Bellows Expander Tool – Fits MerCruiser Alpha One, Alpha Gen II, Bravo 1/2/3, MC-1, R-MR & Blackhawk Drives (Replaces 91-45497A1)

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

This marine exhaust bellows expander tool is designed for MerCruiser stern drives, providing a scissor-style mechanism to stretch and install the exhaust bellows during replacement. It is compatible with a wide range of MerCruiser drive models, including Alpha One (Generation I & II), a range of Bravo models, Blackhawk, MC-1, and R-MR.

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

• Installation Method: Scissor-style mechanism with a screw lock to securely hold the bellows.
• Construction: Made from durable steel with a vinyl grip handle for comfortable operation.
• Function: Specifically used to stretch the exhaust bellows through the transom opening for proper installation.

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

This package includes the following item:

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

Installation Guide

Follow these steps to use the bellows expander tool correctly. Note: The stern drive must be removed before using this tool.

1. Install the new exhaust bellows onto the gimbal housing.
2. Insert the expander tool into the bellows and use the scissor-action handle to stretch it.
3. Carefully guide the stretched bellows through the exhaust hole in the bell housing.
4. Once the bellows is properly positioned, tighten the hose clamp to secure it in place.

Troubleshooting & FAQ

Q: How do I confirm this tool fits my MerCruiser drive?
A: This tool is designed for a broad range of MerCruiser stern drives, including Alpha One (Gen I & II), Bravo (One, Two, Three), Blackhawk, MC-1, and R-MR models. You can verify fitment by checking if your original tool's part number is 91-45497A1 or 8M0096108.

Q: Why is this tool required for the job?
A: The exhaust bellows is designed to fit snugly and must be stretched significantly to pass through the transom opening during installation. This tool provides the necessary leverage and holding power to perform this task safely and correctly, preventing damage to the new bellows.

Q: Is the stern drive really required to be removed for use?
A: Yes. Accessing the exhaust bellows connection points on the bell housing and gimbal housing is not possible with the stern drive in place. It must be removed to perform the replacement.

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.