Workshop Manual: Downloaded From Manuals Search Engine

Workshop manual A
2(0)
MS2, MS2B-A, MS2B-L, MS2A-D

MS2A-E, MS2L-D, MS2L-E, MS2V
120S, 120S-B, 120S-C, 120S-D, 120S-E
Downloaded from www.Manualslib.com manuals search engine

Reverse gear
MS2, MS2B-A, MS2B-L, MS2A-D
MS2A-E, MS2L-D, MS2L-E, MS2V
Sailboat drive
120S, 120S-B, 120S-C, 120S-D, 120S-E
Contents
Safety information ......................................................... 2

Introduction ................................................................. 2
Important .................................................................... 2
General information ...................................................... 5
About the workshop manual ........................................ 5
Spare parts ................................................................. 5
Repair instructions........................................................ 6
Our common responsibility .......................................... 6
Tightening torque ........................................................ 7
Torque-angle tightening ............................................... 8
Lock nuts .................................................................... 8
Strength classes ......................................................... 8
Sealants ..................................................................... 8
Safety rules for fluorocarbon rubber ........................... 9
Special tools ................................................................10
Other special equipment ............................................ 13
Chemicals ..................................................................13
Design and function ..................................................... 14
History ....................................................................... 16
Disassembly - upper and lower gear housings
120S, 120S-B, -C, -D, -E ................................................18
Repair of MS2 reverse gear, upper gear housing
120S, 120S-B, -C, -D, -E ................................................20
Repair of MS2V reverse gear .......................................51
Repair - lower gear housing
120S, 120S-B, -C, -D, -E ................................................61
Pressure testing .........................................................80
Inspection and painting ..............................................80
Technical data .............................................................. 81
References to Service Bulletins ..................................83
7752950-1 English 01-2001

General instructions
Safety information
Introduction If work is done adjacent to a running engine, a

careless movement or a dropped tool can lead
The workshop manual contains technical data, de- to personal injury in the worst case. Be careful
scriptions and repair instructions for products or prod- with hot surfaces (exhaust pipes, turbos, charge
uct versions noted in the table of contents, supplied air pipes, starting heaters etc.) and hot fluids in
by Volvo Penta. Make sure you use the correct work- pipes and hoses on an engine which is running
shop literature. or which has just stopped. Re-install all guards
Read the available safety information, “General in- which have been removed during service work,
formation” and “Repair instructions” in the work- before re-starting the engine.
shop manual before you start to do any service
work. Make sure that the warning or information labels
on the product are always clearly visible. Re-
place labels which have been damaged or paint-
Important! ed over.
The following special warning signs are found in the
workshop manual and on the product. Engines with turbocharger: Never start an en-
gine without the air filter in place. The rotating
WARNING! Warns for the risk of personal inju- compressor turbine in the turbocharger can
ry, major damage to product or property, or seri- cause severe injury. Foreign bodies in the inlet
ous malfunctions if the instruction is ignored. pipe can also cause severe mechanical dam-
age.
IMPORTANT! Is used to call attention to things
which could cause damage or malfunctions to Never use start spray or similar products as a
product or property. starting aid. Explosions could occur in the inlet
manifold. Danger of personal injury.
NOTE! Is used to call attention to important informa-
tion, to facilitate work processes or operation. Avoid opening the coolant filling cap (on fresh
water cooled engines) when the engine is hot.
To give you a perspective on the risks which always Steam or hot coolant could spray out. Open the
need to be observed and precautions which always filler cap carefully, and release the excess pres-
have to be taken, we have noted them below. sure in the cooling system. Be extremely careful
Make it impossible to start the engine by cutting if a tap, plug or coolant hose has to be removed
system current with the main switch(es) and from a hot engine. Steam or hot coolant can
lock it (them) in the off position before starting stream out in an unexpected direction.
service work. Fix a warning sign by the helms-
man’s seat. Hot oil can cause burns. Avoid skin contact with
hot oil. Make sure that the oil system is de-pres-
All service work should normally be done on a surized before doing any work on it. Never start
stationary engine. Some work, such as adjust- or run the engine with the oil filler cap removed,
ments, need the engine to be running, however. because of the risk of oil spillage.
Going close to a running engine is a safety risk.
Remember that loose clothes, long hair etc. can Stop the engine and close the sea cocks before
catch on rotating components and cause severe doing any work on the cooling system.
injury.
Only start the engine in a well-ventilated area.
When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.

Always use goggles when doing any work where Make sure that oil and fuel soaked rags, and
there is any risk of splinters, grinding sparks, used fuel and oil filters are stored in a safe
acid splash or other chemicals. Your eyes are place. Oil soaked rags can self-ignite in certain
extremely sensitive, injury could cause blind- circumstances. Used fuel and oil filters are pol-
ness! luting waste and must be handed to an approved
waste management facility for destruction, to-
Avoid skin contact with oil! Long-term or repeat- gether with used lubrication oil, contaminated
ed skin contact with oil can make your skin dry fuel, paint residue, solvents, degreasers and
out. The consequence is irritation, dry skin, ec- wash residue.
zema and other skin disorders. Used oil is more
hazardous to health than new oil. Use protective Batteries must never be exposed to open
gloves and avoid oil-soaked clothes and rags. flames or electric sparks. Do not smoke close
Wash regularly, especially before meals. Use to the batteries. The batteries generate hydro-
special skin cream to avoid drying and facilitate gen gas when charged, which forms an explo-
skin cleaning. sive gas when mixed with air. This gas is very
flammable and highly explosive. A spark, which
Most chemicals intended for the product (e.g. can be formed if the batteries are wrongly con-
engine and transmission oils, glycol, petrol (gas- nected, is enough to make a battery explode
oline) and diesel oil) or chemicals for workshop and cause damage. Do not move the connec-
use (e.g. degreasers, paints and solvents) are tions when you attempt to start the engine (risk
hazardous. Read the instruction on the packag- of arcing), and do not stand and lean over one of
es carefully! Always observe the safety advise the batteries.
(e.g. use of breathing protection, goggles,
gloves etc.). Make sure that other personnel are Never mix up the battery positive and negative
not inadvertently exposed to hazardous sub- poles when the batteries are installed. If the bat-
stances, such as via the air they breathe. En- teries are wrongly connected, this can cause se-
sure good ventilation. Handle used and surplus vere damage to the electrical equipment. Please
chemicals in the prescribed manner. check the wiring diagram!
Be very careful when searching for leaks in the Always use goggles when charging and handling
fuel system and testing fuel injectors. Use gog- batteries. Battery electrolyte contains highly cor-
gles. The jet from a fuel injector is under very rosive sulfuric acid. If this comes into contact
high pressure, and has considerable penetration with your skin, wash at once with soap and a lot
ability; fuel can force its way deep into body tis- of water. If you get battery acid in your eyes,
sues and cause serious injury. Risk of blood flush at once with a generous amount of water,
poisoning (septicemia). and get medical assistance at once.
All fuels, and many chemicals, are flammable. Stop the engine and cut the system current with
Make sure that open flames or sparks can not the main switch(es) before doing any work on
set them alight. Petrol (gasoline), some thinners the electrical system.
and hydrogen gas from batteries are extremely
flammable and explosive when mixed with air in The clutch must be adjusted with the engine
the correct ratio. Do not smoke! Provide good shut off.
ventilation and take the necessary precautions
before you start welding or grinding in the vicini-
ty. Always have a fire extinguisher easily avail-
able near the workplace.

The existing lugs on the engine/reverse gear the lifting devise and other who makes sure that
should be used for lifting. Always check that the components move freely and are not damaged
lifting devises are in good condition and that during lifting.
they have the correct capacity for the lift (the When you work aboard a boat, always make
weight of the engine plus the reverse gear and sure that there is enough space for disassembly
extra equipment if installed). where you are working, with no risk for personal
The engine should be lifted with a customized or or material damage.
adjustable lifting boom for safe handling and to
avoid damaging components on top of the en- Components in the electrical system, the igni-
gine. All chains or cables should be parallel to tion system (on petrol (gasoline) engines) and
each other and should be as square as possible fuel systems on Volvo Penta products have
to the top of the engine. been designed to minimize the risks of explo-
If other equipment connected to the engine has sion and fire. The engine must not be operated
altered its centre of gravity, special lifting devis- in environments with adjacent explosive media.
es may be needed to obtain the correct balance
and safe handling. Remember the following when washing with a
Never do any work on an engine which just high pressure washer: Never aim the water jet at
hangs from a lifting devise. seals, rubber hoses or electrical components.
Never use a high pressure washer for engine
Never work alone when heavy components are cleaning.
to be dismantled, even when safe lifting devises
such as lockable blocks & tackle are used. NOTE! The fuel delivery pipes must not be bent,
Even when lifting devises are used, two people twisted or tampered with in other ways. Change
are needed in most cases. One who operates damaged fuel delivery pipes.
Only use the fuels recommended by Volvo Pen-

ta. Please refer to the instruction book. The use
of fuel of inferior quality can damage the engine.
In a diesel engine, poor fuel can cause the regu-
lation rod to bind and the engine will over-rev,
entailing a strong risk of personal injury and ma-
chinery damage. Poor fuel can also lead to high-
er maintenance costs.

General information
About the workshop manual Spare parts

This workshop manual contains technical data, de- Spare parts for electrical and fuel systems are subject
scriptions and repair instructions for the MS2 reverse to various national safety requirements such as the
gear, all versions, and sail boat drive 120S, all ver- US Coast Guard Safety Regulations. Volvo Penta
sions. The repair methods for the reverse gear and Original Spares comply with these requirements.
drive (upper gear) are essentially the same. Where No damage whatever, occasioned by use of non-origi-
they differ, this is noted. nal Volvo Penta spares for the product, will be com-
In all correspondence, the product designation and se- pensated by the warranty offered by Volvo Penta.
rial number must be specified.
The workshop manual has been primarily prepared for
Volvo Penta service workshops and their qualified per-
sonnel. This assumes that people who use the Manu-
al have basic knowledge of marine drive systems and
can do the tasks of a mechanical or electrical nature
associated with the trade.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on
product data which was available up to the date on
which the manual was printed. Any material changes
introduced into the product or service methods after
this date are notified by means of Service Bulletins.

Repair instructions
The work methods described in the workshop manual

apply to work in a workshop environment. For this rea-
Our common responsibility
son, the reverse gear and drive are lifted out of the Each engine consists of a large number of collaborat-
boat. ing systems and components. Any deviation of a
The warning signs which occur in the workshop manu- component from its technical specification can dra-
al (please refer to “Safety information” for their mean- matically increase the environmental impact of an oth-
ings) erwise good engine. For this reason, it is extremely
important that specified wear tolerances are main-
WARNING! tained, that systems with adjustment facilities are cor-
rectly adjusted and that Volvo Penta Original Spares
IMPORTANT! are used for the engine. The times noted in the engine
maintenance schedule must be observed.
NOTE! Some systems, such as components in the fuel sys-
tem, may require special competence and special test
are not comprehensive in any way, since we can not
equipment. For environmental reasons etc., some
foresee everything, since service work is done in high-
components are sealed at the factory. It is only per-
ly varying circumstances. For this reason, all we can
missible to work on sealed components if you are au-
do is to point out the risks which we believe could oc-
thorized to do such work.
cur due to incorrect work in a well-equipped workshop,
using work methods and tools tested by us. Remember that most chemical products, incorrectly
used, damage the environment. Volvo Penta recom-
In the workshop manual, all tasks for which there are
mends the use of biodegradable degreasers whenever
Volvo Penta special tools, are done using these tools.
engine components are de-greased, unless otherwise
Special tools are specially prepared to permit the saf-
specified in the workshop manual. When working
est and most rational work methods possible. For this
aboard a boat, be careful to ensure that oils, wash
reason, it is the responsibility of the person who uses
residue etc. are processed for destruction, and are not
other tools or other work methods than those recom-
inadvertently discharged with bilge water into the envi-
mended by us, to ensure that there is no risk of per-
ronment.
sonal injury or material damage, and that they can not
cause any malfunctions.
In some cases, special safety regulations and user in-
structions are available for the tools and chemicals
mentioned in the workshop manual. These rules must
always be observed, so there are no special instruc-
tions about this in the workshop manual.
The majority of risks can be prevented by taking cer-
tain elementary precautions and using common
sense. A clean workplace and a clean engine elimi-
nate many risks of both personal injury and malfunc-
tion.
Above all, when work on fuel systems, lubrication
systems, induction systems, turbocharger, bearing
caps and seals is done, it is extremely important that
no dirt or other kinds of foreign particles are able to
get in, since this would otherwise cause malfunctions
or shortened repair life.

Tightening torque Lock nuts

The tightening torques for vital fasteners, which Disassembled locknuts shall not be re-used, they
should be tightened with a torque wrench, are listed in shall be replaced by new ones, since the locking prop-
“Specifications: Tightening torque” and noted in the erties are impaired or lost when the nut is used sever-
job descriptions in the book. All torque specifications al times. On locknuts with plastic inserts, such as Ny-
apply to clean screws, screw heads and mating faces. lock®, the tightening torque specified in the table must
The torque specifications apply to lightly oiled or clean be reduced if the Nylock® nut has the same nut height
screws. If lubricants, locking fluids or sealants are as a standard fully metallic hexagonal nut. Reduce the
needed on a fastener, the type of preparation to be tightening torque by 25% if the screw dimension is 8
used will be noted in the job description and in “Tight- mm or greater. On Nylock® nuts with higher nut
ening Torques”. Where a particular torque value is not height, where the fully metallic thread is as high as on
specified for any fastener, the general tightening a standard hexagonal nut, use the tightening torques
torques in the table below shall apply. The torque in the table.
specification is a target value and the fastener does
not need to be tightened with a torque wrench.
Strength classes
Dimension Tightening torque Screws and nuts are sub-divided into different
Nm lbf ft strength classes. Classification is indicated by mark-
ings on the screw head. A marking with higher number
M5 6 4.4 indicates stronger material. For example, a screw
M6 10 7.4 marked 10-9 is stronger than one marked 8-8. For this
M8 25 18.4 reason, when fasteners are removed, it is important
M10 50 36.9 that the screws are put back in the correct places
M12 80 59.0 when they are re-installed. When you change screws,
M14 140 103.3 please check the spare parts catalogue to ensure that
the correct versions are obtained.
Torque-angle tightening
In torque/angle tightening, the fastener is tightened to
the specified torque, and tightening then continues
through a pre-determined angle. Example: for 90° an-
gle tightening, the fastener is turned a further 1/4 turn
in one sequence, after the specified tightening torque
has been achieved.

Sealants Anaerobic preparations

These preparations harden in the absence of air.
Several different types of sealant and locking fluids These preparations are used when two solid compo-
are used on the engine. The properties of the prepara- nents, such as two cast components, are fitted to-
tions differ, and they are intended for different gether without a gasket. Common uses are also to
strengths of fastener, temperature, resistance to oil lock and seal plugs, stud threads, taps, oil pressure
and other chemicals, and for the different materials monitors etc. Hardened anaerobic preparations are
and gap thicknesses found in the engine. glassy and for this reason, the preparations are col-
It is therefore important that the correct types of seal- ored to make them visible. Hardened anaerobic prepa-
ant and locking fluids are used on the fasteners where rations are highly resistant to solvents, and old com-
needed, to give a fully acceptable service result. pound can not be removed. On re-installation, de-
grease carefully and then apply new sealant.
In the workshop manual, the relevant chapters contain
notes on the preparations used in our production. The following anaerobic preparations are mentioned in
the workshop manual:
In service work, the same preparations or preparations Volvo Penta part no. 1161053-2, Loctite® 243.
of corresponding properties, but of other makes, shall
be used.
When sealants and locking fluids are used, it is impor- The following polymer preparations are mentioned in
tant that the surfaces are free from oil, grease, paint the workshop manual:
and rust-protection, and that they are dry. Volvo Penta part no. 1141570-0 (white)
Always observe the manufacturer’s instructions about
temperatures of use, hardening times and other in- NOTE! Loctite® is a registered trademark belonging to the Loctite
structions for use of the product. Corporation, Permatex® is a registered trademark belonging to the
Permatex Corporation.
Various basic types of preparation are used, charac-
teristics are as follows:
RTV preparations (Room Temperature Vulcanizing).
These are mostly used together with gaskets, such as
sealing gasket joints, or are brushed on gaskets. RTV
preparations are fully visible when the component has
been disassembled; old RTV compound must be re-
moved before the joint is sealed again.
The following RTV preparations are mentioned in the
workshop manual: Volvo Penta part no. 840879-1,
Loctite® 574; Volvo Penta part no. 1161099-5, Perma-
tex® No.3. Remove old sealant with denatured alcohol
in all cases.

Safety rules for fluorocarbon • Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles.
rubber • Handle the removed seal in the same way as cor-
Fluorocarbon rubbers are commonly used materials in rosive acid. All residues, including ash, can be
seal rings on shafts, O-rings etc. strongly corrosive. Never use compressed air to
blow components clean.
When flourocarbon rubber compounds are exposed to
high temperatures (above 572°F), hydrofluoric acid • Put the remains in a plastic container, seal it and
can be formed, which is highly corrosive. Skin contact apply a warning label. Wash the gloves under run-
can cause severe chemical burns. If it splashes in ning water before you take them off.
your eyes, this can cause severe chemical burns. If The following seals are most probably made from fluo-
you breathe the fumes, you can suffer lung and bron- rocarbon rubber:
chial injury.
Seal rings for the crankshaft, camshaft, drive shafts.
WARNING! Be very careful when working on O-rings, irrespective of where they are installed.
engines which have been exposed to high tem- O-rings for cylinder liner sealing are almost always
peratures, such as overheating caused by a sei- made of fluorocarbon rubber.
zure or fire. Seals must never be cut with a
flame torch during disassembly, or burned in un-
controlled circumstances afterwards. Please note that seals which have not been ex-
posed to high temperature can be handled normal-
ly.

Special tools
884078 884143 884161 884264 884611 884637
884679 884720 884721 884723 884724 884725
884726 884728 884729 884730 884731 884732
884078-7 Extractor. Disassembly of output shaft 884724-6 Hook wrench. Removal, assembly of
884143-9 Shaft for expander 884750. nuts.
884161-1 Slide hammer. Removal of propeller shaft 884725-3 Drift Removal, assembly of retention ring
halves.
884264-3 Sleeve for vertical shaft. Can be replaced
by 884830 884726-1 Expanding mandrel. Removal of outer
bearing race.
884611-5 Extractor. Used together with 884161
884728-7 Drift Removal of bearings, gear wheels.
884637-0 Sleeve. Disassembly of tubular shaft
MS2V 884729-5 Drift Installation of bearing.
884679-2 Drift Installation of seal ring 884730-3 Drift Disassembly of output bearing hous-
ing.
884720-4 Extractor. Removal of outer bearing race.
Used together with 884761 884731-1 Drift Installation of bearing.
884721-2 Extractor. Removal of outer bearing race. 884732-9 Drift Installation of bearing.
Used together with 884761
884723-8 Drift Splitting of rear bearing housing
10

Special tools
884733 884735 884736 884738 884739
884743 884746
884744 884747
884745 884748 884750 884752 884753
884754 884755 884756 884757 884761
884733-7 Drift. Installation of bearings, removal of 884752-7 Drift. Installation of seal rings in rear
gear wheels. bearing housing.
884735-2 Tool. Checking of marking pattern. 884753-5 Fixture, 120S
884736-0 Wheel. For checking pre-load. 884754-3 Drift. Installation of bearing.
884738-6 Brake tool. Checking of marking pattern. 884755-0 Drift. Installation of roller bearing, lower
884739-4 Counterhold gear housing.
884743-6 Removal of vertical shaft. Used together 884756-8 Drift. Installation of outer bearing race in
with 884744 and 884745 rear bearing housing.
884746-9 Installation of needle roller bearing. Used 884757-6 Drift. Installation of outer bearing race in
together with 884747 and 884748 lower gear housing.
884750-1 Expanding mandrel. Removal of outer 884761-8 Extractor. Used together with tool 884721
bearing race.
11

Special tools
884766 884830 884833 884834
884835 884836 884855 884856 884857
884859 884860 3858852 9991801
884766-7 Press. For pressing down the vertical 884857-4 Plate. Removal of bearing race from cov-
shaft. Used together with 884753 er, MS2V
884830-1 Sleeve for vertical shaft. Can be replaced 884859-0 Shaft, MS2V
by 884264 884860-8 Hook wrench. Installation, removal of nut
884833-5 Drift. Installation of outer bearing race. on tubular shaft, MS2V
884833-5 Drift. Removal of bearing in cover, MS2V 3858852-1 Counterhold. Removal of pinion nuts.
884834-3 Plate. Installation of bearing race and 120S
seal ring, MS2V 9991801-3 Standard shaft
884835-0 Sleeve. Installation of rolling bearing on
tubular shaft, MS2V
884836-8 Ring. Installation of rolling bearing on pin-
ion, MS2V
884855-8 Plate. Installation of bearing race in cov-
er, MS2V
884856-6 Plate. Removal of bearing race from gear
housing, MS2V
12

Other special equipment
9999683
9985472 9999701
9985494
3810152
9985472-1 Depth micrometer Chemicals

9985494-5 Spring balance
RTV preparations:
9999683 -7 Dial gauge Volvo Penta part no. 840879-1, Loctite® 574;
9999701-7 Micrometer Volvo Penta part no. 1161099-5, Permatex® No. 3.
3810152-3 Equipment for pressure testing drives Anaerobic preparations:
Volvo Penta part no. 1161053-2, Loctite® 243.
Polymer preparations:
Volvo Penta part no. 1141570-0 (white)
Water resistant grease:
Volvo Penta part no. 828250-1
13

Design and function
Reverse gear MS2
Forward position
Reverse position
14

Design and function
Sailboat drive 120S
Forward position
Reverse position
15

Design and function
History, sail boat drives

Model 120S Model 120S-B
1
1
2
2
3
1. Adapter, loose 1. Adapter, integrated into

2. Rubber sleeve gear housing
3. Gasket 2. Adapter plate
Model 120S-C Model 120S-D
1. Dipstick, new version New material in slid-

Production rationalization ing sleeve
changes New color, gray
16

Design and function
Model 120S-E
1. Rubber mounting, new version

Shot blasted gear wheels
Fully synthetic oil
17

Disassembly - upper and lower gear housings,
sailboat drive
4
1. Clean the outside of the reverse gear and drive. 3. Split the drive and save the spacer ring (1), shims,
Remove the drain plug and drain the oil. Remove the (2) and gasket (3).
screws in the adapter section. Four socket cap
screws on the inside and two on the outside. Model 120S
Remove the rubber sleeve (4).
NOTE! The rubber sleeve must be changed every 5
years.
2. Remove the locking wire from the four screws.

Then remove all the screws, 10 pcs below the division
line of the drive.
Model 120S:
Also remove the four nuts on the front and rear of the 4. Model 120S
upper gear. Remove the adapter section. Tap carefully with a
plastic or rubber faced mallet. Change the O-ring (1).
18

Disassembly - upper and lower gear housings, sailboat drive
5. Models 120S-B, -C, -D, -E 6. Remove the slipping clutch (1).

Remove the adapter plate and remove the rubber Check that the clutch is not damaged.
sleeve.
Prize carefully. Use a tool with no sharp edges.
Remove and scrap the O-ring on the sleeve of the
adapter plate.
Repair of the lower gear housing, please refer to page
61.
Reverse installed drive (180°)
Remove and scrap the O-ring (1) on the adapter plate.
19

Repair - MS2 reverse gear and
upper gear housing, sailboat drive
Gear shift mechanism,
disassembly
1. Disassemble the gear shift mechanism, 2 screws.
3. Drive in the spring pin so far that the pin (1) is re-
leased.
1
2. Remove the dog (1) and spring (2). 4. Pull the pin out.
20

Repair - MS2 reverse gear and upper gear housing, sailboat drive
Gear shift mechanism,

assembly
884679
5. Pull the eccentric piston out.
8. Oil all components before assembly starts. Install

the seal ring. Align the side with the spring inwards.
Use tool no. 884679 or a pipe whose diameter is
slightly smaller than the outer diameter of the seal
ring.
6. Shake the pin out of the eccentric piston.

3
1
2
9. Install the eccentric piston (1) and press the pin (2)
in. Lock it with the spring pin (3).
7. Remove the seal ring with a screwdriver. Clean all

components of the gear shift mechanism and check
for wear. Change components as necessary.
21

12. NOTE! During assembly, the dog must be aligned

as shown in the illustration. The gear shift mechanism
will not work if the dog is turned the other way round.
10. Put a new O-ring (1) on the gear shift mechanism.

Install the spring (2) and dog (2).
1
13. Undo screw (1) about 2 turns and install the gear
shift mechanism in the housing. Check the position of
the dog. The screw must be displaced backwards, i.e.
to the right in the illustration.
Disassemble the screw, remove the shim and re-tight-
en the screw. It will now be impossible to turn the out-
put shaft round.
11. Put the gear shift mechanism in a position be- Install one shim at a time until the shaft can be turned
tween forwards and neutral. The pin should rest in one without resistance.
of the “notches”.
After adjustment, apply sealant with Volvo Penta part
no. 1141570-0 to the shims and screw, then tighten
the screw.
22

Reverse gear/upper gear

housing, disassembly
16. Drive, 120S, 120S-B, -C, -D, -E

Remove the cooling water valve.
Remove the gear shift cable holder and the rear cover
with rubber mounting.
14. Disassemble the double bearing seal housing, 6
screws. Change the O-ring on the cover.
NOTE! Tap carefully with a plastic-faced mallet etc.
Do not use a screwdriver to prize between the housing
and the bearing seal housing. This can damage the
sealing surface.
Save the shims.
15. Reverse gear MS2. 17. Unscrew the oil filler cap and remove the dipstick
Disassemble the rear bearing housing. 6 screws. Also and outer casing.
tap carefully here with a plastic-faced mallet, until the Model 120S
bearing housing comes away from the reverse gear. Also remove the throttle control bracket. The two front
Save the shims. screws on the bearing cover are removed later.
23

884725
18. Reverse gear MS2. 20. Turn the reverse gear/upper bearing housing over
Turn the reverse gear upside down and remove the and put it in a press. Put tool no. 884725 over the ver-
bottom cover. 4 screws. tical shaft, so that it rests on the large washer. Press
the washer down, to release the retention ring halves.
Scrap the O-ring.
Remove the halves.
19. Reverse gear MS2. 21. Remove the cover. A lock washer, a large spring
Remove the slipping clutch. Remove the sleeve bear- washer, three small spring washers and possibly one
ing from the vertical shaft. In some cases, the bearing or two spacers will come away with the cover. In addi-
might remain in the slipping clutch. tion, the ball bearing and gear wheel are fixed to the
NOTE! If there is any fault in the slipping clutch, it cover.
must be replaced as a unit. The clutch is only avail- NOTE! Remove the needle roller bearing. The bearing
able as a complete spare part. might remain on the shaft.
Change the roller bearing as necessary. Please refer
to items 73-83.
24

2
1
5
4
3
22. Pull up the sliding sleeve with a turning motion. 25. Remove the lock washer (1), the large domed
washer (2), the three smaller domed washers (3), any
spacer washers (4) and the needle roller bearing (5).
9991801
23. Reverse gear MS2

Press the outer bearing race out, using the vertical
shaft. Keep hold of the vertical shaft, to prevent it
from falling and being damaged. Save any shims be-
neath the bearing race.
NOTE! On the sailboat drive, the shaft is loose since
there are no bearings.
884733
884725
26. Press the gear wheel out. Use tool no. 884733 in
combination with standard shaft 9991801.
24. Put the vertical shaft in a press and press the

large washer with tool no. 884725, to release the re-
tention ring halves. Remove the halves.
25

Input bearing seal housing,

disassembly
27. Remove the circlip, using circlip pliers.
29. Fix the bearing housing in a vise. Press a screw-

9991801 driver into the seal ring. Then place a thick piece of
rubber or leather between the screwdriver and the
bearing housing casting. Prize out the seal ring and
scrap it.
884728
884724
28. Press out the taper roller bearing. Use tool no.
884728 and standard shaft 9991801. Then wash the
gearbox housing out.
30. Fix the gear in a vise. Use soft facings on the vise
jaws. Then disassemble hook nut with tool no.
884724.
26

9991801
884728
33. Drive out the small outer bearing race, using tool
884728 and shaft 9991801.
NOTE! Be careful to offer up the tool against the bear-
31. Drive or press the input shaft out of the bearing ing race.
housing. Use a plastic-faced mallet or similar, to avoid
damaging the end of the shaft and the splines.
884143
884726
32. If the roller bearings are damaged, they must be 34. Remove the roller bearing from the input shaft, us-
changed. Remove the large outer bearing race from ing a knife-type extractor. Then remove the washer.
the bearing housing, using tool no. 884726 and shaft Clean the components and check for wear, replace
884143. worn and damaged components.
27

Input bearing housing, 1
installation.
884732
37. Put the metal sheet (1) on the drive shaft.
35. Press the small outer bearing race into the bearing
housing. Use tool no. 884732.
9991801 884729
884731
36. Press the large outer bearing race into the bearing 38. Press the large roller bearing onto the drive shaft.
housing. Use tool no. 884731 and shaft 9991801. Use tool no. 884729.
28

884729
9985494
2.25-4.05 lbf
39. Place the drive shaft in the bearing housing and 41. Test the pre-load with a spring balance. Fix the
press the small roller bearing on, using tool no. gear wheel or shaft in a vise with soft jaw pads. Wind
884729. a string round the bearing housing, and pull with spring
NOTE! Do not press the bearing until it bottoms. A balance no. 9985494.
certain amount of clearance must be left. When the Pre-load: 10-18 N (2.25-4.05 lbf)
nut is torqued to the correct value, the bearing hous-
Not enough pre-load: Increase the torque on the nut.
ing is pre-loaded and the clearance disappears.
Too much pre-load: Reduce the torque on the nut.
884724
884757
40. Screw a new nut on. Turn the chamfer inwards. 42. Oil and install the seal ring carefully, to avoid
NOTE! The nut must always be changed. damage to the seal lip. Use tool no. 884757 to drive
the ring in.
Use tool no. 884724. Start off with low torque. Please
refer to the following chapter.
29

Upper bearing housing,

disassembly 9991801
884728
9991801
884733
884723
884723
43. Put the bearing housing in tool no. 884723 and 45. Put the bearing housing in tool no. 884723 and
press the gear wheel out. Use tool no. 884733 and press roller bearing out of the bearing housing. Use
shaft 9991801. Save any shims. tool no. 884728 and shaft 9991801.
44. Remove the circlip, using circlip pliers.
30

Upper bearing housing,

assembly
884731
9991801
884731
46. Press the upper roller bearing into the bearing 48. Put shims on the gear wheels for the upper bear-
housing. Use tool no. 884731 and shaft 9991801. ing housing and gear housing. Start off with 0.50 mm
NOTE! The narrow ring on the bearing, at the arrow, for each gear wheel. This is a value which is based on
should face the bearing housing. Make sure that the experience.
bearing does not go in crookedly.
9991801
884728
47. Install the circlip, using circlip pliers. Turn the 49. Press the gear wheel into the gear housing. Use
chamfered side down, towards the gear housing. tool no. 884728, shaft 9991801 and 884739 as a sup-
Make sure that the circlip is securely seated in the port for the inner race.
groove.
31

Reverse gear MS2

Output gear housing,
9991801
disassembly
884728
884739
50. Press the gear wheel into the upper bearing hous-
ing. Use tool no. 884728, shaft 9991801 and 884739
as a support for the inner race.
52. Remove the nut.

Socket size: 27 mm
884078
51. Install the upper bearing housing on the reverse

gear.
53. Disassemble the propeller shaft flange. Use tool

no, 884078, wrench dimension 19 mm, or a claw pull-
er.
Pull the seal ring off the propeller shaft flange.
32

1
2
884730
54. Press the output shaft out of the bearing housing. 56. Remove the O-ring (1) and ball bearing (2) from
Use tool no. 884730. the bearing housing.
55. Remove the seal ring. Use a screwdriver or similar 57. Remove the ferrule (1) from the output shaft.
tool.
NOTE! Use rubber or leather to protect the edges of
the bearing housing.
Clean off all traces of sealant.
33

58. Press the shaft out from the roller bearing. Use a 60. Check that the cooling water pipe is in good condi-
knife puller. tion. Change as necessary.
Remove the screw and lift the manifold off.
884143
884726
59. Remove the outer bearing races from the output 61. Remove the O-rings from around the cooling water
bearing housing. Use tool no. 884726 and shaft pipe and screw hole. The O-ring for the screw hole is
884143. mounted on the screw.
Press the cooling water pipe out from the bearing
housing.
Clean off all traces of sealant.
34

Reverse gear MS2

Output gear housing,
assembly
9991801
2
884731
1
64. Install the cooling water pipe and install the two
larger O-rings (1). Press the small O-ring (2) onto the
screw.
62. Install one of the outer bearing races in the bear-

ing housing. Use tool no. 884731 and shaft 9991801.
NOTE! Make sure that the bearing race does not go in
crookedly.
884726
884731
65. Apply sealant, Volvo Penta part. no. 840879-1 on

the mating face against the bearing housing.
Install the cooling water union. Check that the O-ring
is correctly aligned. Tighten the screw.
63. Turn the bearing housing over and press in the

other bearing race. Use tool no. 884731 and shaft
9991801.
35

884729
884729
66. Press a roller bearing onto the output shaft. Use 68. Place the drive shaft in the bearing housing and
tool no. 884729. press the other roller bearing on, using tool no.
884729.
NOTE! Do not press the bearing until it bottoms.
Some clearance must be left. When the nut is torqued
to the correct value, the bearing housing is pre-loaded
and the clearance disappears.
67. Install a new ferrule (1). 69. Apply sealant, Volvo Penta part. no. 840879-1 on
NOTE! Always use a new ferrule when the output the mating face of the seal ring against the bearing
shaft has been removed from the housing. housing.
Install the seal ring in the bearing housing. Press the
outer diameter of the seal with a mandrel.
Wipe some grease, Volvo Penta part no. 828250-1 on
the ring.
36

Reverse gear MS2

Lower bearing cover,
disassembly
1
70. Put on O-ring (1) and thread seal ring (2) on.
Install the propeller shaft flange and install a new nut.
Tighten the nut.
72. Disassemble the outer bearing race with tool no.
NOTE! Start off with low torque and check with a
884720.
spring balance. Please refer to item 71.
Remove the shim and the O-ring.
9985494
1.91-3.60 lbf
71. Use spring balance 9985494 to check that the cor-

rect pre-load has been obtained.
Pre-load: 8.5-16.0 N (1.91-3.60 lbf)
Tighten the nut progressively until the correct pre-load
has been obtained.
37

Reverse gear MS2 Reverse gear MS2. Slipping

Slipping clutch, clutch/lower bearing cover,
disassembly assembly
884733
73. When the bearings need to be changed. Press the 75. Press the small ball bearing onto the slipping
small ball bearing off the slipping clutch. Use a man- clutch. Use tool no. 884733.
drel and knife extractor.
76. Preferably use the shims which were installed pre-

884729 viously, if only new bearings have been installed. In
other cases, the shim thickness can be calculated as
in items 77–84.
Calculate the shim thickness for the small bearing
race in the slipping clutch. The housing is stamped
with a D dimension and an E dimension.
Let us assume that the D dimension = 88.82 mm and
the E dimension = 61.30 mm.
NOTE! The D dimension is based on 88.00 and only
the decimals are stamped. The E dimension is based
on 61.00, to which the stamped value should be add-
ed.
Thus: 88 + 0.82 = 88.82 and 61.00 + 0.30 = 61.30.
74. Press the large ball bearing off the slipping clutch.
Use a knife extractor and tool no. 884729. The example below shows how the shim thickness is
calculated.
Example:
D = 88.82 NOTE! only 82 is stamped
E = 61.30 NOTE! only 30 is stamped
D–E = 27.52
38

77. Assume that the marking on the gear wheel =

65.00 mm. Only 00 is stamped on the gear wheel.
Put the outer bearing race on and measure the depth
of the gear wheel and the small roller bearing, as
79. Place the shims, as calculated, in the housing. In
shown in the illustration. For example, 37.10 mm.
this case, they are 0.40 mm.
The marking on the gear wheel is 65.00 mm and we
have measured the gear wheel + bearing to 37.10
mm. This gives us 65.00–37.10 = 27.90 mm.
Since D–E = 27.52 mm, this gives the shim thickness
27.90–27.52 = 0.38 mm.
884732
884732
80. Press the small bearing race into the housing. Use
tool no. 884732.
884732
78. Press the large ball bearing onto the slipping

clutch. Use tool no. 884732 and tool no. 884733 under
the small gear wheel.
Use the original shims when only new ball bearings
have been installed. In other cases, the shim thick-
ness must be calculated as in items 76–77.
39

83. Measure the cover on the inside (B) down to the

shim seat. Then measure the cover on the outside
(C).
81. Put the slipping clutch into the housing and place Example:
the outer bearing race loose on top of the bearing.
S = (C–B)–A, where S is the shim thickness.
First press the bearing race, and turn the gear wheel
about 10 turns. The ensuing measurement A becomes
2.5 mm, for example.
We now measure distance B, which becomes 16.05
mm, for example. We then measure distance C, which
9985474 becomes 18.10 mm, for example.
This gives: C–B = 18.10-16.05 = 2.05 mm.
This should be subtracted from the A dimension,
which we measured as 2.5 mm.
2.50 -2.05 = 0.45 mm
NOTE! To obtain the correct pre-load, shims with a
thickness of 0.45 + 0.05 = 0.50 mm should be put in
the cover.
82. Calculate the shim thickness as follows:

Press the outer bearing race with your fingers and turn
the gear wheel (pinion) round about 10 turns, to re-
move any slack in the rollers.
Measure with a depth micrometer 9985474 from the
housing plane, down to the bearing race (A).
40

Reverse gear MS2

Flank clearance
84. Put in shims of the calculated thickness, plus a

further 0.5 mm in the cover and install the bearing
race. Put a plate on the bearing race and press.
NOTE! Align the bearing race carefully, to ensure that 86. Put an 0.20 mm shim on the outgoing bearing
it does not go in crookedly. housing, and install it on the housing.
The extra shim thickness will be removed later, when
the flank clearance has been tested.
9999683
87. Measure the flank clearance with a dial gauge and

rocker 9999683.
Flank clearance: 0.10-0.25 mm (0.004-0.010")
Adjust the flank clearance if necessary.
Not enough clearance:. Add more shims to the out-
put bearing housing.
Not enough clearance:. Reduce the shim thickness
in the bearing housing.
85. Install the cover on the housing, and tighten it with
four screws.
41

Reverse gear MS2

Marking pattern
884735
90. If the marking pattern is similar to B, the output

shaft must be moved inwards by removing shims from
the bearing housing.
If the flank clearance is too small after this operation,
the lower drive must be moved downwards by reduc-
ing the shim thickness underneath the bearing race in
the cover.
NOTE! To retain the preload in the lower gear wheel
bearing, the shim thickness for the upper bearing out-
88. Remove the output bearing housing and apply a er race must be increased to the same extent.
thin layer of marking dye to the lower gear and the
gear wheel on the output shaft.
Install the bearing housing again and turn tool no.
884735 round in both directions, at the same time as
the propeller shaft flange is braked.
91. If the marking pattern is similar to C, move the

output shaft and lower gear wheel in the opposite di-
rections to what was specified in item 74.
89. Remove the output bearing housing and check
whether the marking pattern on the gear wheel corre-
sponds with marking pattern A, which is correct. The
pattern should be located at the centre of the tooth, in
height, but displaced towards the small end.
42

Reverse gear MS2

884720
Preload
884736 3.37-6.74 lbf
9985494
884735
92. When the correct flank clearance and marking pat-

tern have been obtained, disassemble the output bear-
ing housing, lower bearing cover and slipping clutch.
Wash off the marking dye. Then disassemble the out-
er bearing race in the cover, using tool no. 884720.
94. Install the slipping clutch and tighten the cover.
Turn the housing over and install tools 884735 and
884736. Turn the shaft round with tool no. 884735 in
both directions, to make the bearing “seat” itself.
Wind a string round tool no. 884736 and measure the
pre-load with a spring balance, 9985494.
Preload, new bearings: 15-30 N (3.37-6.74 lbf).
Too much pre-load: Reduce the shim thickness in
the upper cover.
Not enough pre-load: Increase the shim thickness in
the upper cover.
884833
99991801
884728
93. Remove the extra 0.5 mm shim thickness which

was installed in item 84.
Then put the calculated shim thickness in the lid and
install the bearing race. Press, using tool no. 884833.
95. When the correct pre-load has been obtained, re-

move the lower bearing cover, the slipping clutch and
the small outer bearing in the gear housing.
Use tool no. 884728 and shaft 9991801.
NOTE! Save the shims.
43

Gear housing Checking the marking pattern

and gear flank clearance
96. Install the lower roller bearing in the housing.

NOTE! Align the narrow ring by the arrow upwards.
The ring has a sharp edge which would cut into the 98. Try installing an 0.40 mm shim in the input bearing
casting if it were installed crookedly. For this reason, housing.
be careful to ensure that the bearing is correctly Install the bearing housing on the housing.
aligned in the bearing seat.
Use tool no. 884731 and shaft 9991801.
2
97. Install the circlip, using circlip pliers.
NOTE! The chamfered side must face upwards. Make
sure that the circlip is securely seated in the groove.
99. Put the vertical shaft, with needle roller bearing, in

the housing. The lower needle roller bearing is retained
by a rubber band or O-ring.
The illustration shows the location of the bearing (1)
and O-ring (2).
44

9999683
884738
100. Measure the gear flank clearance on both gear 102. Apply marking dye to the gear wheel. Turn the in-
wheels, using a dial gauge 9999683. Press the gear put shaft round in the direction of engine rotation. Pro-
wheel downwards. tect the splines on the input shaft with a rubber sheet
The clearance should be 0.10-0.25 mm (0.004-0.010") etc.
If the flank clearance is not enough, further shims Brake with tool no. 884738.
should be added to the input bearing housing.
If the flank clearance is too great, reduce the thick-
ness of the shims.
NOTE! It may be necessary to reduce the shim thick-
ness below the gear wheel.
103. Check whether the marking pattern corresponds

with marking pattern A, which is correct. The pattern
9999683
should be located at the centre of the tooth, in height,
but displaced towards the small end.
NOTE! Consideration can not be given to the marking
pattern on the input pinion, since this is influenced by
both gear wheels.
101. Turn the gear housing upside down. Press the

other gear wheel down and do the same operations as
in the previous item.
45

Final assembly
104. If the marking pattern resembles B, the shim

thickness in the input bearing housing should be re-
duced. If the gear flank clearance becomes too small, A
the gear wheels must be disassembled.
Remove the shims from the gear wheels to the same
extent, and re-install the gear wheels.
Apply marking dye to the gears again, turn them round
and check the contact patches.
106. Measure distance (A) between the bearing and

gear wheel hub. This distance should be between 3.4
and 3.8 mm (0.13 and 0.15").
If the distance is 4.10 mm (0.161"), for example, a
spacer washer must be inserted.
If the distance exceeds 4.20 mm (0.165"), two spacer
washers must be inserted.
4
3
2
1
input gear housing and gear wheel in the opposite di- 4
5
rections to what was specified in item 104.
When the correct flank clearance and marking pattern
have been obtained, the input gear housing and upper
gear housing should be disassembled, and all marking
dye washed off.
NOTE! Keep the reverse gear upside down when the
lower gear wheel is washed clean, to prevent the dye 1
from finding its way into the bearing. 2
3
107. Put a needle roller bearing (1) on the vertical

shaft.
Then put on the measured spacer washer (2), the
three domed small washers (3), the large domed
washer (4) and the lock washer (5).
46

884725
2
TOP
1
108. Put the shaft in a press. 110. Align the “TOP” marking upwards, and install
Use tool no. 884725 and press the lock washer down sliding sleeve (1) and needle roller bearing (2).
so far that the retaining ring halves can be put into the
groove.
884732
111. Put a new O-ring in the groove in the upper bear-

ing housing. Then install the bearing housing on the
housing.

Put the shaft in the housing. Put the calculated thick-
ness of shims on, followed by the outer bearing race.
Press the outer bearing race on with tool no. 884732.
47

884725
112. Measure the distance between the gear wheel 114. Press down the large washer so far that the re-
and the bearing. taining ring halves can be put in the groove.
Also refer to item 106. Use tool no. 884725.
113. Put on, from the left, the measured spacer wash- 115. Put the plain bearing (1) on the shaft and install
er, three small domed washers, a large domed washer the slipping clutch.
and the lock washer.
48


Put a new O-ring on the cover.
118. Drive, 120S, 120S-B, -C, -D, -E
Make sure that the oil drain is correctly aligned. Screw Put on a new O-ring and install the rear cover and
the cover down onto the housing. gear bracket on the upper gear.
Install the sea water valve. Use sealant, Volvo Penta
part no. 1141570 on the threads.
117. Reverse gear MS2 119. Put a new O-ring and the tested thickness of
Put on a new O-ring, put the tested thickness of shims on the input bearing housing.
shims on the output bearing housing, and then fix it to NOTE! The bearing housing can only be installed in
the housing with screws. one position, because of the hole pattern. Screw the
Turn the shaft slightly, to allow the gear teeth to bearing housing down onto the housing.
mesh. Install the gear bracket with two of the screws.
49

120. Install the gear change mechanism in the reverse

gear housing. Please refer to items 10-13.

Install the dipstick. Fill up with oil.
Please refer to Technical Data for oil volume, grade
and viscosity.
Check the oil level with the dipstick and install the oil
filler cap.
125. Drive, 120S, 120S-B, -C, -D, -E

Install the dipstick and oil filler cap.
The lower gear must be installed before the oil is put
in.
and viscosity.
50

Repair of MS2V reverse gear, angle gear
This section only refers to repair of the angle gear and

its sub-components. Please refer to the MS2 informa-
Tubular shaft,
tion for general information about the reverse gear. disassembly
1. Clean the outside of the reverse gear. Remove the

drain plug (1) and drain the oil.
3. Undo the six screws which hold the tubular shaft in

the housing, and drive out the tubular shaft with a lead
hammer etc. Save the shims between the cover and
the gear housing.
2. Undo the 4 nuts, the 2 socket cap screws and re-

move the angle gear from the reverse gear.
4. Undo the four socket cap screws which retain the

pinion in the housing, and disassemble the pinion.
Save the shims between the gear housing and the pin-
ion.
51

5. Remove the seal ring. 7. Screw two screws into the tubular shaft and fix it by
NOTE! The seal ring must always be replaced by a putting the two screw heads in a vise. Undo the tubu-
new one. lar nut with a hook wrench. When the tubular nut is re-
moved, remove the outer ball bearing as well. Please
refer to item 8.
884859
884856
6. Press the bearing race out of the housing. Use tool

no. 884856 and shaft 884859. Save the shims be-
neath the bearing race.
8. A claw extractor must be used to free the bearing

fully from the tubular shaft. Grip round the tubular nut.
52

884859
884857
884637
9. Put the tubular shaft in sleeve 884637 and press 11. Remove the bearing race from the cover. Use tool
out the tubular shaft, which also removes the crown no. 884857 and shaft 884859.
wheel and the inner roller bearing.
10. Remove the seal ring from the cover. The seal
ring must always be replaced by a new one.
53

Pinion,
disassembly
14. Remove the roller bearing from the pinion, using a

knife extractor and press.
12. Fix the pinion in a vise and undo the two nuts with
a hook wrench.
884720
884723
15. Remove the two bearing races in the pinion hous-

ing with tool no. 884720.
13. Put the pinion in sleeve 884723 and press out the
pinion, which also removes upper roller bearing.
884859
16. Remove the needle roller bearing in the pinion nut

with mandrel 884859.
54

Pinion,
assembly
884859
884732
884834
17. Install the bearing races in the pinion housing with 19. Place the pinion in the housing (turn the housing
tool 884834 and shaft 884859. so that the recessed holes for the socket cap screws
are on top). Press the other roller bearing on, using
tool no. 884732.
NOTE! Do not press the bearing until it bottoms.
Some clearance must be left. When the nut is tight-
ened, the bearing housing is pressed together and the
clearance disappears.
9985494
884732
2.25-3.93 lbf
884836
18. Install the inner roller bearing on the pinion, use 20. Apply thread locking fluid, Volvo Penta part no.
the two sleeves 884732 and 884836 . 1161053-2 on the threads of the nut and install it with
the chamfered side upwards.
Start off with low torque and check the preload with a
spring balance 9985494 and a piece of string wrapped
round the bearing housing.
Pre-load: 10,0-17,5 N (2.25-3.93 lbf).
55

Bearing and tubular shaft,

assembly
884859
21. Install a new needle roller bearing in the pinion nut,

using mandrel 884859.
Apply thread locking fluid, Volvo Penta part no.
1161053-2, on the threads and install the nut.
Tightening torque: 140 Nm (103.26 lbf ft)
22. Apply sealant, Volvo Penta part no. 1161099-5 to
the gearbox housing and install a new seal ring. Use
tool no. 884834 and shaft 884859.
Wipe some grease, Volvo Penta part no. 828250-1 on
the lip of the seal ring.
884859
884834
23. Put shims with a total thickness of 0.70 mm in the

housing and install the bearing race with tool 884834
and shaft 884859.
56

884859
884833
884834
24. Apply sealant, Volvo Penta part no. 1161099-5 to 26. Put the cover in the tubular shaft and press the
the cover and install a new seal ring. Use tool no. roller bearing on with sleeve no. 884833. Press the
884834 and shaft 884859. Wipe some grease, Volvo bearing all the way down to the step on the shaft.
Penta part no. 828250-1 on the lip of the seal ring.
884833
884859
884855
25. Install the bearing race in the cover with tool 27. Press the crown wheel on with sleeve no. 884833.
884855 and shaft 884859.
57

884860 9985494
2.25-3.60 lbf
28. Screw two screws into the tubular shaft and fix it
in a vise. Align the tubular nut with the un-threaded
section towards the crown wheel and install it with tool
no. 884860.
30. Put shims with a total thickness of 0.70 mm be-
tween the cover and the housing.
Install the tubular shaft in the housing and fix it with
two diagonally opposed screws.
Check the pre-load with a spring balance, 9985494
and a piece of string wound round the tubular shaft.
Pre-load: 10-16 N (2.25-3.60 lbf)
Too low pre-load: Increase the shim thickness under
the upper cover.
Too high pre-load: Reduce the shim thickness under
884835
the upper cover.
Check the pre-load again and continue until the cor-
rect pre-load has been obtained.
29. Press the outer roller bearing on. Use sleeve

884835.
58

Flank clearance,
checking
9999701
33. Remove the pinion and check whether the marking

pattern on the pinion corresponds with illustration A,
which is correct.
The pattern should be located at the centre of the
tooth, in height, but displaced towards the narrower
end.
31. Install the pinion in the gearbox housing, without
an O-ring and with a total shim thickness of 0.35 mm
between the pinion and the gearbox housing.
Install two of the socket cap screws, diagonally op-
posed. Torque to 9 Nm (6.64 lbf ft).
Check the flank clearance on the nut, as in the illus-
tration. Use dial gauge 9999701 and a stand.
Flank clearance: 0.10-0.25 mm (0.004-0.010") B
Adjust the flank clearance if necessary, by adding or
removing shims from between the pinion and the gear- 34. If the marking pattern is similar to B, move the
box housing. crown wheel down.
NOTE! To retain the pre-load on the tubular shaft, the
thickness of shims between the cover and the gear-
box housing must be reduced to the same extent.
32. Remove the pinion and apply a thin layer of mark-
er dye to the crown wheel and pinion. If the flank clearance is too small after this operation,
move the pinion upwards by increasing the thickness
Install the pinion again and turn it round in both direc- of the shims between the gearbox housing and the
tions. Brake the tubular shaft at the same time. pinion.

crown wheel and pinion in the opposite directions to
what was specified in the previous item.
When the correct flank clearance and marking pattern
has been obtained, wash off all marker dye from the
crown wheel and pinion.
59

Angle drive,
final assembly
36. Install the pinion in the gearbox housing together

with a new O-ring.
37. Install the tubular shaft in the gearbox housing to-

gether with a new O-ring.
Install a new seal ring on the tubular shaft.
38. Assemble the angle drive and reverse gear.

Use a new O-ring.
Tightening torque: 28 Nm (20.65 lbf ft).
60

Repair - lower gear housing, sailboat drive
Repair - lower gear housing,

sailboat drive
Disassembly of the drive

1
1. Clean the outside of the drive. Remove the propel- 3. Separate the upper and lower gear housings. Re-
ler and remove the fishing line cutter. Unscrew the move and scrap the gasket at the division line.
drain plug and drain off the oil.
Remove the shims. Note the number of shims.
Remove the spacer ring (1). Tap the shaft lightly with
a plastic-faced hammer.
884264
884830
884753
2. Remove the locking wire from the four socket cap 4. Fix fixture 884753 in a vise. Install the lower gear
screws below the division line of the drive, two on housing in the fixture, so that the four pins fit the cut-
each side. Throw the wire away. outs in the shaft nut. Fix the gear housing with four of
the socket cap screws.
Then remove all the (10) screws.
Install tool 884264 or 884830 on the shaft. Use a
17 mm socket and undo the nut by turning the shaft
clockwise.
NOTE! Only turn enough to make the nut just come
into contact with the fixture.
Remove the fixture from the lower gear and screw the
nut off the shaft.
61

3858852
5. Remove the zinc ring. 8. Lock the pinion nut with tool no. 3858852. Press
the shaft down and make sure that the pinion nut en-
gages in the tool. Fix the tool to the rear bearing hous-
ing, using socket cap screws.
884264
884830
6. Remove the two socket cap screws in the bearing 9. Install tool 884264 or 884830 on the vertical shaft.
housing. Unscrew the pinion nut.
Remove the pinion. If the pinion has got stuck, it will
come loose when the shaft is pressed out later on, in
item 11.
884611
884161
7. Remove the propeller shaft and bearing housing.

Use slide hammer 884161 and extractor 884611.
62

884761
884721
884761
10. Disassemble the bearing race with tool no. 12. Disassemble the outer bearing race from the upper
884761. part of the gear housing, using tool no. 884761 in
combination with tool no. 884721.
NOTE! Note the number of shims between the bearing
race and the gear.
884143
884750
884743
11. Install tool no. 884743 in the lower gear housing. 13. Remove the bearing race with expander 884750
Use a 5/16" x 20 mm (3/4") screw. Alternatively, one and shaft 884143.
of the drive fixing screws can be used together with a The expander is inserted from underneath, and the
5 mm thick washer. shaft from above.
Take out the loose needles (25 pcs) if the needle roller
bearing needs to be changed.
Tighten the screw with the steel ball so that it presses
the vertical shaft up. Wrench size 24 mm. Then dis-
assemble the tool.
63

Vertical shaft, Vertical shaft,

disassembly assembly
NOTE! Oil all components before or during assembly.
14. Remove the roller bearings with a knife extractor 17. Put a new ferrule (1) on the vertical shaft.
as counterhold. Use a hydraulic press together with a
suitable mandrel.
884755
15. Remove the ferrule (1). Use a knife puller as a

counterhold. 18. Install a new roller bearing with mandrel 884755.
NOTE! The ferrule must always be changed when the NOTE! Press until the bearing touches the ferrule.
shaft has been removed or when the pinion has been
changed.
1
884755
16. The ground needle roller bearing race on the verti- 19. Install the other roller bearing inverted, i.e. with the
cal shaft should not be changed. If the roller bearing is smaller end upwards. Use mandrel 884755.
damaged, the entire shaft must be changed.
NOTE! Press so far that the bearings touch each oth-
Then clean all components. Change worn or damaged er.
components.
64

Propeller shaft,
disassembly of bearings and
drive
884753
22. Remove the gear wheel with tool no. 884753. Use
a socket to protect the end of the shaft.
NOTE! The gear wheel and pinion are classed togeth-
er and can only be changed as a complete unit.
20. Remove the front roller bearing.
Use a knife extractor as a counterhold and press the
bearing out with a hydraulic press and a suitable man-
drel.
Rear bearing housing,

disassembly
9991801
884752
21. Remove the rear roller bearing. Use a knife ex-

tractor as a counterhold, with a 17 mm socket on the
884723
shaft end.
NOTE! If the gear wheel is going to be changed as
well, the bearing can be pressed off at the same time.
Please refer to item 22.
23. When the seal rings are changed, the outer bear-
ing race should also be changed.
Put the bearing housing on tool no. 884723. Press out
the seal rings with tool 884752 and shaft 9991801.
Press the outer bearing race out at the same time as
the housing.
NOTE! Note the number of shims. Save the shims.
65

Propeller shaft, assembly of Propeller shaft, shimming

bearings and drive 26. For when only new bearings have been installed.
Use the previously installed shims in the first in-
stance. In other cases, the shim thickness can be
calculated as in items 27–29.
884753
24. Press the gear wheel down to the step on the pro-
peller shaft with tool no. 884753. Make sure that it
seats securely.
27. Put the outer bearing race on the front ball bear-
ing. Press it hard against the bearing and measure
distance (X) with a caliper gauge, between the rear
plane of the gear wheel and the outer front plane of
the bearing race.
884754
In this case, the distance is 100.20 mm.
25. Install the front roller bearing with tool no. 884754.
28. Dimension (T) is stamped on the starboard side of

the gear housing division to permit the shim thickness
under the front bearing race to be calculated, which is
17 in this case. The dimension of the division plane
can vary between 0 and 30.
66

884756
29. The illustration shows the K dimension (– 5) en- 31. Install the outer bearing race in the gear housing
graved on the gear wheel. The other engraved figure with mandrel 884756. Use the rear bearing housing as
(7) shows the pinion which the gear wheel belongs to- a guide.
gether with. The pinion should have the same figure
engraved on it.
Example:
T = Stamped dimension on the division plane (17)
K = Engraved dimension on the gear wheel (–5) 884754
X = Dimension measured with caliper gauge (100,20)

101 = Constant
Shim thickness = 101 + (T + K) – X
100
Shim thickness = 101 + (0,17 + – 0,05) – 100,20
Shim thickness = 101 + 0,12 – 100,20
Shim thickness = 0,92 mm
32. Press the rear roller bearing down onto the propel-
ler shaft. Use mandrel 884754.
30. Put shims of the correct thickness in the lower

gear housing. Add a further 0.05 – 0.10 mm. In this
case, we put a total of 1.00 mm shims in the housing.
Shims are available in the following standard thick-
nesses: 0.10 mm, 0.15 mm, 0.35 mm, 0.50 mm.
67


shimming
For when only new bearings have been installed. Use
the previously installed shims in the first instance.
When the gear housing or rear bearing housing is B
changed, the shim thickness should be calculated as
below.
9985472
35. There is a dimension (B) punched on the rear

bearing housing. This dimension is stamped under-
neath the bearing housing, and varies between 50-70.
In this case, the distance is 65 mm.
Example: Y is measured to 1.05 mm in this case.

Shim thickness = Y – B
33. Shimming, alternative 1 100
Put the propeller shaft in the gear housing. Install the Shim thickness = 1,05 _ 65
outer bearing race for the propeller shaft roller bearing. 100
Press the bearing race hard and turn the shaft round,
Shim thickness = 1,05 – 0,65 = 0,40
to take up any play in the bearing.
Shim thickness = 0,40 mm
Then use a depth micrometer 9985472 to measure the
distance between the rear plane of the gear housing
and the rear outer bearing race for the propeller shaft. Shims are available in the following standard thick-
We call this dimension Y. nesses: 0.10 mm, 0.15 mm, 0.35 mm, 0.50 mm.
Use shim thickness 0.35 + 0.10 = 0.45 mm.
34. Shimming, alternative 2

Alternatively, we can add shims until the outer bearing
race is flush with the gear housing. Clean off all traces
of sealant from the mating surface of the gear housing
against the bearing housing.
IMPORTANT! Make sure that the surface is not

damaged. Do not use steel tools.
Use a steel rule or caliper gauge to check.
68


assembly
884756
9991801
884752
40. Assemble the outer bearing race with tool no.

884756.
Oil and install new O-rings, 2 pcs.
36. Install a new seal ring in the bearing housing, us-
ing tool no. 884752 and shaft 9991801. Apply sealant,
Volvo Penta part no. 1161099-5, to the mating face
between the seal and the bearing housing.
NOTE! Align the open side of the seal ring backwards
(aft).
37. Install the other seal ring by using the same tool.
NOTE! Align the open side of the seal ring forwards
(towards the bow). When the seal rings have been in-
stalled, the spring in the rings should face away from
each other.
38. Apply some grease to the seal rings, Volvo Penta
part no. 828250-1.
41. Install the propeller shaft in the gear housing.

NOTE! Turn the shaft carefully, to avoid damaging the
sealing lips on the seal rings.
Check the preload. Please refer to item 42.
During final assembly:
Apply sealant, Volvo Penta part no. 1161231-4, to the
mating face between the bearing housing and the
drive.
39. Put shims of the correct thickness in the bearing 1161231-4, to the screws and install the bearing hous-
housing. In this case, they are 0.45 mm. ing on the drive.
69

Pre-load
9985494 884747
884748
42. Check that there is no slack in the propeller shaft

Check the preload in the shaft.
Method 1. Wind a piece of string round the shaft and 44. Install a new needle roller bearing. Use tool no.
pull with spring scale 9985494. Please refer to the fig- 884746.
ure above. The tool consists of three sections. Please refer to
Permissible preload: 0 (no slack) – 35 N (0–7.87 lbf). the Special Tools section.
Method 2. Install the propeller nut on the shaft. Turn NOTE! The needle roller bearing has loose rollers. For
the shaft with a torque wrench. Turn at an even this reason, the new bearing has a transport shield.
speed, about 1 revolution/sec.
Permissible preload: 0.5 ± 0.3 Nm (0.37 ± 0.22 lbf ft). Press bearing retainer 884747 into the needle roller
bearing. The transport shield (foam rubber) is then
When there is slack in the shaft, or the pre-load is in- pressed out. Insert the screw with flange 884748 from
correct, change the thickness of the shims under- above and the bearing retainer with needle roller bear-
neath the bearing race in the rear bearing housing. ing from below. Turn the screw round until the needle
If preload is correct: Disassemble the bearing hous- roller bearing is in place. Use a wrench on the bearing
ing and remove the propeller shaft. holder to keep it in place. Then disassemble the tool.
Vertical shaft
884757
45. Install the vertical shaft in the housing. Be careful

to ensure that the needle rollers do not fall out. Then
install the pinion. Apply thread locking fluid, Volvo
Penta part no. 1161075-5, on the threads and install
43. Install the lower one of the two bearing races. Use
the nut.
mandrel 884757.
NOTE! One side of the nut has a chamfer which
should face the pinion.
70

3858852
884264
884830
46. Lock the pinion nut with tool 3858852. Press the 48. Install the upper nut on the vertical shaft.
shaft down and make sure that the pinion nut engages NOTE! The chamfered side of the nut must face
in the tool. Fix the tool to the rear bearing housing, us- downwards.
ing socket cap screws.
Install tool 884264 or 884830 on the vertical shaft.
Tighten the pinion nut.
Wrench size: 17 mm.
Tightening torque: 110 ± 10 Nm (81.13 ± 7.38 lbf ft).
884753
47. Install the bearing housing on the propeller shaft. 49. Then screw tool 884753 to the division plane, so
that the “teeth” engage on the nut. Fix the tool, with
NOTE! Turn the shaft carefully, to avoid damaging the
the lower gear housing, in a vice.
sealing lips on the seal rings.
NOTE! First tighten the nut by hand, so that the tool
Apply sealant, Volvo Penta part no. 1161231-4, to the lies flush against the division plane.
mating face between the bearing housing and the
drive.
Then install the propeller shaft and bearing housing on
the gear housing.
1161231-4, to the screws.
71

Flank clearance Install dial gauge 9999683 on the propeller shaft

splines. Tap the vertical shaft from above, so that it
comes as far down as possible. Turn the propeller
shaft forwards and backwards.
Flank clearance: 0.04-0.10 mm (0.002-0.004")
If the clearance is too small, the nut must be tight-
ened a further turn. 1/4 turn is about 0.02–0.03 mm
(0.0008–0.0012") .
IMPORTANT! Only tighten a small amount at a

time, and check the clearance each time.
If the flank clearance becomes too large, the vertical

shaft must be disassembled and the ferrule changed,
since it can only be used once.
50. Install tool 884264 or 884830 on the vertical shaft.

Turn the shaft clockwise with a heavy wrench or
torque wrench. Wrench size: 17 mm.
NOTE! The nut must be tightened so hard that the fer-
rule is deformed. The torque needed is about
230–250 Nm (169.64–184.40 lbf ft).
The flank clearance is zero (0) before the nut begins
to nip up.
9999683
51. When the highest torque specified above has been

reached, the gear housing should be removed from
the vice and fixed vertically instead. Let the tool re-
main on the gear housing.
72

Marking pattern
884264
884766 884830
A 884753
54. Disassemble the propeller shaft and check that

the marking pattern on the gear teeth corresponds
with the marking pattern in the illustration above or the
figures in items 55 and 56.
52. When the correct gear flank clearance has been
obtained, remove tool 884753 from the lower gear.
Then turn the tool so that the “teeth” (A) face out-
wards. Fix the tool with two screws to the lower gear
housing.
Press the vertical shaft in with tool no. 884766 which
is screwed to the other tool. Leave tool 884264 or
884830 in place.
Then disassemble the propeller shaft and apply mark-
er dye to the gear wheels.
884766
55. If the marking pattern is displaced in relation to
the figure above, the thickness of the shims under-
neath the front bearing race must be reduced and the
thickness of the shims behind the bearing race in the
rear bearing housing must be increased to the same
extent. It is important that the preload is not changed.
NOTE! In this case, the propeller shaft is displaced
forwards (towards the pinion), which reduces flank
clearance. For this reason, it is necessary to install
tool no. 884753 and tighten the upper nut a bit more
until correct flank clearance has been obtained.
53. Install the propeller shaft again and turn it round in Please refer to items 50 and 51. Then check the con-
both directions. tact patch again, as in items 52-54.
Brake the propeller shaft strongly.
NOTE! Press the vertical shaft in with tool no. 884766
at the same time as it is turned round.
73

Model 120S
Installation, lower gear
housing–adapter housing
Preferably use the shims which were installed previ-
ously, if only new bearings have been installed. Shim
thickness can also be measured as in the points be-
low.
56. On the other hand, if the marking pattern is dis- 1

placed in relation to the figure above, the thickness of
the shims underneath the front bearing race must be
increased and the thickness of the shims behind the
bearing race in the rear bearing housing must be re-
duced to the same extent.
NOTE! In this case, the propeller shaft will be dis-
placed backwards (away from the pinion), which
means that the flank clearance will be too large. This
can not be changed in any other way than by remov-
ing the vertical shaft, pressing off the roller bearings
and changing the ferrule.
58. Check that there is no end float in the vertical
Install a new ferrule. Then re-install the bearings and shaft. Then install spacer ring (1).
put the shaft back in the gear housing. Turn round to
establish the new flank clearance and check the
marking pattern. Please refer to items 50-51.
A
9985472
884757
1
57. When the correct flank clearance has been ob- 59. Use a depth micrometer 9985472 to measure the
tained, disassemble the tool and propeller shaft, and distance (A) from the division plane down to the spac-
wash off all marker dye from the crown wheel and pin- er ring (1).
ion.
Re-install the propeller shaft and rear bearing housing.
Please refer to item 47. Then install the upper, outer
bearing race. Use tool no. 884757.
74

9999701
62. Install the calculated thickness of shims and gas-

ket on the division plane of the lower gear housing.
60. Measure the thickness of gasket (B) with mi- NOTE! The text on the gasket must face upwards.
crometer 9999701. The hole pattern in the gasket only fits one way round.
61. Measure the height of flange (C) on the adapter 63. Install the adapter housing with rubber sleeve on
housing. the lower gearing housing. Apply MoS2 based grease,
Volvo Penta part no. 1161029-2 to the socket cap
screws. Put washers on the six socket cap screws
Example: and use a torque wrench to tighten them.
a) When distance (A) is measured, we obtain a dis- Tightening torque: 30 Nm (22.13 lbf ft).
tance of 5.70 mm in this case.
NOTE! Torque the screws diagonally, then re-check
b) Gasket (B) thickness is measured as 0.30 mm. their tightening.
c) Flange height (C) is measured as 3.85 mm. Install the cooling water tap on the port side. Apply
A + B – C = shim thickness sealant, Volvo Penta part no. 1141570-0 on the
threads.
5.70 + 0.30 – 3.85 = 2.15
NOTE! Check that the adapter flange has entered the
Shim thickness = 2.15 mm
gear housing and presses the shims down, so that
there is no end float in the vertical shaft. Also check
the flank clearance.
75

Models 120S-B, -C, -D, -E

Installation, lower gear
housing–adapter plate.
Preferably use the shims which were installed previ-
ously, if only new bearings have been installed. Shim
thickness can also be measured as in the points be-
low.
64. Install the adapter section on the upper housing.

Torque the socket cap screws alternately. 1
Only tighten bracket (1) by hand.
66. Check that there is no end float in the vertical

shaft. Then install spacer ring (1).
9985472
A
65. Put a new O-ring on the adapter section neck.
Check that the slipping clutch is in place in the upper
gear housing and then fit the housings together.
NOTE! Put washers under the screw heads.
Secure the four screws with locking wire. Tighten the 1
four nuts.
Tighten the two screws on the front bracket.
67. Use a depth micrometer 9985472 to measure the
distance (A) from the division plane down to the spac-
er ring (1).
76

9999701
70. Install the calculated thickness of shims and gas-

ket on the division plane of the lower gear housing.
NOTE! The text on the gasket must face upwards.
68. Measure the thickness of gasket (B) with mi- The hole pattern in the gasket only fits one way round.
crometer 9999701.
C 9985472
71. Put the rubber sleeve on the upper gear housing.

69. Measure flange (C) on the adapter plate with mi- Install the cooling water tap. Apply sealant, Volvo
crometer 9985472. Penta part no. 1141570-0 on the threads.
Example:
a) When (A) is measured, we obtain a distance of
5.70 mm in this case.
b) Gasket (B) thickness is measured as 0.30 mm.
c) Flange height (C) is measured as 3.85 mm.
A + B – C = shim thickness
5.70 + 0.30 – 3.85 = 2.15
Shim thickness = 2.15 mm
77

72. Oil and install a new O-ring on the adapter section

neck.
73. Install the adapter plate on the upper gear hous-

Reverse installed drive (180°) ing. Apply MoS2 based grease, Volvo Penta part no.
1161029-2 to the three socket cap screws. Put wash-
ers on the socket cap screws and use a torque
wrench to tighten them. Torque the screws alternately.
1 Install the slipping clutch (1).
Oil and install a new O-ring (1) in the cutout in the

adapter plate.
74. Fit the gear housings together. Apply MoS2 based

grease, Volvo Penta part no. 1161029-2 to the socket
cap screws. Install the screws, 10 pcs. The two long
screws should be located by the rear edge.
Put washers under the screw heads and distribute the
screws with holes in the screw heads so that there are
two on each side.
78

Other components,
installation
75. Secure four of the screws, the ones with holes in 76. Install a new zinc ring.
their heads, with locking wire, two screws on each Tightening torque: 12 Nm (8.85 lbf ft)
side as in the illustration.
77. Change the gasket on the oil drain plug.
IMPORTANT! The gasket must be allowed soak

in oil for about 15 minutes before assembly.
Leakage would otherwise occur.
Pressure test the drive, please refer to the Pressure

Testing section.
Fill up with engine oil.
and viscosity.
Check the oil level with the dipstick and install the oil
filler cap.
IMPORTANT! When the drive is installed on the

engine the screws must be dipped in oil (includ-
ing the heads) and torqued.
Tightening torque: 20 Nm (14.75 lbf ft), alternately,

diagonally. Also do an extra
check of tightening.
79

Pressure testing Painting of the drive

When the drive has been removed, it must be pres- Most countries have legislation which regulates the
sure tested to check for any leakage. Use special tool use of growth inhibiting paints. In some cases, their
3810152, which consists of a pressure gauge with use is completely banned on pleasure boats. Ask your
union, and a hand pump. Volvo Penta Dealer for advice on alternative methods
in this case.
IMPORTANT! Find out about current legislation

for painting with growth inhibiting paints / anti-
3810152 fouling paints.
The drive
The top coat is part of the corrosion protection of the
drive, and it is important that any paint damage is re-
paired.
Sand metal surfaces lightly with 120 grit emery paper,
and use finer paper on painted surfaces. Wash with
78. Connect the pressure gauge to the oil drain hole. cellulose thinners or an equivalent product. Pores
Pump the pressure up to a level not exceeding must be filled and sanded.
78 kPa (11.31 psi). Paint with Volvo Penta original primer plus a top coat.
Check that the pressure remains constant for 1 Give the paints time to harden.
minute. The drive should be coated with Volvo Penta anti-foul-
NOTE! Make sure that no air leakage can occur via ing paint to prevent the growth of weed and barnacles.
the hand pump. Apply in accordance with the directions on the pack-
age.
If the pressure falls, the leakage must be localized by
using soapy water which is brushed over all joints on
the outboard section.
IMPORTANT! The protective anodes on the
drive and propeller must not be painted over.
80

Technical data
Type designation
Drive ....................................................................... 120S, 120S-B, 120S-C, 120S-D, 120S-E
Reverse gear........................................................... MS2, MS2B-L, MS2V
Gear ratio
Drive ....................................................................... 2.2:1
Reverse gear........................................................... 2.4:1 and 3.0:1
Flank clearance
Input gear - gear wheel, measured directly on
the gear wheels ....................................................... 0.10–0.25 mm (0.004–0.010")
Output shaft - lower drive measured on the
gear wheels. Only MS2, MS2B-A, MS2B-L,
MS2A-D, MS2A-E, MS2L-D, MS2L-E ..................... 0.10–0.25 mm (0.004–0.010")
Pinion - crown wheel. Only MS2V ........................... 0.10–0.25 mm (0.004–0.010")
Propeller shaft - vertical shaft, measured on
propeller shaft splines ............................................. 0.04–0.10 mm (0.0016–0.004")
Preload, bearings:
Input shaft bearings ................................................ 10–18 N (2.25–4.05 lbf)
Output shaft bearings .............................................. 13–25 N (2.92–5.62 lbf)
Lower shaft bearings, slipping clutch ....................... 15–30 N (3.37–6.74 lbf)
Propeller shaft bearings .......................................... No slack up to 35 N (7.87 lbf), measured on propeller shaft
Pinion bearing. Only MS2BV ................................... 10.0–17.5 N (2.25–3.93 lbf)
Tubular shaft bearing Only MS2BV ......................... 10.0–16.0 N (2.25–3.60 lbf)
Lubrication system
Oil grade, MS2A-E, MS2L-E ................................... API GL5/SAE 75W/90, synthetic
Oil grade 120S-E ..................................................... API GL5/SAE 75W/90, synthetic
Oil grade, other reverse gears and drives ................ Engine oil for Service SE or CD
Viscosity, Service SE ............................................. Multigrade SAE 10W/40 *
Viscosity, Service CD ............................................. Over +10°C: SAE 20W/30 *
Viscosity, Service CD ............................................. Below +10°C: SAE10W *
Oil volume, drive. .................................................... 2.8 l (0.74 US gallon)

With 2” extension, total ....................................... 3.1 l (0.82 US gallon)
With 4” extension, total ....................................... 3.3 l (0.87 US gallon)
Oil volume, reverse gear. ........................................ 0.8 l (0.21 US gallon)

Oil volume, MS2V reverse gear .............................. 1.8 l (0.48 US gallon)
*) Or Volvo Penta oil for diesel engines, please refer to the handbook.
81

Technical data
Tightening torque
Reverse gear MS2, MS2B-A, MS2B-L, MS2A-D,

MS2A-E, MS2L-D, MS2L-E
Lower cover .............................................................................. 23 Nm (16.96 lbf ft)
Reverse gear MS2V

Nut on pinion ............................................................................. 140 Nm (103.26 lbf ft)
Nut on tubular shaft ................................................................... 140 Nm (103.26 lbf ft)
Cover for tubular shaft ............................................................... 25 Nm (18.44 lbf ft)
Adapter housing – gear housing ................................................ 9 Nm (6.64 lbf ft)
Angle drive – gear housing ........................................................ 28 Nm (20.65 lbf ft)
Reverse gear and drive

Input bearing housing ................................................................ 8 Nm (5.90 lbf ft)
Upper bearing housing ............................................................... 23 Nm (16.96 lbf ft)
Screws for gear change mechanism ......................................... 20 Nm (14.75 lbf ft)
Screw for eccentric piston, gear shift mechanism ..................... 12 Nm (8.85 lbf ft)
Rear bearing housing, reverse gear ........................................... 23 Nm (16.96 lbf ft)
Upper gear housing – adapter housing, engine .......................... 40 Nm (29.50 lbf ft)
Oil drain plug ............................................................................. 10 Nm (7.38 lbf ft)
Drive 120S, 120S-B, 120S-C, 120S-D, 120S-E

Lower nut, vertical shaft ............................................................ 160 Nm (118.00 lbf ft)
Propeller bearing housing .......................................................... 25 Nm (18.44 lbf ft)
Zinc ring .................................................................................... 12Nm (8.85 lbf ft)
Rubber pad, drive, old model ..................................................... 23 Nm (16.96 lbf ft)
Rubber mounting, 120S-E, M8 .................................................. 25 Nm (18.44 lbf ft)
Model 120S
Upper gear housing – adapter housing nut ................................. 23 Nm (16.96 lbf ft)
Lower gear housing – adapter housing ...................................... 30 Nm (22.13 lbf ft)
Upper gear housing – adapter housing- lower gear housing ...... 23 Nm (16.96 lbf ft)
Model 120S-B, 120S-C, 120S-D, 120S-E
Upper gear housing – adapter plate ........................................... 30 Nm (22.13 lbf ft)
Upper gear housing – lower gear housing .................................. 30 Nm (22.13 lbf ft)
82

References to Service Bulletins
Group No. Date Refers to
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83

Notes
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84

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Do you have any complaints or other comments about this manual? Please make a
copy of this page, write your comments down and send it to us. The address is at
the bottom of the page. We would prefer you to write in English or Swedish.
From: ............................................................................
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Refers to publication: .............................................................................................................................................

Publication no: ............................................................ Date of issue: ....................................................................
Suggestion/Motivation:...........................................................................................................................................
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Date: ............................................................
Name: ..........................................................
AB Volvo Penta
Teknisk Information
405 08 Göteborg

7752950-1 English 01-2001

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Workshop manual A

MS2, MS2B-A, MS2B-L, MS2A-D

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Safety information ......................................................... 2

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Introduction If work is done adjacent to a running engine, a

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Only use the fuels recommended by Volvo Pen-

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About the workshop manual Spare parts

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The work methods described in the workshop manual

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Tightening torque Lock nuts

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Sealants Anaerobic preparations

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884078 884143 884161 884264 884611 884637

884679 884720 884721 884723 884724 884725

884726 884728 884729 884730 884731 884732

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884733 884735 884736 884738 884739

884754 884755 884756 884757 884761

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884766 884830 884833 884834

884835 884836 884855 884856 884857

884859 884860 3858852 9991801

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9985472-1 Depth micrometer Chemicals

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Reverse gear MS2

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Sailboat drive 120S

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History, sail boat drives

1. Adapter, loose 1. Adapter, integrated into

3. Gasket 2. Adapter plate

Model 120S-C Model 120S-D

1. Dipstick, new version New material in slid-

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1. Rubber mounting, new version

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2. Remove the locking wire from the four screws.

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5. Models 120S-B, -C, -D, -E 6. Remove the slipping clutch (1).

Reverse installed drive (180°)

Remove and scrap the O-ring (1) on the adapter plate.

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1. Disassemble the gear shift mechanism, 2 screws.

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Gear shift mechanism,

5. Pull the eccentric piston out.

8. Oil all components before assembly starts. Install

6. Shake the pin out of the eccentric piston.

7. Remove the seal ring with a screwdriver. Clean all

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12. NOTE! During assembly, the dog must be aligned