Lower Unit Repair/ Remanufacture Process

More about our quality remanufactured gear cases:

Inspections:

We begin by disassembly of the drive, and visual inspection of all components.   The cases are inspected for any damage.  We repair and damage to the gear case by the Heliarc Welding process.  Primarily, the splach plate, cavitation plate or skeg is likely for repair.  We weld up damage in a gear case housing if that damage is minor and no distortion results.  Again, the bottom line is well within O.E.M. specs, period.  If the case passes initial inspection, micrometers are employed to make sure the housings are well within factory O.E.M. specs.  All other components are inspected by both a visual check and by Magna-Flux process to detect stress levels and degree of wear. All shafts are inspected with a dial indicator in a lathe to insure trueness and freedom from any spline wear, twist or damage.  The gears and clutch are subject to the same rigid inspection.  Any component that is not within O.E.M. specifications will be discarded and replaced.

Cleaning of Components:

Cleaning of all components is as important a step as anything else we do, for to ensure reliability and longevity, absolute cleanliness is a necessity.  Any type of contaminant can damage seals and bearing surfaces and cause failure.  We put all parts through our multi-step cleaning process which eliminates all contaminants inside and out.

There is clean and then there is U.S. Boatworks clean.  This standard is reinforced daily at our facility.  Another visual inspection takes place now and it is a very careful one to confirm that cleaning of all components is 100% complete and ready for assembly.

Assembly of Components: 

The inspected and cleaned components are now moved to one of our assembly stations.   This is where we build in QUALITY.  You may have heard of the term "Blue Printing".  This refers to any multi-component piece of machinery, be it an engine or an outdrive or lower unit.  It means an assembly of components put together as closely as possible to the design blueprints.  This results in a unit which is as close to the original design of the unit as you can get. 

 All of our assembly is performed by factory trained personnel.  We have every factory tool made for the marine industry and the people who know how to use them.  Precision assembly of all components is assured.  All preload tolerances and bearing clearances are set well within O.E.M. specifications and as close to "blue print" as we can make them.  Of course, we replace all parts which do not meet strict O.E.M. specifications.  New gaskets and seals are always used. 

Quality parts and procedure, plus precision assembly equals reliability.

Rigid Testing:

Every stern drive and lower unit from U.S. Boatworks is tested for smoothness of operation - correct forward, neutral and reverse shifting.  A pressure and vacuum test preclude the possibility of case leakage.  The pressure and vacuum tests are conducted over a lengthy specified time period.  These factory tests are proof of a positive seal.  At this point, the completed unit moves to our refinishing department.

Highest Quality Refinishing:

Our paint department employs a multi-step refinishing process on every unit to assure maximum durability and corrosion protection as well as a "like new finish".   After curing, factory decals are reapplied to finish off the job.  At U.S. Boatworks, we feel our remanufactured units should not only perform like new, they should look like new.

Substantial Savings:

Savings with a U.S. Boatworks remanufactured unit are two fold.

MONEY.. certainly.  A remanufactured unit is much less than a new unit, but normal operation and care result in "like new" performance and long life. 

TIME Savings.  Installation of one of our units takes much less time than an overhaul... and we will install for you, saving you even more time which you can use to enjoy your boat.  We pride ourselves on keeping you on the water which is why you should buy from us..

Availability: 

Most units are available in stock in our Kansas City facility.  If a completed unit is not on the shelf, rest assured we have the components on hand so we can build one for you immediately. 

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