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

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

This specialized tool is designed for stretching and installing exhaust bellows on MerCruiser sterndrive units. It is compatible with Alpha One (Gen I & II), Bravo (One, Two, Three), Blackhawk, MC-1, R, and MR drive units from 1983 and newer.

This tool is a direct replacement for Mercury part numbers 91-45497A1 and 8M0096108, as well as aftermarket equivalents a from Sierra (18-9847) and GLM (90360).

• Installation Method: Manual operation with a scissor-handle and screw lock mechanism.
• Required Step: The sterndrive (Z-drive) must be removed from the gimbal housing to use this tool correctly.
• Durable Construction: Made from high-quality steel with a PVC grip for secure handling.

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 91-45497A1/8M0096108)

Installation Guide

1. First, install the new exhaust bellows onto the gimbal housing.
2. Use this tool to gently stretch the other end of the bellows through the exhaust hole in the bell housing.
3. Once the bellows is properly seated, tighten the hose clamp to secure it.
4. Note: The sterndrive (Z-drive) must be completely removed from the boat to access the bellows and use this tool correctly.

Troubleshooting & FAQ

Q: How do I confirm this tool fits my sterndrive?
A: This tool is designed for a wide range of MerCruiser drives, including Alpha One (Gen I & II), Bravo Series, Blackhawk, and others made since 1983. Check the compatible models list and cross-reference your original tool part number with 91-45497A1, 8M0096108, Sierra 18-9847, or GLM 90360.

Q: Do I have to remove the outdrive to use this tool?
A: Yes. The sterndrive unit (Z-drive) must be removed to gain access to the exhaust bellows for replacement. दिस tool cannot be used with the drive installed.

Q: Is this tool the same as the original Mercury 91-45497A1?
A: This is an aftermarket tool designed to perform the same function as the OEM tool. It is built to match the specifications required for successfully stretching and installing the exhaust bellows on compatible MerCruiser drives.

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.