Hello All,

Pair #7 is going to be installed this week!  This is one of the notorious 2003 / 2004 350 Mags with the exhaust manifold gasket issue.  The last set was put on 25 hours ago!  The engine has a total of 380 hours.  That is a new set of gaskets about every 55 hours!!!   Most of these have been covered by warranty.

It has been suggested from one of my esteemed boating friends and motor guy that there is a manifold warp and that done right an exhaust manifold should not need a gasket. So, I am looking for the following:   A specific contact at Mercury that I should reach out and speak too!  This is getting very old not to mention it is dangerous.

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III

Yeah, that is crazy.  Have you retorqued the manifolds after the the engine was ran?  

 Although Crownline can't help you directly with your Merc, maybe they could offer some assistance in getting somebody higher up in Merc to offer some assistance in making sure it is permanently fixed. 

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Steve Kroesen
Apollo Beach, FL
Kroes Nest

Crazy....a nicer word choice than I would have liked to use!

I have never retorqued the manifolds after running the engine.  It has never been suggested.  I can tell you everytime this happens I get retorqued!

I have posted an inquiry to Mercury via their website.  I am also hopeful that one of the contact names at Mercury pops up from CL....Jim Duff do you have a name of someone to contact?  Perhaps one of those Mercury folks from the Table Rock Rally will pop in.

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III

Well...I am trying to rated PG!

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Steve Kroesen
Apollo Beach, FL
Kroes Nest

Kevin,

Boy that brings back memories!!  My first car was a 77 chevy panel van and boy did we let the good times roll!!!  One problem I had with it is that the 350 would blow the header gaskets like you describe on your boat.  The re-torque did the trick there.  Here is what I would do.  Torque to spec on a new gasket, wait a couple of days and re-torque, wait a month and re-torque, recheck periodically.  Worked like a charm but I know how hard it can be to reach some of the bolts.  I think the root source of the problem is inconsistencies in the  two mating surfaces but I was poor and this made for more beer money!  I think that’s what made the world go around back then?  Right?

Chris

 

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2007 19SS w/4.3L Carb 1.87 Alpha 1

Kevin, I would work with my dealer first, and ask them to contact Mercruiser on your behalf. If, after going this route. you do not get assistance, you can contact Mercruiser Customer Service at 1-405-743-6566.

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Jim Duff
Crownline Boats, Inc

Thank you for the info Jim,

I am working with the dealer and they are always very supportive and in my opinion one of the best!  This just has me tweaked as it has been going on for so long.  Who would have imagined!

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III

Hey Chris,

Thanks for the trip down memory lane....panel van...good times!  Also, the tips on the header gaskets are great!  I guess tightening these headers is an option.  I am imagining swing-away hinges for the sunpad and quick-disconnects on the piston arms and a torque wrench fighting for space in the ski locker!  LOL!

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III

Kevin,  Sometimes dealers can lose focus, and in the process of keeping their customer happy by replacing the damaged part, may not consider asking for outside help. You should insist that they contact Mercruiser Tech Support and explain what has been going on.

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Jim Duff
Crownline Boats, Inc

Just to be clear on this. Are the gaskets you are discussing the gaskets between the block and the manifold, or between the manifold and risers?

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Wayne
242CR 5.7 liter
Ocean Gate, NJ
http://home.comcast.net/~wkroeck/242cr.htm

Hello Wayne,

The issue is between the block and the manifold.

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III

Kevin,

     How did the gasket thing turn out for you.  Did Mercury pay for the repairs?  I just found out I have another bad one.  This is only my 2nd, so I guess I'm lucky so far.  After my 1st, I called Mercury and complained, but they weren't much help.  They pretty much said since I was out of warranty and there was no recall, I was on my own.  I thought that was pretty crappy considering it should be a known problem by now and also the safety issue. 

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Chris & Cherie Blair
Granite City, Illinois
"Aquatic Justice"
'04 230BR - 350 Mag B3 (Opal/Spinal Wine)

Update!

The exhaust gasket leak turns out to be a noisy captain's call.  The dealer has been through the motor and that is the determination from them.  These guys at Walt's Boats in Springfield are VERY good and it is with relief that we learn it is not the gaskets again. 

The mechanic agreed that the sound that got me tweaked....errrr....kinda upset...is basically an identical sound to the gasket leak.  So, with relief, we put the boat away for winter. 

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III

Thanks for the update.  My mechanic installed Felpro Header Gaskets instead of the Mercury ones.  He said the header gaskets are a little thicker and might help.  Time will tell I guess. 

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Chris & Cherie Blair
Granite City, Illinois
"Aquatic Justice"
'04 230BR - 350 Mag B3 (Opal/Spinal Wine)

Hey Chris,

Good luck!  It is frustrating to have such a basic item fail.  Keep us posted.

 

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Kevin and Athena
Athena's Odd-a-Sea
2003 225 BR
350 MAG / Bravo III