Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One, Alpha Gen II, Bravo & Blackhawk Drive Units (Replaces 91-45497A1, 91-8M0096108)

Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One, Alpha Gen II, Bravo & Blackhawk Drive Units (Replaces 91-45497A1, 91-8M0096108)

This specialized service tool is designed for the proper installation of exhaust bellows on MerCruiser stern drive units. It provides the necessary leverage and expansion to correctly seat the bellows without causing damage, ensuring a secure fit.

This tool is a direct replacement for Mercury MerCruiser part numbers 91-45497A1 and 91-8M0096108, compatible with MC-1/R/MR, Alpha One, Alpha One Gen II, Bravo (I, II, III), and Blackhawk drive units.

• Engineered for installing exhaust bellows on a wide range of MerCruiser stern drives.
• Features a robust scissor handle with a screw lock mechanism for controlled, even expansion.
• Constructed from durable steel to withstand mechanical force during use.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below. For Mercury owners, here’s a guide to help you identify your engine’s serial/model: Mercury Serial Number Guide. You can also review exploded diagrams to verify part numbers: Mercury Parts Diagrams & Catalog.

Technical Specifications

Package Contents

• 1 x Exhaust Bellows Expander Tool (Replaces 91-45497A1 / 91-8M0096108)

Installation Guide

1. Ensure the stern drive unit is properly supported and secured before beginning work.
2. Lightly lubricate the inside lip of the new exhaust bellows with a suitable marine adhesive or soap solution.
3. Insert the collapsed expander tool fully into the end of the bellows.
4. Turn the handle's screw lock mechanism to slowly and evenly expand the bellows. Do not over-expand.
5. Once the bellows is wide enough, carefully slide it over the exhaust tube on the gimbal housing until it is properly seated.
6. Release the tension on the tool by reversing the screw lock, then carefully remove the tool.
7. Secure the bellows in place with the designated clamp and tighten to the manufacturer's torque specification.
8. Double-check that the bellows is secure and properly aligned before completing reassembly.

Troubleshooting & FAQ

Q: How do I confirm this tool will work with my MerCruiser drive?
A: This tool is designed for a broad range of MerCruiser drives, including the MC-1, R, MR, Alpha series, Bravo series, and Blackhawk models. Please check the compatibility table and verify that your drive type is listed. It directly replaces OEM part numbers 91-45497A1 and 91-8M0096108.

Q: What is the purpose of the screw lock on the handle?
A: The screw lock mechanism allows you to expand the bellows in a slow and controlled manner. This prevents tearing the bellows and allows you to lock the tool at the desired width, making it easier to hold the bellows in place while sliding it onto the drive housing.

Q: Can I install a bellows without this tool?
A: While other methods may exist, they carry a high risk of damaging the new bellows or failing to achieve a secure seal. This expander tool is specifically designed to apply even pressure for a safe and proper installation.

Q: OEM vs. Aftermarket?
A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?
A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?
A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.