1998–2003 Volvo Penta SX-M/DP-SM Sterndrive & Transom Shield Workshop Manual (VPA 7743008)

This Volvo Penta workshop manual, VPA 7743008, dated July 2003, covers the 1998–2003 SX-M and DP-SM sterndrive families, including SX-MTD, DP-SMTD, and DP-SMTD1, and the transom shields listed above.

Searchable Text, Bookmarks, and PDF Contents

Text search and diagram detail: Technical text is searchable, and embedded bookmarks provide access to chapters and individual procedures. Back-cover text does not search reliably. The Hydraulic Flow Diagram labels are legible at normal viewing size and remain clear when enlarged.

The ZIP download contains one printable, English-language, 270-page PDF. This total includes the front and back covers, two blank pages, and six Notes pages.

Sterndrive Overhaul, Transom Service, and Trim Diagnosis

The selected topics below cover the main workshop areas. The manual also discusses antifouling paint compatibility and how trailer support can affect the boat’s hull and performance.

• Transom shield repair: Separate SX-M and SX-MHP procedures cover gimbal bearings, pivot housings, steering components, trim senders, and U-joint and exhaust bellows.

• Upper gear housing: Pinion bearing carrier and output gear service, cone clutch and shift actuator repair, gear lash checks, and tooth-contact assessment.

• SX and DP-S lower gearcases: Disassembly, propeller shaft bearing and seal replacement, pinion and propshaft shimming, rolling-torque checks, and pressure and vacuum testing.

• Trim/tilt hydraulics: Complete up/down circuit tests, pump isolation, motor and reservoir service, cylinder overhaul, and dry-system filling and bleeding.

• Drive installation and controls: Sterndrive removal and installation, engine-coupler alignment checks, remote-control cable stroke measurement, and shift and throttle cable adjustment.

• Maintenance and propellers: Lubrication schedules, anode testing, storage preparations, SX propeller rotation, and DP-S matched-propeller selection and installation.

The precision gear setup and hydraulic tests suit marine technicians equipped with a press, measuring instruments, and the specified service fixtures.

Transom Shield and Gimbal Service

Separate SX-M and SX-MHP chapters explain gimbal-housing inspection, gimbal-ring support arrangements, transom and exhaust seal replacement, and hydraulic line service.

Component-specific torque tables cover steering-arm fasteners, trim-line fittings, and transom mounting hardware. The SX-M transom shield Service Chart connects the exploded assembly to its torque, lubricant, and sealant references.

The water-hose instructions warn that an incorrectly positioned O-ring can obstruct winter drainage and cause freeze damage.

Upper Gear Housing and Shift Mechanism

Step-by-step procedures cover bearing carrier disassembly and reassembly, output-gear installation, and shift actuator service. Shim calculations, Correcting Gear Lash tables, and illustrated tooth-contact patterns guide gear positioning; the Upper Gear Housing Service Chart supplies assembly references.

Cone-clutch orientation, shift-shoe positioning, and upper driveshaft clearance receive specific attention. Interchanging the upper and lower output-gear needle bearings can cause premature failure.

SX and DP-S Lower Gearcase Overhaul

The SX Lower Gearcase and DP-S Lower Gearcase Service Charts distinguish the single- and dual-propeller assemblies. Detailed overhaul instructions address gear-ratio-dependent rolling torque, bearing preload, and final sealing checks. DP-S coverage also includes inner and outer propeller shaft service and runout measurement.

For DP-S work, Level 1 Kit P/N 3855955 supports disassembly and reassembly for resealing and inspection. Level 2 Kit P/N 3856041-3 supplies shimming fixtures for bearing or gear-set replacement and must be used with Level 1.

Trim/Tilt Fault Isolation and Repair

In-line pressure tests separate pump/manifold faults from leaking trim cylinders, helping identify which assembly needs repair. Running-pressure, stall-pressure, and leak-down checks are accompanied by a Hydraulic Flow Diagram and test specifications.

Cylinder procedures cover piston-rod removal, seal and scraper replacement, reassembly, and bleeding. The hydraulic pump is serviced as a complete assembly; internal pump rebuilding is outside the prescribed procedure.

Electrical information covers trim-sender resistance checks, connector details, and motor-current specifications. Electrical wiring diagrams are not included.

Maintenance, Propellers, and Coverage Limits

Lubrication and storage instructions include synthetic gearcase lubricant requirements, capacity tables, and periodic maintenance schedules. U.S. and metric specifications accompany the service procedures.

Propeller guidance distinguishes SX right- and left-hand rotation from DP-S matched sets, including D-series aluminum and F-series stainless steel propellers.

Engine repair and water-pump overhaul require separate engine documentation. The referenced Engine Service Manual and Engine and Sterndrive Installation Manual are not included. The separately referenced Safety chapter is also absent, although individual chapters contain safety warnings.

Critical servicing and structural checks should be performed by a qualified marine technician, following the precautions for suspended drives and pressurized trim hydraulics.

A Preview of Gear Clearances and Trim Test Values

Upper gear housing setup specifies 0.002–0.010 in. (0.05–0.25 mm) of vertical upper-driveshaft clearance. Gear lash between the pinion and either output gear is 0.006–0.011 in. (0.15–0.28 mm).

The hydraulic test table lists trim-out/tilt-up running pressure at 290–310 psi (2,000–2,137 kPa), with maximum motor current of 24 amps.