Sailing Zephyr · video

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A failing Volvo shaft seal on the 40-foot sailboat Zephyr caused significant seawater ingress into the engine compartment during a coastal passage from New Bern, North Carolina.10:55 The crew discovered three inches of water in the bilge while motoring, identifying the source as the rubber boot of the shaft seal, which had worn down its internal carbon lip seals after approximately eight years of service.11:45 To resolve the leak, the crew performed an emergency haul-out at Zimmerman Marine near Holden Beach.14:29 Technicians disconnected the propeller shaft from the transmission, removed the seized coupling using hydraulic equipment, and replaced the worn seal.16:12 During the repair, the crew also replaced the pitted, corroded shaft coupling to ensure precise engine-to-shaft alignment and installed new sacrificial anodes to prevent further underwater metal corrosion.19:43 The repair required approximately 15 hours of labor.13:15 Regular monitoring of shaft seal integrity and engine alignment is essential to prevent catastrophic water ingress during operation.

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