2000 Mercury MerCruiser Bravo Sterndrives Service Manual #28 (P/N 90-863160)
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Mercury Models Covered & Key Technical Specifications
Models: Bravo Sterndrives, Bravo One, Bravo Two, Bravo Three, Bravo X, Bravo XZ, Bravo XR, Diesel Bravo One X, Diesel Bravo Two X, Diesel Bravo Three X
Sub-models / Variants: Sterndrive Unit, Transom Assembly (Standard, High Performance), Power Trim, Steering System; Bravo One and Bravo Two (right-hand or left-hand rotation), Bravo Three (front left-hand and rear right-hand rotation); D7.3L Diesel (water-bypass fitting installation), 7.4L MPI (shift-cable routing).
Drive Ratio Variants (Original U-Joint Shaft Markings): Bravo One and Diesel Bravo One X (1.65:1 — C, 1.50:1 — F, 1.36:1 — H); Bravo Two and Diesel Bravo Two X (2.20:1 — C, 2.00:1 — F, 1.81:1 — H, 1.65:1 — T; also 1.50:1); Bravo Three and Diesel Bravo Three X (2.43:1 — N, 2.20:1 — K, 2.00:1 — B, 1.81:1 — G, 1.65:1 — C, 1.50:1 — F, 1.36:1 — P); Bravo XZ (1.50:1 — Z, 1.36:1 — T); Bravo XR (1.50:1 — R). Shaft markings identify the original ratio only if the gearing has not been changed.
Model Year: 2000
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Torque (Sterndrive Unit Fill/Drain/Vent Plugs): 40 lb-in. (4.5 Nm)
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Torque (Propeller Nut): Bravo One: 55 lb-ft (75 Nm) minimum; Bravo Two: 60 lb-ft (82 Nm); Bravo Three front: 100 lb-ft (136 Nm) minimum; Bravo Three rear: 60 lb-ft (81 Nm) minimum
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Torque (Steering Cable Coupler Nut): 35 lb-ft (48 Nm)
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Torque (Sterndrive Unit to Bell Housing Attaching Nuts): 50 lb-ft (68 Nm)
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Drive Shaft Bearing Preload (Bravo One): 3-5 lb-in (0.3-0.55 Nm)
Mercury Manual Features & Content Preview
Mercury MerCruiser Service Manual #28 (P/N 90-863160), May 2000 edition, covers Bravo One, Bravo Two, Bravo Three, Bravo X, Bravo XZ, Bravo XR and Diesel Bravo X sterndrives. Engine removal, installation and engine repair require the appropriate engine manual.
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Sterndrive overhaul: Drive shaft housing, clutch, shifter and U-joint service, with separate gear housing procedures for the main Bravo configurations.
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Transom assembly: Gimbal bearing, bell housing, U-joint bellows, exhaust bellows and shift cable removal, inspection and installation.
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Power trim hydraulics: Oildyne pump pressure testing, cylinder leak checks, shock-piston testing and motor repair.
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Trim controls: Dual Power Trim relays and diodes, plus Auto Trim II troubleshooting and adjustments.
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Steering systems: Power steering pump overhaul, hydraulic pressure testing and compact hydraulic steering installation.
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Corrosion protection: MerCathode testing, continuity circuits, ground wires and anodic plate replacement.
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Power Shift: Vacuum drop-off testing, shift-assist cylinder rebuilding and input/output cable adjustment for assembly 38638A4.
Written for Mercury Marine dealer mechanics and service personnel, this manual assumes training, familiarity with the equipment and access to the specified tools.
Gear Housing Overhaul and Shift Setup
Exploded views, bearing preload, pinion height, shim calculations and torque conversion charts support gear housing assembly. Bravo Three procedures distinguish propeller-shaft spline lash from actual gear backlash, helping prevent a misleading reading from driving the wrong shim adjustment.
Bravo XZ and XR heavy-duty propeller shaft instructions address bearing carrier and propeller hub differences. The U-joint service section contains two notices that certain Bravo XZ, Bravo XR and Diesel Bravo illustrations were unavailable at publication.
Transom, Bellows and Alignment
Standard and High Performance transom assemblies have different hinge-pin procedures. Shift cable setup identifies the Shift Cable Adjustment Tool, P/N 91-12427.
Incorrect seating of the U-joint bellows bead can admit water, while poor engine alignment can damage the coupler splines. The Bravo Three Trim-In Limit Insert warning links incorrect positioning to unsafe high-speed handling.
Trim Pump Tests and Control Circuits
The Power Trim Hydraulic Schematic, Auto Trim II System Wiring Diagram and Dual Trim Harnesses drawing show the hydraulic paths and control connections used during diagnosis.
Separate electrical, pressure and cylinder leak tests help distinguish a control fault from a pump or cylinder problem. Pressure testing calls for Trim Pump Test Gauge Kit 91-52915A6.
Oildyne procedures cover motor and adapter repair and relief-valve replacement. The pump gear assembly is replacement-only; it is not rebuilt.
Steering Repair and Configuration Limits
Power steering coverage includes pump disassembly, inspection and reassembly, along with system pressure tests. The steering control valve is nonserviceable and is replaced as an assembly.
Compact hydraulic steering includes cylinder installation and filling/purging for a single station with a single cylinder. Twin-station or twin-cylinder purging requires the separate SeaStar instructions. This compact system is not suitable for through-transom exhaust installations.
MerCathode and Corrosion Diagnosis
The MerCathode Monitor and MerCathode Controller wiring drawings support electrical checks. Corrosion troubleshooting separates fresh water from salt water and accounts for reference-electrode position, so test readings can be interpreted against the appropriate conditions.
Heavy components, moving linkages and pressurized systems require the support and isolation precautions specified for each procedure.
Examples of Trim Pressure and Gear Setup Data
These examples are a small selection of the manual's hydraulic test and gear setup data.
Oildyne OUT/UP testing specifies 2,200–2,600 psi; the IN/DOWN test specifies 400–600 psi.
For Bravo Three, actual front and rear gear backlash is 0.012–0.016 in., after accounting for propeller-shaft spline lash. A separate 10-hour break-in schedule applies to new sterndrives and units with replacement gears.
Text Search, Navigation and PDF Contents
Search and diagram detail: Body text is searchable, although some graphic labels are not. Subchapter bookmarks provide navigation; the Models Covered entry has no destination. Some small wire labels require enlargement to read clearly.
One printable English-language PDF contains 596 pages: one cover, one spine-label sheet, ten introductory pages and 584 chapter pages. The total already includes 17 intentionally blank pages and the two notices about unavailable U-joint illustrations.
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