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What is this assembly? (pic) 1996 Mercruiser 5.7 Alpha 1

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  • #16
    Well, I can tell you with 100% certainty, that impeller was run dry, and for more than 1 minute.You will also need to replace the housing and cup, and the base as well. That much heat and they are both history.... There's also a very high likelihood the hot exhaust gasses have distorted the water pocket cover in the bottom of the upper housing... Plan on replacing that too. (Or you'll get 'overheats at high speed')

    Chris......

    EDIT: Just reread the first post... If this engine is a 1996, that makes it a Gen II. That much damage to a GEN II impeller I take it back, it wasn't 1 minute. It would need to have been about 5! I had assumed it was a Gen I by the photo! So, no water pocket cover to deal with, and the pump housing is stainless, so it MIGHT be ok. The seal carrier under the pump base will be melted though... Replace that... And pull the exhaust elbows, and replace the shutters (what's left of them!)
    Last edited by achris; February 9th, 2019, 02:17 PM.
    xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
    The world takes on a whole new perspective when viewed from 100’ below.
    1972 Bertram ‘Bahia Mar’ 20
    2006 Mercruiser 4.3MPI (0W617679) w/Alpha One Gen II (0W829301)
    (Original - 1972 '165' In-line 6. Previous - 1994 4.3LX)


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    • #17
      Originally posted by achris View Post
      Well, I can tell you with 100% certainty, that impeller was run dry, and for more than 1 minute.You will also need to replace the housing and cup, and the base as well. That much heat and they are both history.... There's also a very high likelihood the hot exhaust gasses have distorted the water pocket cover in the bottom of the upper housing... Plan on replacing that too. (Or you'll get 'overheats at high speed')

      Chris......

      EDIT: Just reread the first post... If this engine is a 1996, that makes it a Gen II. That much damage to a GEN II impeller I take it back, it wasn't 1 minute. It would need to have been about 5! I had assumed it was a Gen I by the photo! So, no water pocket cover to deal with, and the pump housing is stainless, so it MIGHT be ok. The seal carrier under the pump base will be melted though... Replace that... And pull the exhaust elbows, and replace the shutters (what's left of them!)
      You are right- Gen 2. it does look melted, right? I had a professional marine mechanic do the work. He said that the housing was OK. Not sure what he replaced but he is the go-to company for the workyard at my marina so I feel pretty good about it. Not cheap. The previous (and original) owner kept the boat very clean inside and out but was not a mechanical genious. He had attempted to replace the thermostat but didn't use the correct gasket (just a TON of gasket sealant goop) so the temp gauge wasn't working when I bought it. And of course, it had been overheating because of the fried impeller. I have no idea how long it had been like that and how long it had been overheating. That said, the engine runs strong and I am hoping there is no serious permanent damage. It wouldn't suprise me if he ran it dry. Thanks for the analysis, Chris.

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      • #18
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        As Chris stated...I would check the exhaust shutters. They probably got fried too. And their metal flappers can break loose and fall into some bad places where they can do harm. I found one all the way inside my outdrive when I was doing impeller replacement.

        There's also a plastic water tube that joins between the lower and the upper drive. Forgive me, I don't know the proper name for it. Mine was distorted from excessive heat.
        Point is...a lot can go wrong when an overheat happens. Always keep an eye on your temperature gauge and make sure water is flowing out of your stern drive.

        Be very careful when running it on muffs in your driveway. Make sure your garden hose has enough pressure, your muffs are connected properly and don't run the engine above idle. You can rev it slightly for short low RPM bursts, but don't do it for long.

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