It is time for me to replace the U-joint bellows in my 1998 Mercruiser Alpha1 Gen2 stern drive. I have noticed that it has been developing wear marks on some of the convolutions on the sides of the bellows. The rubber has grooves worn in it, so I want to fix it before it begins to leak. If the bellows leaks, the water will damage the u-joints and gimbal bearing, as well as leak into the boat, with risk of sinking.

NOTE: THIS VIDEO is PART2, Be Sure to check you PART1 for removal and a summary:
Part 1 Remove U-Joint Bellows:    • Change Mercruiser Alpha1 U-Joint Bell...  

I have purchased a number of parts and supplies, because in order to replace the bellows, there are a number of other parts that should be replaced due to age. Also, removal of certain hoses from the barbed fittings is near impossible and required cutting and replacing.

Content:
Prepare to Install U-Joint ans Shift Bellows 00:03
Install Intermediate Shift Cable Bellows 5:22
Install U-Joint Bellows 10:06
Prepare Bell Housing for Installation 13:16
Install Bell Housing, Water Hose, and Water Tube 17:02
Install Water Tube Grommet / Bushing 21:31
Finish Bell Housing Installation - Install Pivot Pins 37:22
Install U-Joint Bellows Retaining Ring 46:20
Repairing Bad Spot In Casting - Water Pickup 52:45
Install Lube Monitor Hose 55:50
Install Shift Cable Bellows Clamp, Show Special Pliers I Made 57:30
Install Outdrive (Summary- Full video Link Below) 1:02:26
Install Intermediate Shift Cable Engine End and Check Adjustment 1:04:50

Part 1 Remove U-Joint Bellows
   • Change Mercruiser Alpha1 U-Joint Bell...  

Remove / Install Outdrive Full Video:
   • Check Engine Alignment Mercruiser 1 A...  

Parts, Supplies, and Tools that I purchased:
U-Joint Bellows- 816431A1
Shift cable Bellows- 74639A2
Bellows adhesive- 92-86166Q-1
Water inlet hose to engine- 32-8M0215001
Lube monitor hose - 8M0214996
Outdrive gasket set Quicksilver- 94996Q2
Water tube grommet- 8165991
Red Loctite 271
Loctite activator 7649
Permatex Aviation Form a Gasket- 80019
Special socket for shift cable removal- SEI Marine 91-12037
Special tool for hinge pin removal- Sierra 18-9861
Bellows Retainer ring install tool- 91-818162
Made a special tool for shift boot clamp installation
Liquid Electrical tape- Starbrite

DISCLAIMER: In my videos and written or text comments, I provide demonstrations, suggestions, and opinions on techniques, methods, and materials for various projects. While I try to be accurate, there are no guarantees, expressed or implied, that my information is correct and will work for you. If you wish to use any of this information, you must check and verify that it is appropriate for your use - use it at your risk. Do-it-yourself projects are variable and there are risks in conducting them.