2000 Challenger 2000 M2 jet pump failure

[First_Doo]

Hello all, new here. Just bought a 2000 Challenger 2000 with what was supposed to be a 240 EFI but turns out it’s been replaced with a V200. That’s besides the point though. Finally got itvrunning today and the jet pump has the sound of a rod broken. Looking for advice on what to check or what might be a common issue. These beasts are super expensive to “replace”...I’m thinking do a rebuild of it. Any input appreciated!!!

thanks all

 

[Tim75]

Hello all, new here. Just bought a 2000 Challenger 2000 with what was supposed to be a 240 EFI but turns out it’s been replaced with a V200. That’s besides the point though. Finally got itvrunning today and the jet pump has the sound of a rod broken. Looking for advice on what to check or what might be a common issue. These beasts are super expensive to “replace”...I’m thinking do a rebuild of it. Any input appreciated!!!

thanks all

Don't judge its sound unless you are in the water

Have you checked/changed the gear oil? Looking for sparkling oil, chips, chunks. The drain holes are not very big. Failure of this gearbox is rare.

The biggest concern is the spline in the bottom of the crankshaft. The spline for the pump is different from outboard crank.

 

[First_Doo]

Don't judge its sound unless you are in the water

Have you checked/changed the gear oil? Looking for sparkling oil, chips, chunks. The drain holes are not very big. Failure of this gearbox is rare.

The biggest concern is the spline in the bottom of the crankshaft. The spline for the pump is different from outboard crank.

Thanks for your reply. I have pulled the rear section off including the stator. The fluid in there was clean as can be. The next thing I’m going to do is pull the pump off the boat so that I can run the engine and know for peace of mind the noise I’m hearing ISN'T coming from the engine.
The only real failure point I can see from the diagrams would be where the pinion gear meshes with the shaft gear…will update once I have the pump out

 

[Tim75]

Thanks for your reply. I have pulled the rear section off including the stator. The fluid in there was clean as can be. The next thing I’m going to do is pull the pump off the boat so that I can run the engine and know for peace of mind the noise I’m hearing ISN'T coming from the engine.
The only real failure point I can see from the diagrams would be where the pinion gear meshes with the shaft gear…will update once I have the pump out

I think you are making a lot of work.
If you REALLY want to run the engine off the pump, then just pull the engine. The engine must come up. The pump must go down to remove.

Has the engine been run in the water? Have you checked the gear oil?

 

[First_Doo]

From what I can see I can drop the pump out the bottom without removing the engine first, am I correct with that? I know the manual says pull power head but I don’t see why I would have to. I can access the 4 nuts no problem….

 

[Tim75]

From what I can see I can drop the pump out the bottom without removing the engine first, am I correct with that? I know the manual says pull power head but I don’t see why I would have to. I can access the 4 nuts no problem….

Better to go by the book. See Dr. Honda's threads on his rebuild journey.

Even to rebuild the gear box, you don't have to drop the pump.

 

[First_Doo]

@Dr Honda can chime in with any reason why I can’t drop the pump out by taking the 4 nuts off and leaving the power head in?
The noise I’m hearing is seriously loud and has somewhat a pattern to it. This boat has been neglected and sat in the water for a long time since there are zebra mussels all over everything

 

[First_Doo]

@Dr Honda are you able to explain to me why I couldn’t just pull the jetdrive without pulling the engine? Thanks!

 

[Shortrun]

The jet pump is bolted to the hull. The engine is bolted to the jet pump.

 

[First_Doo]

Ok so I know the jet drive bolts to adapter plate, sandwiching a gasket, snd the engine bolts to adapter plate as well. Still confused as to why I can’t drop the pump…any insight is appreciated!

 

[Tim75]

Ok so I know the jet drive bolts to adapter plate, sandwiching a gasket, snd the engine bolts to adapter plate as well. Still confused as to why I can’t drop the pump…any insight is appreciated!

According to service book-
Removing jet pump- (BEFORE step #1) Remove engine according to Sect. 4.

I have had my boat more than 10 years. I have never had to remove the pump.

 

[Tim75]

According to service book-
Removing jet pump- (BEFORE step #1) Remove engine according to Sect. 4.

I have had my boat more than 10 years. I have never had to remove the pump.

Captain Obvious here...........
If you drop the pump and figure a way to crank the engine in the boat and you find that the rattle is in fact the engine, you have to pull the engine for rebuild and you have dropped the pump for no reason.