This will define how to change the shaft seal on a 2001 Beneteau 361 sailboat based on my own experience as a DIY person. The seal on the boat is a Volvo 25 mm part # 828254. The old rubber part of the seal had a visible number of 828081 on it. I ordered the 828254 seal on-line from General Propeller Co. for $120, which included shipping. It includes all the seal parts needed (clamp, screws, seal, grease, and split installation cap).
Now that you have the parts needed, remove the 4 nuts and bolts the hold the drive shaft to the engine transmission. Allow the shaft to slide back enough to get a 15/16" long socket on the nut inside the shaft coupling. Break it loose, but do not remove it completely. If you are lucky, the coupling will be loose and easily pulled off the shaft when the nut is removed. In my case the coupling was still bonded to the shaft. To prevents the coupling from jumping off when the shaft to coupling bond is broken free, leave the nut on the shaft but backed off one or two turns.
To get the coupling off, I used an inexpensive RAM-TOOL 46 pcs Bolt Type Puller Set and a 1 1/4" flange that I got from the hardware store. The puller had to be modified by the use of a grinder to allow the use of four bolts. The attached picture shows what the modified piece looks like. This is placed on the coupling and tightened (See the attached pictures). To break it free, I also had to use a propane torch on the smaller diameter portion of the coupling, turning the coupling with the flange as the heat was applied. Extreme caution must be used when using a torch in the confined area. Use heat resistant gloves and sleeves and make sure there is no flammable liquids or other flammable material close by in this area of the boat. Also keep a fire extinguisher at hand while using the torch. After heating the coupling tighten the bolts again and it should pop off the shaft. If not you must let everything cool back down before attempting again. If the coupling is heated too slowly, the shaft will be heated at the same rate as the coupling and thermal expansion will not help release the coupling.
The rest is easy. Remove the key and slid off the old seal and install the new one as defined in the instructions provided with the seal.
I checked the alignment of the shaft before the coupling was removed and after the coupling was reinstalled and found less than .002 inches difference in alignment. See attached photos.
Now that you have the parts needed, remove the 4 nuts and bolts the hold the drive shaft to the engine transmission. Allow the shaft to slide back enough to get a 15/16" long socket on the nut inside the shaft coupling. Break it loose, but do not remove it completely. If you are lucky, the coupling will be loose and easily pulled off the shaft when the nut is removed. In my case the coupling was still bonded to the shaft. To prevents the coupling from jumping off when the shaft to coupling bond is broken free, leave the nut on the shaft but backed off one or two turns.
To get the coupling off, I used an inexpensive RAM-TOOL 46 pcs Bolt Type Puller Set and a 1 1/4" flange that I got from the hardware store. The puller had to be modified by the use of a grinder to allow the use of four bolts. The attached picture shows what the modified piece looks like. This is placed on the coupling and tightened (See the attached pictures). To break it free, I also had to use a propane torch on the smaller diameter portion of the coupling, turning the coupling with the flange as the heat was applied. Extreme caution must be used when using a torch in the confined area. Use heat resistant gloves and sleeves and make sure there is no flammable liquids or other flammable material close by in this area of the boat. Also keep a fire extinguisher at hand while using the torch. After heating the coupling tighten the bolts again and it should pop off the shaft. If not you must let everything cool back down before attempting again. If the coupling is heated too slowly, the shaft will be heated at the same rate as the coupling and thermal expansion will not help release the coupling.
The rest is easy. Remove the key and slid off the old seal and install the new one as defined in the instructions provided with the seal.
I checked the alignment of the shaft before the coupling was removed and after the coupling was reinstalled and found less than .002 inches difference in alignment. See attached photos.