[Amel Yacht Owners] Re: Mainsail outhaul gearbox


Mike Ondra
 

Thanks Gary and Bill. Amazingly fast response.



To answer Bill’s question, the gearbox is basically the box with top and bottom plates with lipseals that seal to the gearbox “core” (for lack of a more precise term). The drive shaft that passes up through the boom tends to bind on that “core” with rust. In pounding on the shaft the upper plate broke at all four corner screws. Its shot. Looking at a new gearbox.

With the top plate broken, the rest of the gearbox housing could easily be taken apart. I am left with the shaft through the boom, the top plate, the “core” (rusted to the shaft) and the brass gear on the “core”. I need to separate the shaft from the “core” to get is out of the boom and reuse the shaft with a new gearbox.



Gary’s “pusher” approach will likely be my next effort.

Note that the sledge hammer approach is NOT the way to do this. Annual removal and greasing cannot be over stated.



Mike Ondra

ALETES SM#240

Rock Hall, MD



From: amelyachtowners@yahoogroups.com [mailto:amelyachtowners@yahoogroups.com]
Sent: Monday, June 06, 2016 8:01 AM
To: amelyachtowners@yahoogroups.com
Subject: [Amel Yacht Owners] Re: Mainsail outhaul gearbox









Hey Mike -



Sorry to hear about your troubles... I too have been a victim of this process and due to "lack of maintenance" (no offense of course). Just to be clear and so I can paint a better picture in my head. There are two "plates" or covers that also house a seal on the top and bottom of the transmission... Was it this piece which broke?



Does the transmission spin when the out haul motor is engaged? If not does it spin at all or is it completely seized in its place?



From what I remember, there are two gears. A worm gear coming from the motor shaft, and a main gear attached to that stainless steel shaft that your Andersen shaft runs through. That stainless steel shaft also has 2 large race bearings and a few locking snap clamps.



Please provide a few more details and I will do my best to help you out. I know if I cannot you will have no problem getting responses/advice from some of the more experienced members on this site.



Cheers,



Bill Maffei

SM #195

It's all Good


Alexandre Uster von Baar
 

Hello Mike,

Here is how I removed the shaft on my vessel.
http://nikimat.com/outhaul_motor_rebuild.html

Thanks for the advice on lobbying the shaft Gary!
If you are still in Puerto Rico, would love to meet you!
I am at the San Juan Nautico Club, but I could rent a car and meet you at Fajardo!

Sincerely, Alexandre
SM2K #289 NIKIMAT
Club Nautico de San Juan, Puerto Rico




--------------------------------------------

On Mon, 6/6/16, amelliahona <no_reply@yahoogroups.com> wrote:

Subject: [Amel Yacht Owners] Re: Mainsail outhaul gearbox
To: amelyachtowners@yahoogroups.com
Date: Monday, June 6, 2016, 6:58 AM


 









Mike:
I feel
for you but I hope you don't make a bad situation worse.
 I pounded on my shaft with a bolt screwed in the bottom
until I thought I would damage the boom and then sought
help.  What is needed was a too that rather easily
"pushed" the shaft upwards.  It was a unique type
of "pusher" as opposed to a "puller".
 I seem to recall a photo of the device somewhere on the
forum.  Basically it is a bar of steel that inserts
transversely thru the opening in the gearbox mounting
bracket that is below the boom.  Shims are placed under it
to bear on the upper surface of the gearbox shaft (the
hollow shaft into which the solid shaft seats and drives
with a woodruff key) and then this is tied with bolts to a
bar parallel to the upper one that is below the gearbox
shaft.  A threaded bold is screwed thru threads in the
lower bar such that as the bolt is screwed in, it pushes up
on the shaft (with a protective piece of metal in place so
as not to damage the shaft end).  Counter pressure is
supplied by the upper bar of steel [basically a puller in
reverse].  A picture would be worth a thousand words here.
 
Please remember
that aluminum remembers every stress and will fatigue fail
if stressed to much from pounding etc.  That is the reason
it is so important to have the pressure on the shaft bear on
the gearbox receptacle shaft (steel) rather than on the
aluminum cover of the gearbox or worse yet on the boom and
its bracket.
WARNING
TO ALL AMEL OWNERS WITH THIESE GEARBOXES, REMOVE AND LUBE
THIS SHAFT YEARLY or suffer the consequences.
Find someone with the right
"pusher".  In my case after I spent hours
pounding, penetrating oiling etc. the mechanic I consulted
had the pusher in his shop and extracted the pin in 10
minutes. 
I wish you
the best, 
Gary S.
Silver Amel SM #335Fajardo, Puerto
Rico   Puerto Del Ray Marina









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amelliahona <no_reply@...>
 

Hi Mike:

email you address to garysilver at mac dot com

Unfortunately we left the boat on 4 June and are back in Utah.  Would have loved to meet you.  Great photo essays you do.  I visited your web site but couldn't find links to all of your great work, only thru the forum here could I access those.  Any chance I am missing something and that I could access all those from one place.

Would also love to see a photo of the Onan board you replaced.  Mine is weeping the potting compound (varnish like goo that is driving me nuts).  It is 15 years old now so all those years and heat have taken their toll.  I may want to obtain a spare. 

Sincerely, 

Gary S. Silver
s/v Liahona
Amel SM 2000 #335
Puerto Del Rey Marina  - Puerto Rico 


Mike Ondra
 

Hi Gary,

In this request were you referring to Alexandre on NIKIMAT re the web site and Onan issues? Or perhaps another Mike? I don’t have a website for boat issues.

Mike Ondra

ALETES SM#240

Rock Hall, MD





From: amelyachtowners@yahoogroups.com [mailto:amelyachtowners@yahoogroups.com] On Behalf Of amelliahona
Sent: Tuesday, June 07, 2016 10:48 AM
To: amelyachtowners@yahoogroups.com
Subject: Re: [Amel Yacht Owners] Re: Mainsail outhaul gearbox





Hi Mike:



email you address to garysilver at mac dot com



Unfortunately we left the boat on 4 June and are back in Utah. Would have loved to meet you. Great photo essays you do. I visited your web site but couldn't find links to all of your great work, only thru the forum here could I access those. Any chance I am missing something and that I could access all those from one place.



Would also love to see a photo of the Onan board you replaced. Mine is weeping the potting compound (varnish like goo that is driving me nuts). It is 15 years old now so all those years and heat have taken their toll. I may want to obtain a spare.



Sincerely,



Gary S. Silver

s/v Liahona

Amel SM 2000 #335

Puerto Del Rey Marina - Puerto Rico





[Non-text portions of this message have been removed]


amelliahona <no_reply@...>
 

My bad!  Yes I was referring to Alexandre.  Sorry Mike.

Alexandre, did you copy that?

send me your email address to  garysilver at mac dot com

Gary


Alexandre Uster von Baar
 

Good afternoon Gary,

I sent you an email, let me know you receive it, sometime they go to spam folder.

I know about my web site, I actually design, update web site for work, so as people say for shoe maker mine is terrible.
I do plan with time to link everything together...
I want the site to help new owner to see the boat in detail, how to repair, etc.

Since it was pretty straight forward I unfortunately did not take any pictures of the control board replacement.
just remove the top 4 bolt of the cover
remove the bolt holding the relay
remove on each side (forward and aft) of the control box 2 bolt on each side (holding little bracket inside which hold the control board).
disconnect the 2 harnesses from the control board, remove it as you can (not easy because tight space).
Note: the onan technicien that came to remove it, was very cautious about switching all the breakers off.

On facebook, I posted a picture (more detail on the whole story), I sent you a message through there as well.
http://nikimat.com/onan_control.jpg
http://nikimat.com/onan_board.jpg
The red arrow is pointed to a harness use for other gages.

I will be in San Juan until July 8, then sailing south.
Hope we meet one day!

Sincerely, Alexandre



Hi Mike:
email
you address to garysilver at mac dot com
Unfortunately we left the boat on 4
June and are back in Utah.  Would have loved to meet you.
 Great photo essays you do.  I visited your web site but
couldn't find links to all of your great work, only thru
the forum here could I access those.  Any chance I am
missing something and that I could access all those from one
place.
Would also love
to see a photo of the Onan board you replaced.  Mine is
weeping the potting compound (varnish like goo that is
driving me nuts).  It is 15 years old now so all those
years and heat have taken their toll.  I may want to obtain
a spare. 
Sincerely, 
Gary S. Silvers/v
LiahonaAmel SM 2000 #335Puerto Del Rey
Marina  - Puerto Rico 









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Mike Ondra
 

So after replacing the outhaul gearbox destroyed during our effort last year to remove the "drive shaft" I was most careful top apply anti-sieze grease. Even so I could not remove the shaft with "modest" pounding from below. the solution that ultimately worked was the application of a 4T "bottle jack". Picture attached. Even so quite a bit of pressure was required with the ultimate release achieved by driving screw driver wedges just under the top of the shaft. A caution would be to be sure to fill in the space between the gear box and the boom to transfer some of the pressure to the boom and off the bolts and gearbox top. We used catalog pages to fill the space.


Mike Ondra

Aletes SM#240

Rock Hall, MD