Mercury sportjet 210 Gear assembly/Stator Questions

[Madmax258]

Hey Everyone

Starting to rip apart my jet drive on my 2000 challenger that I bought for a low price afew months back with a blown motor, and looks like their was no washers left on my gear case vent and fill screws, their was alittle bit of gear lube in case but definitely not what should be, and as picture shows water was leaking in where the washers must of disintegrated gear lube looks creamy. (No sign of washers on the plugs) So that's not good, doesnt seem like much maintenance was done on this machine although the hull of the boat is in really good shape so hoping to restore it. So moved on to the stator and looks like their was barely any gear lube in it as well and from the pictures you can see the scoring on the shaft and the rust on the stator wall. Just wondering what people's option on here about what I should do? Remove the shaft and replace everything like shaft itself, bushings and seal? Sandblast the stator wall carefully to remove rust? I was going to order new vent and fill screws with washers and fill gear assembly with gear oil and also stator while the boat sits over the winter and I start removing the motor. Any advise would be great. Thanks everyone.

 

[Tim75]

Hey Everyone

Starting to rip apart my jet drive on my 2000 challenger that I bought for a low price afew months back with a blown motor, and looks like their was no washers left on my gear case vent and fill screws, their was alittle bit of gear lube in case but definitely not what should be, and as picture shows water was leaking in where the washers must of disintegrated gear lube looks creamy. (No sign of washers on the plugs) So that's not good, doesnt seem like much maintenance was done on this machine although the hull of the boat is in really good shape so hoping to restore it. So moved on to the stator and looks like their was barely any gear lube in it as well and from the pictures you can see the scoring on the shaft and the rust on the stator wall. Just wondering what people's option on here about what I should do? Remove the shaft and replace everything like shaft itself, bushings and seal? Sandblast the stator wall carefully to remove rust? I was going to order new vent and fill screws with washers and fill gear assembly with gear oil and also stator while the boat sits over the winter and I start removing the motor. Any advise would be great. Thanks everyone.

It does appear that you have bad seals in the gear box and stator. The will be a seal under the engine and one on the impeller shaft where it heads aft out of the gear box. Your impeller shaft appears to be damaged in the stator bearing/seal area. (The stator is what you removed to get the left pic.) Since it is aluminum, there wont be any real rust on it. There may be some corrosion under the paint. The rust you see in left pic is the inner cone of the impeller. Harmless. The large nut is tight- 150 ft# plus any corrosion between nut and shaft. There are 2 flats on the shaft in front of the impeller for a wrench. If you use an impact wrench on that nut, you run a risk of damaging the gears in the gear box. Merc sells a special socket for that nut.

Sometimes the "washer" under the fill screws fuses to the casting. Replace the screws and gaskets. Don't "double gasket" those screws. Guaranteed to leak. Don't scratch the casting faces. Another leak.

Used parts on ebay. Best to have the service book in hand. Avail. from this forum.

 

[Madmax258]

It does appear that you have bad seals in the gear box and stator. The will be a seal under the engine and one on the impeller shaft where it heads aft out of the gear box. Your impeller shaft appears to be damaged in the stator bearing/seal area. (The stator is what you removed to get the left pic.) Since it is aluminum, there wont be any real rust on it. There may be some corrosion under the paint. The rust you see in left pic is the inner cone of the impeller. Harmless. The large nut is tight- 150 ft# plus any corrosion between nut and shaft. There are 2 flats on the shaft in front of the impeller for a wrench. If you use an impact wrench on that nut, you run a risk of damaging the gears in the gear box. Merc sells a special socket for that nut.

Sometimes the "washer" under the fill screws fuses to the casting. Replace the screws and gaskets. Don't "double gasket" those screws. Guaranteed to leak. Don't scratch the casting faces. Another leak.

Used parts on ebay. Best to have the service book in hand. Avail. from this forum.

Thanks Tim75 that helps alot