How many hours should a 225 opti engine do, also some gearbox problems

[how900]

Difficult question i know, many variables and different operators and so on make this a question with many possible answers but assuming that the operator does not run WOT from dawn to dusk. We run 2 x 225's opti's (2007) had them from new and generally run at about 4000rpm, all mercury oils and regular service as per manual. just after a ball park figure that you might expect from these motors. Would 2000 hours be a reasonable expectation or not, what the highest hours anyone has seen on these engines. Just actually had a gearbox fail (325hrs) , not sure what has happened but there are 2 lumps on the outside of the gearbox where something on the inside has tried to come out, looks like it might be in the general location of the gear selector. the gearbox still runs and drives in forward and reverse but all in not well inside, as oil was leaking out of the puncture marks. engine are running in salt water, Gearbox is off the boat now and just about to open it and have a look. How good are these boxes, ,,,i see they are dam expensive to replace at about 4000 bucks.

[EuropeanAM]

Welcome to BBC!

Engine hours (lifespan) vary immensely, dependant upon many different conditions. What I can tell you is that I've seen numerous engines will WELL over 2000 hours (one at or above 4000 hours currently) and still running strong, on the original powerhead.

Gearcase failures DO happen. It sounds like you may have a gear or clutch dog failure. May simply be a mechanical failure.... or even possibly a failure from an "inadvertant slam-shift" at higher RPMS (somewhat common on twin engine applications when docking if someone "panics").

[how900]

Just opened the box up, (after having a couple of tools made to do the job) the main drive pinion has 1 1/2 teeth missing. Looking on various websites it look like the gear is not available as separate item. it quotes only available with 43-859321A3 not sure what that is maybe complete gearbox. i think you may be right about the reason for the failure with the dog clutch. just trying to work out the best /most economical way to get back in the water. don't really want to go for a complete new box, are gear sets available. Thanks for your help
How900

[EuropeanAM]

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by how900 &raquo;</TD></TR><TR><TD CLASS="quote">Just opened the box up, (after having a couple of tools made to do the job) the main drive pinion has 1 1/2 teeth missing. Looking on various websites it look like the gear is not available as separate item. it quotes only available with 43-859321A3 not sure what that is maybe complete gearbox. i think you may be right about the reason for the failure with the dog clutch. just trying to work out the best /most economical way to get back in the water. don't really want to go for a complete new box, are gear sets available. Thanks for your help
How900</TD></TR></TABLE>

43-859321A3 is simply a "forward and pinion gear set".

Retail price $368.25 (BBC members receive a 10% discount on orders over $100).

[how900]

Hi,
Thanks for your information, I've been pulling my hair out trying to sort this problem. I have sent a couple of merc dealers requests for info and not had any response people more and more don't seem to put phone numbers on there website these days, only email contact and things just take forever ping ponging emails to and fro with 1/2 a day or more between emails. http://www.bbcboards.net...92677#
http://www.bbcboards.net...7#Its a relief to find someone helpful out there. I'll call you on Monday to get these parts ordered. The serial number of my engine is 1B481909 its a 2007 225 Opti Counter rotation
Can i get the mercury service tool from you also. my location is out of the way so we are finding we need to be self sufficient and by prepared to do our own repair as time is money and all that, sitting on the trailer is costing too much. The forward and reverse gear are marked but not broken, the selector has a chip out. Can't get the nut off the pinion as dont have the service tools. The drive pinion is buggered. Can you price the parts and tool i will need, I've had tools made to remove the bearing carrier screw thingies. also need the nut for the pinion as this is damaged. I've found another CR gearbox on the island which i think i'll rebuild as a spare.
Cheershttp://www.bbcboards.net/zeropost?cmd=reply&id=4292677#
http://www.bbcboards.net...92677#

[EuropeanAM]

We "can" sell you the necessary service tools.... and an OEM Service Manual.

However.... there are "portions" of gearcase repair that are best (or only) covered in technician training classes.

Just let us know what you would like.... we'll be glad to assist however possible.

[how900]

Hey Don,
Thanks for your help, I actually stumbled across a used gearbox which was a really good price so i took a chance and went with it, fitted it yesterday and all seems ok so the panic is over for a while, just noticed the main lift unit main ram seal is popping out and leaking, i've already had one of these fail under warranty, i see there are 2 wire and 3 wire, is there any way to tell without taking it off, I'm looking for a spare unit so i can just swap out and rebuild when they fail. I still have the other busted box, i will probably be looking to get that rebuilt for a spare at some point.
Thanks
H

[EuropeanAM]

ALL of the Opti's have been "two wire trim systems".

Pretty much ANY 3L trim system (EFI or Opti) is interchangeable with yours.

If interested in a new one, we can set you up with one and send it over to you (10% BBC Discount applies).