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ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-1
ALPHA DRIVE UNIT TOOLS
73658
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
• •
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 • •
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 •
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-23
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
ALPHA DRIVE UNIT
Page 1-24 90-806737--2 SEPTEMBER 2001
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
ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-25
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
ALPHA DRIVE UNIT
Page 1-26 90-806737--2 SEPTEMBER 2001
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
ALPHA DRIVE UNIT
90-806737--2 SEPTEMBER 2001 Page 1-27
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ALPHA DRIVE UNIT
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