all Mercury MerCruiserdrive units.
73443
Lube Gun 91-37299Q2
Description: Allows easy access to greasefittings.
73674
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ALPHA DRIVE UNIT
Page 1-14 90-806737--2 SEPTEMBER 2001
MCM Tool Board Overlay Kit 91-877528-1
Description: MCM Tool Overlay Kit (sheetnumbers 10-20 ) contains 11 overlay sheetsand hooks indicating locations for all theMercury MerCruiser gasoline engines andsterndrive units active service tools.
Includes 91-883983 MCM Tool BoardOverlay Update Kit.
77976
Needle Bearing Driver 91-15755T
Description: Installs needle bearings inMC-1, R-MR, Alpha One and Alpha OneGen II bearing carriers.
73815
Needle Bearing Driver 91-33491
Description: Installs the needle bearing inthe forward gear, removes and installs theseals and bearing in the gimbal housing ofthe MC-1, R-MR and Alpha One drive units.
73471
Needle Bearing Driver 91-33492T
Description: Removes and installs thelower swivel pin needle bearings in thegimbal ring on the MC-1, R-MR and AlphaOne drive units.
73470
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-15
Needle Bearing Driver, PilotWasher 91-37324T
Description: Used to pilot the threaded rodwhen installing the pinion bearing in theMC-1, R-MR, and Alpha One drive units.
75938
Needle Bearing InstallationTool, Reverse Gear 91-807944T
Description: Use to install the needlebearing in the reverse gear on the AlphaOne Gen II counter rotation drive units.
75944
Needle Bearing Removal Tool 91-816245
Description: Removes the needle bearingsfrom the back adaptor of the Alpha One GenII counter rotating gear case.
73448
Oil Seal Driver 91-31108T
Description: Installs the oil seals in thebearing carrier on the MC-1, R-MR, AlphaOne and Alpha One Gen II drive units.
73651
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ALPHA DRIVE UNIT
Page 1-16 90-806737--2 SEPTEMBER 2001
Oil Seal Driver 91-817569T
Description: Installs and removes theAlpha One Gen II counter rotating bearingcarrier seals; also, install seals in the driveshaft seal carrier.
73450
Pilot Washer 91-36571T
Description: Use as a centering guide toinstall the pinion bearing in the MC-1, R-MR,Alpha One and Alpha One Gen II drive units.
74187
Pilot Washer 91-37350T
Description: Use with 91-31229A7Universal Bearing Puller Kit.
75939
Pinion Gear Shimming Tool 91-56048T
Description: Measures the pinion height ofthe MC-1, R-MR, Alpha One and Alpha OneGen II drive units.
73436
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-17
Pinion Nut Adaptor 91-61067A3
Description: Holds the pinion nut whenremoving the pinion gear and drive shaft onthe MC-1, R-MR and Alpha One drive units.
73442
Pipe Tap 91-95639
Description: Taps the bell housing for shiftcable installation on the MC-1, R-MR andAlpha One drive units.
73475
Plate Puller 91-29310
Description: Use as a guide to remove andinstall the gimbal bearing on MC-1, R-MR,Alpha One and Alpha One Gen II drive units.
74190
Power Steering Adaptor Kit 91-806908A1
Description: Adapts Power Steering TestGauge 91-38053A4 to test later modelpower steering control valves.
74168
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ALPHA DRIVE UNIT
Page 1-18 90-806737--2 SEPTEMBER 2001
Power Steering Test Gauge Kit 91-38053A4
Description: Tests power steering systempressure.
74167
Propeller Shaft Adaptor 91-61077T
Description: Provides a wrench surface toturn the propeller shaft on the MC-1, R-MR,Alpha One and Alpha One Gen II drive units.
73427
Puller Head 91-38919
Description: Removes the swivel pins fromthe R-MR and Alpha One gimbal rings.
73820
Puller Head 91-63616T
Description: Removes the upper swivelshaft on MC-1, R-MR, Alpha One and AlphaOne Gen II gimbal rings.
73428
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-19
Puller Jaw 91-34570
Description: Replacement jaw for the91-34569A1 Slide Hammer Puller Tool.
77890
Puller Jaw 91-816242
Description: Use with either the two prongor three prong puller on all MercuryMercruiser drive units.
75946
Puller Jaw AssemblyPuller Bolt
91-46086A1 91-85716
Description: Removes bearing carrier onthe MC-1, R-MR, Alpha One and Alpha OneGen II drive units.
73599
91-85716
91-46086A1
Reverse Gear Needle BearingDriver 91-816244
Description: Installs the needle bearingsinto the reverse gear of the Alpha One andAlpha One Gen II counter rotating gearcase.
73488
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ALPHA DRIVE UNIT
Page 1-20 90-806737--2 SEPTEMBER 2001
Roller Bearing Removal andInstallation Tool 91-37292
Description: Part of 91-31229A7 BearingRemoval and Installation Tool Assembly,use with the threaded puller rod or driverrod.
75935
Seal and Bushing InstallationTool 91-806928A1
Description: Installs the shift shaftbushings in the Alpha One Gen II drives withserial number 0F094775 and Above.
74169
Seal Driver 91-43591T
Description: Installs the upper drive shaftoil seal on the Alpha One and Alpha OneGen II drive units.
73467
Seal Driver 91-44110T
Description: Installs the oil seals in thewater pump base on the Alpha One andAlpha One Gen II drive units.
73472
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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-21
Shift Cable Tool 91-12037
Description: Installs the shift shaft upperbushing in the R-MR, Alpha One and theearlier Alpha One Gen II transomassemblies.
73459
Shift Shaft Bushing Tool 91-31107T
Description: Removes and installs the shiftshaft bushing in the gear case on the MC-1,R-MR and Alpha One drive units.
73658
73608
Shift Shaft Slide Stabilizer 91-809815A1
Description: Use to hold the Alpha shiftshaft slide in the proper position as the driveunit is installed onto the bell housing studs.
75199
Shift Shaft Tool 75104A7
Description: Manually shifts the MC-1,R-MR, Alpha One and Alpha One Gen IIdrive units. The tool connects onto the gearhousing shift shaft when the gear housing isseparated from the drive shaft housing.
74186
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ALPHA DRIVE UNIT
Page 1-22 90-806737--2 SEPTEMBER 2001
Shimming Tool, Drive Gear 91-60523
Description: Measures the upper drivegear clearance on the MC-1, R-MR, AlphaOne and Alpha One Gen II drive units.
73445
Shimming Tool, Driven Gear 91-60526T
Description: Measures the upper drivengear clearance on the MC-1, R-MR, AlphaOne and Alpha One Gen II drive units.
73452
Shimming Tool, Driven Gear 91-854377
Description: Use to shim the driven gear onthe Alpha One Gen II starting with SerialNumber 0L100009 and above. Can beidentified by the letters “A, B, C.”
75947
Sleeve Installation Tool 91-818162
Description: Installs the aluminum sleevein the U-joint bellows of all the Alpha OneGen II drive units.
73485
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Sleeve Removal Tool 91-818169T
Description: Removes the aluminumsleeve from the U-joint bellows of the AlphaOne Gen II drive units.
7
73484
Slide Hammer Puller 91-34569A1
Description: Removes the bearings andbearing cups.
91-34570 Replacement jaw.
73655
Snap Ring Pliers 91-37240A1
Description: Removes the snap ringlocated at the gimbal housing bearing on theMC-1 drive units.
73431
Spanner Wrench 91-821709TDescription: Removes the trim cylinderend cap on all Mercury MerCruiser, Mercuryand Mariner trim cylinders. Usesinterchangeable pin sets:
91-811907 Large pin set 0.235 in. (5.97 mm)91-811908 Medium pin set 0.180 in.(4.57mm)91-811909 Small pin set 0.150 in. (3.81 mm) 71233
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ALPHA DRIVE UNIT
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Tab Washer Pliers 91-38277A2
Description: Bends the propeller tabwasher tangs off of tab nut on the MC-1,R-MR, and Alpha One drive units.
73653
Torch Lamp 91-63209
Description: 120v Torch Lamp, heats thebearing bores to make bearing removal andinstallation easier.
91-63210 Replacement bulb 120v
NOTE: 91-74042 Torch Lamp 240v is nolonger available. 88-68664 Replacement240v bulb is available..
73437
Torque Wrench, lb-in. 91-66274
Description: Sets torques from 9 to150 lb-in; 3/8 in. drive.
73430
Transom Cutout and DrillFixture 91-43693A2
Description: Use for cutting and drilling theboat transom for sterndrive installation.
22056
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Trim Pump Test Gauge Kit 91-52915A6
Description: Use in various trim pumptests.
73835
U-joint Adaptor 91-38756
Description: Supports the yoke whendisassembling U-joint on all the drive units.
74229
Universal Puller Plate 91-37241
Description: Removes gears andbearings.
73652
Upper Drive Shaft HousingSeal Driver
91-817570T
Description: Installs the seals in the AlphaOne Gen II upper drive shaft housing.
73449
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Washer 12-34961
Description: Use on the threaded puller rodbetween the nut and plate when removingbearings.
75934
Water Pump Alignment Pins 91-821571A1
Description: Aligns the Alpha One Gen IIwater pump during installation.
73822
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