1981 Sea Ray Sundancer won't shift/running hot. Lower removed

Discussion in 'Classic Sea Rays' started by Bill Nelson, Oct 26, 2019.

  1. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Got the lower removed on my outdrive. Oh...my...

    Good news is that the spline shaft moves freely, and I can shift the lower into gear by hand! So I guess that means it's in the transom shift cable? Removing the upper now.
    Last pic is the "naughty bits" (as my British friend would say) that fell out of the lower. Not sure what to think about them.

    lower1.jpg lower2.jpg lower4.jpg lower3.jpg
     
  2. Handsome Transom

    Handsome Transom Active Member GOLD Sponsor

    546
    Jan 26, 2018
    Penetanguishene Ontario Canada
    1989 SeaRay Sundancer 268 454 Bravo
    454 Mercruiser bravo drive
    Two of the pieces are damaged parts of one shutters that belong at the top of the y pipe,
    The other next largest piece looks to be a shaft seal or the centre part of an impeller. It is likely when the impeller parts went through your exhaust system they knocked out the shutter .
     
  3. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Ahh, yep that's what it is! I was looking on the wrong parts diagram. It's on the exhaust system drawing!

    Somehow, I think I escaped any long lasting damage to the outdrive. Seems unthinkable but it appears to work fine!

    Many Thanks, sir! Now I need to pull the Shifter Cable, which is still frozen. ;)
     
  4. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    I can't figure out how that would mount at the top of the Y-Pipe? Sierra Calls it a Water Shutter, and from the looks of the shape of it, the only place I can see it would mount is where the exhaust pipe meets the gimbal:

    baffle.jpg
     
  5. Espos4

    Espos4 Well-Known Member

    Jan 1, 2017
    Long Island NY
    2007 240 Sundeck
    350 MAG Bravo 3 W/DTS
    You have to go much higher than that.
    Up on the motor, there is an elbow on the exhaust that attaches to the top of the Y pipe.

    Remove that elbow and you will see the shutter sitting at the top of the Y pipe.
     
  6. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Yep, that's what I thought, but I pulled the elbow and that pipe is 4" in diameter and round not ovular like the baffles. Seems an odd place and would think there would be a gap.?
    ypipe1.jpg
    Unless it goes below the exhaust elbow, but above the exhaust bellows?

    ypipe2.jpg
     

    Attached Files:

  7. Espos4

    Espos4 Well-Known Member

    Jan 1, 2017
    Long Island NY
    2007 240 Sundeck
    350 MAG Bravo 3 W/DTS
    Hmmm.

    The newer style y pipe is oval at the top with 2 notches 180° apart for the shaft of the flapper to sit in.

    Maybe another look at the parts diagram will help point you in the right direction.
     
  8. Loyd Dinneen

    Loyd Dinneen Active Member

    386
    Jul 29, 2017
    Las Vegas
    1977 Sea ray 240 SDA cruiser w/ twin 470 mercs.
    Twin 470 Mercruisers
    What engine do you have? It looks like you have lost both shutters by the junk I see. And what is that growing in the exhaust? Looks like it has been awhile for any maintaince has been done.
     
    Last edited: Oct 28, 2019
  9. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    It's a 5.7 L Merc. I think what is growing in the exhaust is called "neglect"!
     
  10. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Agreed!
     
  11. El Capitan

    El Capitan Active Member

    455
    Jul 9, 2014
    Chicago IL./Vero Beach, Fl
    1970 SRV 180 w 2.5L Mercruiser.
    2000 Ford Expedition Eddie Bauer
    120HP Mercruiser
    Just imagine for a second the condition of all this if you were in salt!
     
    Bill Nelson likes this.
  12. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Hahaha yep this boat was based in Key West for most of her life.
     
  13. Thornton69

    Thornton69 Active Member

    455
    Sep 15, 2014
    Northern BC
    1981 245 SDC
    1984 18' Valco sled
    5.7 260 Merc/ Bravo 2
    Evanrude 115/80 jet
    When I removed the prealpha assembly in our boat, it had a 3 piece Y pipe. Pretty sure the exhaust shutters were located at the bottom in both sides of the center manifold.
     
    Bill Nelson likes this.
  14. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Wow, awesome, thanks!! I hate to ask...How do you get them in there? It seems like they are for backing, and when in following seas, yeah? I am wondering if I just take it easy backing, and with not much current in Arizona lakes, if I "need" them?
     
  15. Loyd Dinneen

    Loyd Dinneen Active Member

    386
    Jul 29, 2017
    Las Vegas
    1977 Sea ray 240 SDA cruiser w/ twin 470 mercs.
    Twin 470 Mercruisers
    You will need them or theres a chance you can get water up your exhaust when your stopping the water will follow up your rear and hydrolock your engine. Better to fix it now and not kill your motor. Another thing is you have your outdrive apart replace all the bellows, check your gimbel bearing for roughness, replace all the seals in the upper and lower outdrive (both uppers, carrier seals at the prop, shift shaft seal, impeller assembly with inner and outer housing and waterpump hose) not sure if I missed anything but overall rebuild the outdrive. This is not a hard thing to do just buy or make a few tools to to do the job. Then when your done pressure test it to make sure it will hold pressure and no water can get in. I did this on the two outdrives on my Searay 240. Oh also it is easier to mount the halves together while it is off the the boat just make jig out of plywood and a couple of sawhorses to slide the outdrive onto.
     
    Bill Nelson likes this.
  16. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Good advice Lloyd. Just want to nail down exactly where the Water Shutters go on a drawing. I'm an Engineer, so I over-analyze EVERYTHING! ;)
     
  17. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    I think I found it. Crud. I am not at home, but from memory this is going to be a drag to access

    exhaust.gif
     
  18. Thornton69

    Thornton69 Active Member

    455
    Sep 15, 2014
    Northern BC
    1981 245 SDC
    1984 18' Valco sled
    5.7 260 Merc/ Bravo 2
    Evanrude 115/80 jet
    That was not the style mine had. It was 3 pieces. That looks like a 2 piece and maybe for a 4 cyl? I believe the engine has to come out. It is also a good idea to check the mating surface of the Y pipe to transom assembly as well. It is known to be a bad spot for corrosion and can become a boat sinker. Do you have the Mercruiser s/n?
     
  19. Loyd Dinneen

    Loyd Dinneen Active Member

    386
    Jul 29, 2017
    Las Vegas
    1977 Sea ray 240 SDA cruiser w/ twin 470 mercs.
    Twin 470 Mercruisers
    I only know all this because of having to rebuild both of my outdrives and removing one of them twice. The only thing I regret not doing is replacing both shift bellows I think one may be leaking.
     
  20. Bill Nelson

    Bill Nelson Member

    40
    Oct 21, 2019
    New River, AZ
    1981 Sea Ray Sundancer
    5.7 L Mercruiser
    Yeah I may have the wrong drawing. I latched onto the top section looking similar. Bummer.

    Merc SN: Is this it?
    merc.jpg
     

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