Exhaust leak, Adaptor plate - driveshaft housing. 2005 EFI 60hp

[Kronos]

Hi.

On my 2005 Mercury EFI 60hp outboard I have an exhaust leak between the adaptor plate and the driveshaft housing. There is quite some of the aluminum that has corroded away from both housings so not really sure if it will be reparable. I have sent both casings to a guy claiming to be aluminum weld specialist - so we will see how that turns out.

However, I do have two questions that I was hoping to get some help on!

#1, How to properly assemble these casings again? I read somewhere that a sealant of some kind was recommended? If so, does anyone have a guess on what type? I am expecting quite hot temperatures of the exhaust gas here since a lot of the aluminium has been corroded away.

#2, Aluminum has not only been corroded away where the leak is, also at like the first "bend" of the exhaust gas channel in the adapotor plate casing. What could be the reason for this? Is the engine running to hot for some reason?

Br,
Henrik

 

[Bondo]

What could be the reason for this?

Ayuh,..... Welcome Aboard,..... Is this motor run in saltwater,..??

 

[Kronos]

Ayuh,..... Welcome Aboard,..... Is this motor run in saltwater,..??

Thanks!!

No not really - the water is very brackish, almost no salt.

 

[Bondo]

Ayuh,.... Brackish is not freshwater, so I guess ya got yer answer,....

 

[Kronos]

Ayuh,.... Brackish is not freshwater, so I guess ya got yer answer,....

Hmm, but not sure I understand.. That part of the engine is sealed from water, it is just exhausts there (well before it corrodes to a leak at least).

 

[Bondo]

That part of the engine is sealed from water, it is just exhausts there

Ayuh,.... While the motor's exhaust does go through the mid-section,. So does the exhausted coolin' water,.....

It's "Wet" on both inside, 'n outside,....

 

[Kronos]

Ayuh,.... While the motor's exhaust does go through the mid-section,. So does the exhausted coolin' water,.....

It's "Wet" on both inside, 'n outside,....

I see! But it is in the channel for exhaust re-circulation (or what is called) not the actaul exhaust pipe where the corrosion occurred.

Does anyone have an idea for good reassembly? My parts have been weld repairded now but havn't seen them yet. Can I use some kind of sealing paste that is heat resistant?

 

[SlipperyMullet]

They make a red high temp gasket sealant that might work.

 

[Kronos]

They make a red high temp gasket sealant that might work.

Any idea of how hot it will get in that seal?

 

[SlipperyMullet]

If the high temp gasket sealant for exhaust should do.