45Hp Chrysler, Internal water tube issue

I have a 1980 45hp chrysler Model 457H9K Serial No 3208.<br />Motor has corroded out the top inch of the internal water tube going up the leg. <br />The parts book shows a washer and "o" ring seal at the top.I would like to inspect the upper mating surface, ensuring the old corroded parts are gone and good new installation is achieved. Workshop manual does not show where it connects to (head or block)and accesssing it?<br />I removed the exhaust side cover --its not there. Do I have to split power head and leg for this simple pipe?

Re: 45Hp Chrysler, Internal water tube issue

I dont know of an easy way to remove the motor leg. The grommet or gasket you are refering to is located between the lower kingpin and the motor leg gasket. The service manual has a very detailed procedure concerning the motor leg. You can get one from www.chryslercrew.com My guess is you will need to take the powerhead off then remove the kingpin/spacer plate. You will need a new upper and lower gasket and some permatex. Removing the powerhead is pretty simple and straight forward. If it were me I would just intall the water tube and if the grommet holds it in place when motor is in down position I would not worry about it. If it will not hold it in place you may have to go in there and find out why.

Re: 45Hp Chrysler, Internal water tube issue

Thanks for your guidance - I had purchased the workshop and parts books to try to resolve these issues by myself before troubling you(as a young man i was a mechanic)but there were no details on this item or repair.<br />The quality of your response has given me confidence to be a bit rougher and install the pipe and monitor the cooling system incase a piece of old pipe obstructs flow.<br />Re power head removal.<br />I have an issue with spanners to fit leg screws which i will post as a seperate item as per forum guidelines

Re: 45Hp Chrysler, Internal water tube issue

The shift linkage inside the motor leg uses a 7/16 inch wrench. There is no metric equivilent. Have you removed the lower unit yet? By spanners do you mean wrench?<br /><br />Put motor in a garbage pail of water and run at high neutral. Water should come out of the telltale on the motor leg. You wont see a lot but it should be very warm water coming out. If so you are probably okay. It is possible to back flush by removing the thermostat but I dont recommend it being in australia. If you damage the gasket or the thermostat you will probably have trouble getting new parts for it. If you have any questions please post. If you need pictures of something email me at ralgoetz@comcast.net.

Re: 45Hp Chrysler, Internal water tube issue

Well ---Its never easy!!!!!!!!!!<br />Sadly the grommet at top of the water tube is no longer present. Leaves me no choice but to split power head and leg.<br />Probably for the best,(do it once do it well)I will replace thermostat and impellor since I am that close, plus a quick clean up of the water galleries via the exhaust cover that i had removed and i shouldn't be far off a decent cooling system overhaul --- HMMMMMMMMMM-- will not have done cylinder head and block galleries?? Pull the head and do it?? Damm got to stop somewhere before replacing a waterpipe ends up in a complete motor dismantle!<br />As I have good compressions 127 & 130 i think best left alone and just back flush system when rebuilt.<br />I would value your opinion on my logic?<br /><br />Re: Spanners to fit the 8 powerhead/leg screws.<br />They are 12 spline double hexagonal headed screws which due to corrosion I believed were 9/32 wrench size.Double hexagonal(12 teeth)9/32 sockets and ring spanners are no longer available- not made-.<br />Today i got two screws out with a 1/4" wrench just gripping,so I believe i was mistaken and they started their life as a more standard 1/4".<br />Therefore it is now time to weld bolts onto the heads of these ugly little creatures and remove them to the rubbish bin, and curse the days wasted searching manufacturers for 9/32 spanners to save their worthless little lives.<br /><br />AHHHH it must be the challenges we overcome that give us a sense of achievement

Re: 45Hp Chrysler, Internal water tube issue

My guess is this motor has been in salt water. If so I wish you luck. It has been awhile since I have removed things from my motor however seems the only wrenches I used were 7/16, 1/2 and 9/16 inch. If you are removing the port side exhaust gaskets I believe they are 3/8 inch. I broke three of the 8 screws when I did mine. I had to use JB weld to fill and retap those three holes. Welding is a pain cause it is aluminum. Local welder here would not do it for me. <br /><br />Power head removal is pretty easy if you can get the lower unit off. Salt water may have corroded it to the power head also complicating the head removal. The head is like 9 bolts after you remove most of the electrical and fuel pump and carb. Two of the screws are near the air baffle towards the front near the id plate under the carb. The upper and lower exhaust gasket are very similar however the grommet and water tube hole on the bottom gasket is bigger then the top. One goes under the spacer plate and the other goes above. Email me at above address and I can send you photos and you can send me yours.