Merc I/O over heats at 2000 RPM Plus only in the water

Tucon Dive

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Aug 24, 2009
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some details ...
Merc 5.7L carb + Bravo III in Proline 241 Walk ...
New Recirculating Pump, New Raw Water Pick-up, Thermostat removed, one month on new Risers and Manifolds and Lower-End Service.

Make a long story shorter ... i have an over-heat issue that I've research to the point where I found the following ...

With Boat on the rack and a water hose (muffs) on I don't have any over-heat issues at any RPM but I noticed that water is squirting out of the seam between the gimbel and drive unit. It is in the area of the water "pocket". After a Closer look I see screwdriver gouges resulting probably from service prying the drive apart ... about 1/8 in gap.

With the boat in the water and RPMs below 2000 no over heating issues .. but as soon as I rev the engine past that mark ,,, shortly after the boat planes out the temp raises quickly up to 200, the faster the acceleration the faster to 200. I've done many of the flow checks and rebuilt the raw water pick-up (salt-water) replaced the recirculating pump, removed the thermostat and searched for clogs. Sooo I'm thinking that the gap in the drive seam is allowing air to be sucked into the system at heavy loads, 2000 + RPMs and causing the over-heat situation.

My question is ... does this make sense? Anyone ever see this happen before?

Then, what's the best way to seal these gaps between the gimbel and upper drive housing (bravo III) ?
 

Tucon Dive

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Joined
Aug 24, 2009
Messages
7
Re: Merc I/O over heats at 2000 RPM Plus only in the water

Im sorry ... My confusion I mis- spoke .... I have these gaps is in the Gimbell housing to out drive seam .. the drive was "dropped" as one piece for service ..
 

Tucon Dive

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Joined
Aug 24, 2009
Messages
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Re: Merc I/O over heats at 2000 RPM Plus only in the water

yes that is the area of the leaking .. (page 61 Item 12 letter b) good info .. I'm afraid that a new gasket will not last long , the gouges from the screw drive allow the gasket to move/slide out of place .. are there xtra thick gaskets available or is there a recommended gasket sealer I could use to fill these gouges ? would it be necessary to build up each surface with metal (via welding) ?
 

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