Leaking oil from new driveshaft upon reassembly

[IDoSeaDoo]

Hey everyone. I finally dropped the motor into my Challenger last night and filled it to prime with oil. The motor and all driveline components are out of a 2003 GTX S/C. The driveshaft looks new and the carrier and inner seals are both brand new. I lubricated the shaft before going in, and yes, the bumper was on on the tip. The only thing not installed was the little carbon seal hat. I had not yet put the C-clip on it to retain it in the right place.

Anyway, upon cranking with plugs out to prime all the oil passages, I noticed it started dripping pretty rapidly from the driveshaft seal. Can anyone PLEASE point me to what I'm doing wrong? I'm very desperate to start this baby up after all this time. I really hope I don't have to pull the motor back out and ruin the perfect alignment I've managed to achieve.

Thanks.

 

[IDoSeaDoo]

I looked in the Manual, the it shows two O-rings labeled 26 that I've never seen before. They weren't on the old shaft when I took it out.

When I went online, the microfiche didn't show them though

What's up with that?

 

[IDoSeaDoo]

hmmmm I believe I may have made a mistake in which bellows seal I ordered: I might have bought the one for 2009/10 skis...

 

[devonte007]

I've been doing some research lately about the PTO bearing seal and driveshaft, plan to take mine out soon for some reconditioning. Actually in the process of making my own drive shaft removal tool since I have access to a machine shop and a skilled CNC operator to help me....

What I have learned is that there are two rubber o-rings in the end of the PTO that seadoo recommends replacing each time driveshaft is removed. Seems you discovered this already and if you do not have any o-rings, this is the likely cause of your oil leak. Below is a pic I pulled from the web showing the 2 grooves where the o-rings are supposed to sit.




You mentioned a brand new PTO bearing seal, and I think it odd that the new seal did not come with these o-rings installed already. In any case, I think they are rather universal to engine type. They show up on parts list for my 155hp boat, not sure why they are not available for you. Maybe try a different category in the parts lists, find the one with the PTO seal and it may show up there. I have noticed that the parts lists can vary significantly to the parts diagrams in the shop manual. I am almost sure that every 4-tec seadoo has them so keep looking or call your parts dealer. Not sure if this helps much.

Anyway, I have enjoyed following your build posts, a very ambitious project to say the least. Can't wait to hear about the first water test, summer is just around the corner!

Which reminds me, guess I should start my boat projects too....

 

[IDoSeaDoo]

Thanks Devonte, I can't wait to see how she does either.

I just pulled up ebay history and it turns out I ordered the wrong part number DAMN!! I ordred 420832753 which is only for 2009/2010s. Looks like I'm out $100 and two days of time. I wish there was a seadoo dealer I could get parts from in this state. I'd drive there today! Now I have to wait at least two days before I can water test :facepalm: