85 mercury 35hp outboard exhaust section removal?

Gtomanohio

Recruit
Joined
Aug 13, 2019
Messages
1
Need some help my 35hp mercury outboard 1985 the exhaust housing is cracked and I need to replace it anyone know how? Any schematics for removing...
 

Chinewalker

Fleet Admiral
Joined
Aug 19, 2001
Messages
8,902
Complete disassembly is needed. Remove the powerhead and lower unit. Remove all cowlings, shift rod and support brackets. Remove the upper and lower motor mounts. Basically, remove anything attached to the exhaust housing. Take pics as you go, tape and label any wires. You’ll be replacing some gaskets, notably those under the powerhead. Schematic diagrams can be found all over the web.
 

Chris1956

Supreme Mariner
Joined
Mar 25, 2004
Messages
27,035
If it is like most Mercs, you need to pull the gearcase and powerhead. You will need to work around any corrosion that inhibits your removal.

At this point you may be able to remove the lower motor mount covers and cages, Now pull out on the midsection and she may be free. she will need to drop straight down to clear the water tube. Tilting the motor may help.

If not, try the following steps.

Remove the shift rod.

Separate the exhaust extension halves(top and bottom). Look for some bolts under the powerhead, when it has been removed. You may or may not have any. However, these will likely break.

Now the swivel steering rod and upper motor mounts can be removed, pulling them up and out of the swivel rod yoke. There may be a split ring under the lower swivel rod yoke. This would need to be removed.

The midsection should be free, although some models have more bolts from the exhaust extension to the midsection.

The motor mounts usually rust solid to the mounting bolts. You can reuse them is they are good. Source them before deciding to replace them, as they might be hard to get. The motor mount bolts are likely grade 8 steel.

You will need a powerhead gasket and exhaust extension gasket, plus a midsection gasket.

Good luck.
 
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