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Mercury Alpha 1 gen2 drives around 2004 to 2009

GAS engine, transmission and generator repair and maintenance discussion forum.
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Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby bud37 » March 20th, 2025, 7:19 pm

Since I have no experience with these, the only outdrives we ever had were the cobras in the 80's. We may be considering another boat, ( just miss boating a lot ) small stuff that is why the drive question. Single engine 5.0 to 5.7. , 4500 to 6000 # boats approx.

I have a couple of questions about these drives. Are there any tells as to condition by looking at the general appearance or running the drive in gear out of the water ( cracks etc). Does having a foil on it cause any issues, I see a lot like that. Are the Bravo drives much better ? Are parts available or are complete rebuilds the best way to go in Canada.

I would check the oil condition but if it had been changed then ???

If anyone has any experience, good or bad , any advice here would be greatly appreciated. TIA.. :down:
FWIW.....The above is just my opinion.


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Re: Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby Viper » March 21st, 2025, 12:04 am

Tell tales I'd be looking for through an external inspection first is the condition of the coating (paint), and whether the casing itself is corroded, especially around the bearing carrier (surrounding the front of the prop). A poor coating, signs of corrosion, and spent anodes are usually a pretty good sign that the owner isn't that big on preventive maintenance. This has to lead one to wonder about the condition of hardware that you can't see. Also look for signs of impact. BTW, the Gen II has an anode behind the prop which sometimes doesn't get changed (lazy) as the prop has to be removed to do it.

The next easiest items to check are the bellows but you can't tell with the drive on whether they're leaking or not, you could though look for signs of aging usually presented by cracking in the valleys of bellows. To know for sure if the u-joint bellows is leaking or not you have to remove the drive. A bit of a pain when just shopping for a boat but with the drive off you can check other items like the u-joints, gimbal bearing, whether the input seal is leaking, etc. Repairs here can add up to big bucks if you're paying someone to do it.

You can shift the drive in and out of gear but the true test is of how that system is working is with the engine running and in the water. While there are adjustments that can be made, after initial setup, it's pretty common for shifting issues to arise from a bad lower shift cable.

While at the boat, if the battery is hooked up, check the operation of the trim limit circuit and the trim gauge circuit. Also inspect the wiring to the senders on the transom assembly's bell housing. The wiring needs to be in good condition with no bare wires showing or butt connectors. Butt connectors here are a bad shortcut.

I am not a fan of fins or anything else bolted to a drive that requires drilling holes, that's not a good idea. It compromises structural integrity, and it promotes corrosion.

Bravo drives are better IMO but they're not for every application. A couple of benefits are: water pump is on the engine instead of inside the drive as in the Alpha, and shifting is accomplished with a cone clutch which is a smoother shift over a dog clutch found in the Alpha. The cone clutch system also does not need to cut ignition briefly (interrupt circuit) to shift out of gear.

Not much you can check if the oil has been changed short of tearing the drive down and actually inspecting components (gears, bearings, etc.) You could use your nose to check for lingering burnt gear lube odours but fresh gear lube stinks to begin with. Check the condition of the gear lube in the gear lube monitor (bottle on the engine)

Parts are readily available for Gen II's and Bravos both OEM and aftermarket, you just have to be careful which parts you go aftermarket on. Can't say I like drives, they're just too maintenance heavy, and if you try and save money by skipping regular maintenance, you WILL pay big eventually. They help keep a roof over my head though ;-)
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Re: Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby bud37 » March 21st, 2025, 9:40 am

Thanks, some of the things you mentioned I had forgotten from the cobra....had that thing off and on every year from new to get the zebras out of the water intake and change the bearing....looking back it sure required a lot of fooling when brand new... :-O ......I did like the pump access though.

I will be a lot more armed now as to what and where to look if we go ahead with this...... again thanks... :down:
FWIW.....The above is just my opinion.
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Re: Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby bud37 » August 8th, 2025, 10:04 pm

I came across a boat with a merc alpha gen 2/ the 4 cylinder engine., 1993 vintage.

Anyway with the drive trimmed up a bit and straight centered, when I grab the skeg and lift ( pull up) it has vertical play, a fair bit, maybe 3/4 to an inch vertical play, clunky.
I wish I knew more about these drives, but just never had them.

I am not sure this is normal , doesn't feel right to me, the trim gage that shows the position does not work .....any opinions anyone as we may visit this one again so I need some advice here.
FWIW.....The above is just my opinion.

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Re: Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby Viper » August 9th, 2025, 11:00 am

So we need to clarify first where the play is; if the drive is trimmed up a bit and you lift by grabbing the skeg, the play can be coming from the trim cylinders. You'd see that by looking at the rams and checking to see if they are pulling out when you lift the drive that way. If they are pulling out a bit, that could be part or all of your play and could simply be actuator rebuilds which isn't that bad.

The best way to check drive vertical play is to have the drive all the way down, grab the cav plate on both sides and lift the drive. If you get 3/4" play this way, it's way too much and something is going on. Could be excessive wear on the top or more likely the bottom of the gimbal ring. That's a pricey replacement but you could probably find a decent used one. The problem with drives though is that what you thought on the outset may be the extent of required parts and labour usually turns out to be just the tip of the iceberg. You can't see everything until you dismantle.

More concerning than vertical play is lateral play side to side. This is where you grab the back of the cav plate and try to pivot the drive to port and starboard without actually moving the wheel. If there is play, it will move side to side easily then lock or have resistance to moving. If there is more than just a little play here, you could be in for a huge expense depending on the extent of the wear and whether you do the repair or hire someone else to. I've seen some really bad cases of this and when it gets to that point it's a safety issue so keep that in mind.

The inop trim gage could be a number of things; wiring, gage, connections, but most common is either a sender adjustment or replacement. As I mentioned in a previous post, look for bad wires leading to the sender and make sure there are no butt connectors there (externally). The sender is the puck on the starboard side of the drive, and the one on the port is the trim limit switch. Both are adjustable and can only be purchased as a kit (both units) from Merc. You can loosen the sender a bit and rotate it manually while someone watches the gauge, if it doesn't move, it's either bad wiring, the gauge, or the sender. They also sell replacement internal discs for the sender which are a proper fix only if the wiring is in good shape.

Aside from the drive (or in front of it) I can't stress enough the importance of checking for a solid transom especially around the transom assembly. Constant vibration and stress can loosen things up over time and allow water ingress which is a whole different level to remedy.

This could get really lengthy so I'll end it here for now and delve deeper if your interest in this one progresses. Don't hesitate to inquire about any aspect of the drives even if it seems minor. In my experience there's nothing minor when it comes to drives, even the littlest thing can turn into a nightmare if not looked after. The key here is being informed.
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Re: Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby bud37 » August 9th, 2025, 11:48 am

Thanks man, I know you know your drives..... I hear ya about possible hidden nightmares with these things.

Actually didn't notice much if any movement in the rams. Yep, I knew the drive should be vertical at best but wonder of wonders the battery was dead so had to inspect as it was. The transom is exposed ply on the inside, its a 20' aluminium boat. Transom wood looked and sounded solid and no evidence of stress cracks that I could see in the metal.

There were some other things and the owner is extremely proud of this thing so I left it for the time being. If I go back , will check the side to side/up down with the drive down, and have a real good look at the wiring as that may be where the issue is anyway. Would have bought this thing if it had an outboard, those I get.... ;-)

Too old for another project... :-D
FWIW.....The above is just my opinion.

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Re: Mercury Alpha 1 gen2 drives around 2004 to 2009

Postby Viper » August 9th, 2025, 11:13 pm

Hum, I didn’t know Carver made 20 foot aluminum boats. ;-)

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