water leaking from top cap of upper gearcase

[chs marine service]

i resealed an alpha 1 gen II and after starting it up there is water leaking out of the top cap, i removed the cap and replaced the rubber plug that seals up thewaterjacket and its still leaks, i cleaned all the crud from the 2 mating surfaces and still leaks. no water is getting into the gearcase so thats a good thing. i swapped out the caps with another drive i have but the leak is still there. moreof a weaping but still a leak.

 

[Rick Stephens]

Ignore it. There is cooling water going there. Not hurting a thing.

 

[chs marine service]

its hard to just ignore it, i have a customer staring at a leak on his drive. also iif there is water leaking out, that is water not making it to the engine.

 

[achris]

Lift the cap again and remove the rubber plug. Throw it in the bin! Clean the surfaces around the water jackets and put a THIN smear of sealant ('book' says perfect seal. I use silicone gasket sealer). Allow a few minutes of the sealer to 'skin', then put the cap back on with the bolts still not torqued. Wait a few hours and torque the screws (27Nm)

It's in the Merc manual.

Chris.....

 

[chs marine service]

Lift the cap again and remove the rubber plug. Throw it in the bin! Clean the surfaces around the water jackets and put a THIN smear of sealant ('book' says perfect seal. I use silicone gasket sealer). Allow a few minutes of the sealer to 'skin', then put the cap back on with the bolts still not torqued. Wait a few hours and torque the screws (27Nm)

It's in the Merc manual.

Chris.....

so Chris, your saying to remove #1 and add sealant to #2 plus the cap?

 

[achris]

so Chris, your saying to remove #1 and add sealant to #2 plus the cap?

Yep...

 

[Rick Stephens]

Mine leaked first day I reassembled it after a rebuild and reseal. It just stopped leaking after day 1, all by itself. Hence my ignore it comment. The passageway under the cover, where the rubber dam is, is connected to water passageway coming from impeller.

 

[Djunegarcia]

I’m also having the same issue. Water leaking from top cap however it also leaked into gear box causing milky oil. Had to open both upper and lower gear box and clean/replace any damaged bearings/parts. Have everything back together now except top cap. I will do the “thin” silicone trick and see how it works. Any trick on getting an even thin layer of silicone on water port area achris??

 

[achris]

I’m also having the same issue. Water leaking from top cap however it also leaked into gear box causing milky oil. Had to open both upper and lower gear box and clean/replace any damaged bearings/parts. Have everything back together now except top cap. I will do the “thin” silicone trick and see how it works. Any trick on getting an even thin layer of silicone on water port area achris??

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