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) is backordered and will ship as soon as it is back in stock.
Worry-free returns
Worry-free returns
Shop with confidence. If you’re not completely satisfied, eligible items may be returned within the return window, provided they are unused and in original packaging.
If the return is due to our error or a defective item, we’ll make it right.
Please contact us before returning any item.
Delivery and Shipping
Delivery and Shipping
Orders are typically processed within 1–2 business days.
U.S. orders usually arrive within 6–15 days, depending on stock location and destination.
International delivery times may vary due to customs processing.
Tracking information will be provided once your order ships.
Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One, Alpha Ge...
Exhaust Bellows Expander Tool – Fits MerCruiser Alpha One, Alpha Gen II, Bravo & Blackhawk Drive Units (Replaces 91-45497A1, 91-8M0096108) is backordered and will ship as soon as it is back in stock.
Product Details
This specialized **Exhaust Bellows Expander Tool** is designed for the proper installation of exhaust bellows on a wide range of MerCruiser stern drive units. It is compatible with MC-1/R/MR, Alpha One, Alpha One Gen II, Bravo (I, II, III), and Blackhawk drive units, ensuring a precise fit and seal.
This tool is a direct replacement for Mercury MerCruiser part numbers 91-45497A1 and 91-8M0096108.
- Engineered for manual mechanical operation.
- Constructed from durable steel for long service life.
- Features a scissor handle with a vinyl grip and secure screw lock mechanism.
Part Number Matrix
Use this matrix to confirm equivalent references across OEM and aftermarket.
| Brand | Part Number | Superseded By |
|---|---|---|
| Mercury MerCruiser | 91-45497A1 | 91-8M0096108 |
| Mercury MerCruiser | 91-8M0096108 |
Engine & Model Compatibility
Confirm your engine model/year in the table below.
This tool is designed for use with the following Mercury MerCruiser stern drive units.
| Drive Type | Years | OEM Part No. |
|---|---|---|
| Alpha One Gen II | 1998 and up | 91-45497A1, 91-8M0096108 |
| MC-1 | 91-45497A1, 91-8M0096108 | |
| R | 91-45497A1, 91-8M0096108 | |
| MR | 91-45497A1, 91-8M0096108 | |
| Alpha One | 91-45497A1, 91-8M0096108 | |
| Bravo One | 91-45497A1, 91-8M0096108 | |
| Bravo Two | 91-45497A1, 91-8M0096108 | |
| Bravo Three | 91-45497A1, 91-8M0096108 | |
| Bravo X (I, II, III) | 91-45497A1, 91-8M0096108 | |
| Blackhawk | 91-45497A1, 91-8M0096108 |
Technical Specs
- Product Type
- Exhaust Bellows Expander Tool
- Installation
- Manual mechanical operation
- Housing Material
- Steel
- Design
- Scissor handle with vinyl grip & screw lock
- Other Technical Attributes
- Opens with screw lock mechanism
What’s in the Box
- 1 x Exhaust Bellows Expander Tool (91-45497A1/91-8M0096108)
Installation Notes
- Ensure the engine is off, cool, and the drive is tilted to a safe, accessible position.
- Position the new exhaust bellow onto the bell housing exhaust outlet.
- Insert the expander tool fully into the open end of the bellow.
- Slowly turn the screw handle to expand the tool, stretching the bellow just enough to slide over the exhaust tube lip on the gimbal housing.
- Once the bellow is correctly seated in its groove, secure it with the designated clamp and torque to manufacturer specifications.
- Carefully loosen the screw handle on the tool to contract it, then remove it from the drive.
- Double-check that the bellow is secure, properly aligned, and tightly sealed.
Troubleshooting & FAQ
What is this tool used for?
This tool is specifically designed to expand the exhaust bellows for easier installation on MerCruiser stern drives. It holds the bellow open, allowing it to be correctly seated without damage.
Will this tool work on a Bravo III drive?
Yes, it is compatible with Bravo I, II, and III drives, as well as Alpha One (Gen I and II), MC-1, R, MR, and Blackhawk units.
How does the screw lock mechanism work?
The screw lock allows for gradual and controlled expansion of the tool's arms. This prevents over-stretching or damaging the new bellow and holds it securely in the expanded position during installation.
Is it difficult to use for a DIY installation?
While the tool simplifies the process, installing bellows can be challenging due to tight access. It requires care to ensure a proper seal. We recommend professional installation if you are not experienced with stern drive maintenance.
OEM vs. Aftermarket?
This listing is an aftermarket replacement (not OEM). Built to OEM-level specifications with comparable materials. Manufactured in an ISO 9002 facility, batch-inspected for consistency.
Shipping speed & cost
We ship worldwide quickly—typical transit 5–15 days. Standard shipping is free; expedited options appear at checkout where available.
Warranty & returns
Covered by a 1-year warranty against manufacturing defects under normal use. If issues arise, contact support with your order details. Returns are accepted within our standard window (unused & in original condition). See our policy page or reach out for instructions.
Safety & Important Info
- Verify images/specifications vs your original part. If anything differs—even if your model appears compatible—do not purchase.
- This is an aftermarket replacement, not an OEM component.
- Professional installation is recommended for safety and performance.
About Sea Sierra
- Pro-Grade Standards — We supply marine parts engineered to OEM-level tolerances and tested for real-world conditions.
- Fast Global Fulfillment — Free standard delivery to most regions in 5–15 days.
- Manufacturer-Direct Value — Fair pricing without compromising on materials or QC.
Payment & Security
Payment methods
Your payment information is processed securely. We do not store credit card details nor have access to your credit card information.
