Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One Gen I/II, Bravo 1/2/3, MC-1, R-MR, Blackhawk

Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One Gen I/II, Bravo 1/2/3, MC-1, R-MR, Blackhawk

This specialized marine tool is designed for installing exhaust bellows on MerCruiser sterndrive units. It simplifies the process by stretching the exhaust bellows through the exhaust hole in the bell housing, ensuring a secure installation on models including Alpha One (Gen I and Gen II), Bravo (1, 2, and 3), Blackhawk, MC-1, and R-MR.

This tool is a direct replacement for MerCruiser part numbers 91-45497A1 and 91-8M0096108/8M0096108, as well as several aftermarket equivalents.

• Installation Method: Manual operation with a scissor handle provides leverage to expand the bellows.
• Durable Construction: Made from steel with a black oxide finish for corrosion resistance.
• Enhanced Grip: Features an anti-slip function on the scissor handle for better control 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.

Technical Specifications

Package Contents

• 1 x Exhaust Bellows Expander Tool (91-45497A1)

Installation Guide

1. Ensure the engine is off and the drive unit is safely secured in a suitable position for access.
2. Position the new exhaust bellows over the exhaust tube on the gimbal housing.
3. Insert the expander tool through the exhaust hole in the bell housing and into the open end of the bellows.
4. Squeeze the scissor handles to expand the tool. This will stretch the bellows evenly.
5. While the bellows is stretched, guide it over the designated flange on the bell housing until it is properly seated.
6. Once the bellows is correctly positioned, release the pressure on the tool handles and carefully remove it.
7. Secure the newly installed bellows with the appropriate clamps according to the manufacturer's specifications.

Troubleshooting & FAQ

Q: How do I confirm this tool will fit my engine?
A: This tool is designed for a wide range of MerCruiser sterndrives, including Alpha One (Gen I and II), Bravo (1, 2, 3), Blackhawk, MC-1, and R-MR models. Please check the 'Part Number Cross-Reference' and 'Compatible Engine Models' tables to verify it matches your required OEM part number (91-45497A1 or 91-8M0096108).

Q: What is the benefit of using this expander tool?
A: It provides the necessary leverage to stretch the exhaust bellows uniformly, making it significantly easier to install the bellows through the exhaust hole in the bell housing without causing damage. The anti-slip handles ensure a secure grip during the process.

Q: Can I install the bellows without this tool?
A: While other methods may exist, they risk damaging the new bellows or causing improper seating, which could lead to exhaust leaks. This tool is specifically designed for the task, ensuring a safe and effective installation.

Q: Is this an OEM part?
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.