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Old 08-09-2009, 17:38   #1
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Volvo 2003T/S120 Saildrive

Hi,
I have my boat out of the water to fit a gaiter. On inspection I found the spline
which connects the gear box to the engine is quite badly warn. I am in Malaysia and there
is no Volvo dealer close by. Does anyone know where I can download a service manual for the
S120? Or can anyone advise me if you have had some experience with this?
Thanks
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Old 09-09-2009, 03:28   #2
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Greetings and welcome aboard the CF, yasmin.

Try the Volvo Penta Engine Search (operator's manuals, maintenance instructions, part charts, and other publications for most Volvo Penta engines):
Publication search : Volvo Penta
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Old 09-09-2009, 06:05   #3
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That spline is part of a matched gear set and cannot be purchased alone. Also the bolt on flange on the flywheel is probably also badly worn. Volvo has a new design for replacement of the flange that has nylon bushing to absorb some of the shock when shifting gears.

Wish I was nearer I could loan you service manuals.

I have been through this.

George
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Old 09-09-2009, 09:12   #4
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After reading my post, it may be misleading. The splined input shaft is part of a matched gear set that must be purchased together.

You should also replace the splined receiver plate on the flywheel with the new design.

These things are not cheap.

Check prices at Volvo Penta, Mercruiser and more - Marine Parts Express - engines, outdrives, propellers

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Old 09-09-2009, 09:23   #5
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There is a Volvo dealer in the UK who pioneered the repair for this spline problem. Marine Supplier, Volvo Penta Industrial Parts, Maintenance and Repairs, Cookham, Berkshire, UK.

I've never used them, but I've seen and used their work. Much, cheaper and better than anything the Swedes have to offer.
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Old 10-09-2009, 05:18   #6
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Thank you for the link, A great help .
Gary & pat S/Y Yasmin
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Old 10-09-2009, 06:01   #7
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Yasmin:

Your profile doesn't give your location. Might be able to steer you to other resources if I knew where you are.

George
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