CONSUMER PROTECTION
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Volvo Bellows Failures Vex Owners
By Caroline Ajootian
An ongoing problem with the bellows on certain Volvo sterndrives leaves boaters at a loss for what to do next
B
ellows failures on certain Volvo
sterndrive engines have left doz-
ens of owners frustrated, in some
cases unable to use their boats,
The service bulletins were
issued by Volvo Penta in late 2008
and again in April 2009 and July
2009. They describe how the
U-joint bellows installed on some
of Volvo’s composite XDP outdrives (see box for models and
serial numbers) can buckle and
make contact with the U-joint during high-speed turning or loading maneuvers. The
flexible waterproof bellows are intended
to protect the U-joint linking the outdrive
unit to the inboard engine. Volvo explains
that the series of bulletins reflects “
continuous improvement” as bellows designs
evolved in response to failures.
Bellows failure on this Volvo XDP outdrive resulted in damage
to the U-joint.
PHOTO RUSS HANDY
“While we would’ve liked to avoid
multiple replacements of bellows on
XDP drives, we weren’t happy with the
performance and longevity of the earlier
designs,” said Tony Kelleher, director of
Product and Customer Support. Volvo
Penta told BoatU.S. that approximately
2,400 5.7L and 8.1L engines both in the
U.S. and worldwide are affected. BoatU.S.
has received 12 documented reports of bel-
lows failures and related complications, but
online chat rooms frequented by boat own-
ers and marine surveyors contain dozens
more accounts. Volvo has determined that
bellows failures are most likely to occur in
heavy boats equipped with twin 5.70SXi
or 8.10Si engines, where excess torque is
created in the drive area during high-speed
or high-load turns. Abrasion of the bellows
can cause water entry and possible cor-
rosion of the U-joint and gimbal bearing,
according to reports BoatU.S. has received
from owners and engine mechanics.
