Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One & Bravo Series (Replaces 91-45497A1, 8M0096108)

Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One & Bravo Series

This specialized tool is designed to easily stretch the exhaust bellows for installation on MerCruiser stern drives. It is compatible with a wide range of models, including the Alpha One (Gen I & II) and Bravo (I, II, III) series from 1980 to the current model year.

This tool is a direct replacement for Mercury/MerCruiser part numbers 91-45497A1, 91-8M0096108, and 8M0096108, as well as aftermarket numbers Sierra 18-9847, GLM 90360, and Mallory 79811.

• Material: Constructed from high-strength steel for durability.
• Grip: Features a non-slip, PVC-covered handle for secure operation.
• Installation Note: The stern drive must be removed to use this tool properly.

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 (91-45497A1)

Installation Guide

1. Install the exhaust bellows onto the gimbal housing.
2. Insert the tool and expand it to stretch the bellows through the exhaust hole in the bell housing.
3. Once the bellows is in place, tighten the hose clamp to secure it.
4. Note: The stern drive must be completely removed from the boat to perform this installation correctly.

Troubleshooting & FAQ

Q: Will this tool work for my MerCruiser Bravo III drive?
A: Yes, this tool is compatible with MerCruiser Bravo One, Two, and Three drives for all serial numbers from 1988 to current models.

Q: Is it absolutely necessary to remove the stern drive to use this tool?
A: Yes. For the tool to function correctly and to allow proper installation of the bellows, the stern drive unit must be removed from the gimbal housing.

Q: How do I use the tool?
A: After placing the new bellows on the gimbal housing, insert the tong-like end of the tool into the bellows. Squeeze the handles to expand the bellows, stretching it through the opening in the bell housing. Once it is through, you can secure the hose clamp.

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.