38 Sundancer Transmission Issues

juggernaut1

Well-Known Member
Apr 19, 2015
1,152
Perth, Western Australia
Boat Info
Boatless - sold Searay 38 Sundancer
Engines
8.1’s
In the short time I've owned it, I've had a good run with my boat so far and now maybe this is the start of my woes.

I was making a 70klm trip yesterday up the coast. Approx 20klm's into the trip I struck transmission problems. I had pulled in behind an island and and was coming back out getting onto the plane moving the throttles forward and then I noticed the starboard motor wouldn't rev past 3500 rpm and there was a small but noticeable vibration. So I pulled back to low rpm and cruised to the next island (1 klm away) and went behind that island to sus out the problem. Having determined nothing was wrapped around the props/not lose/no movement/freely rotated our attention turned to the engine bay. No leaking fluids and oil fluids level fine - no alarms nothing on the smartcraft suggested any problems.

Both motors revved freely but when in gear we isolated that there was noise from the starboard transmission which was like a kchunk, kchunk, kchunk when in gear. (This is why we initially thought something was wrapped around the prop)

Anyone have any ideas what could possibly be wrong with the transmission and particularly the limitation of revs on that motor? (Spark plugs were changed 40 hours ago)

By the way I made the rest of the trip (50klm's) on one motor (sat on 2,000 rpm which averaged around 8 knots with full fuel water and 2 p.o.b.) out in the ocean and up the river to to be hauled for antifouling and polishing. After adjusting the trim tabs to compensate it drove with little yaw to my surprise.
 
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Change your spark plugs!!!
Ask me how I know this.

Clunking noise only happens when in gear, at idle.

Don't use the AC Delco, switch over to a Champion equivalent. Sorry I don't know the exact Champion replacement, but your local auto parts should know this info... I switched over years ago and haven't looked back since.
 
Clunking noise and vibration happens at all speeds in gear. However, no vibration when free revved but only when in gear under load.

My Mercruiser tech used NGK TR55IX's when they were last replaced 40 hours ago. Are these rubbish?

Still think spark plugs? I guess there may be a causal link between bad plugs and the rpm limitation I'm experiencing.

As mentioned above it would rev to around 3,500 rpm in gear but didn't want to rev past that regardless of where the throttle was - is this a sign of bad plugs?
 
I'm not a mechanic and no expert so take this with a grain of salt. We experienced a severe vibration on our boat on the Port side and I had to shut it down and limp home (8 hours!) on one engine due to 3 of the 4 coupler bolts shearing off, so the shaft was vibrating at the coupler. I had no idea what the problem was since the engines seemed to be running fine and I couldn't see any problem (no leaks or obvious problem). So could it be a problem at the coupler/transmission, not with the engine and plugs?
 
Hi La Maddalena,

When I rang the Mercruiser tech yesterday he initially suggested that it could be the coupler but said that it shouldn't limit engine rpm that we were experiencing.

He also suggest the prop may have come loose - but my brother dived overboard yesterday when we were behind the island and reported that everything was fine as we initially thought were had something wrapped around the prop or something had come loose causing the vibration, the rotational kchunk noise and limiting engine rpm.

I spoke to the Mercruiser tech moments ago and said he will firstly look at the motor due the to engine rpm issue.

Prior to the problem I had been running at between 3,500 - 4,000 rpm for the first 20 klm's. At no stage had I turned the motors off prior to the problem. I had only shifted into neutral behind the first island for a few minutes then back in gear to head out in open water again - getting back up on the plane is when the problem surfaced.
 
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Can someone please confirm whether or not the fuel pumps are supposed to run constantly when the ignition rocker switch is on prior to starting. Or should the pumps run until they develop the required fuel pressure then stop.

Thanks in advance.
 
I've had similar issues before and each time it's been the plugs. The ZF's are very tough so I have my doubts about them being the issue. In my case, the offending engine would not be able to produce the same power as the other while on plane and would need more throttle. There was also a vibration while getting onto plane probably since the engine was not firing all cylinders. The engine used quite a bit more fuel to get home since it had to have the throttles set wide open just to keep on plane with the other engine at 3/4 throttle. Once off plane the transmission clunking began and freaked me out! This was on the maiden voyage after indoor heated storage for the winter. Boat ran perfectly when put away...

New plugs - problems gone!
 
Thanks Jimmy,

New plugs it is then. The mer cruiser tech found no issues when he did a diagnostic test but found the fuel pumps continuously ran on both motors with the ignition on without the motors being started.
 
Just thought I would report back with what my issue was.

Per the advice here I starting changing plugs on the starboard motor - the NGK Iridiums all looked like brand new - then I was about to put the plug lead back on the No.3 plug and I found it had split in two places down to the wires near the plug and one of the splits had arcing marks. I had previously had the manifolds and plugs changed and the Mercruiser tech must have hung the lead so that it was touching the exhaust manifold causing the problem. So I swapped a lead over from the other motor and straight away it sounder sweeter on startup and the tranny noises disappeared when in gear - thank god! I had bought a couple of off the shelf leads with me from the local auto shop but had to slightly modify to get it to fit into the coil.

Made the 70 klm trip back to the marina with no problems.

Now to find a couple of lead sets as I might as well replace the lot to prevent the above occurring again.

Do I go the genuine leads or aftermarket? If aftermarket does anyone have any suggestions?

Also must say a big thanks for those that chimed in with assistance as it narrowed the problem down to a couple of things :smt001

As a precaution I'd suggest everyone check the proximity of the plug leads to their exhaust manifolds.
 
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I'm not a mechanic and no expert so take this with a grain of salt. We experienced a severe vibration on our boat on the Port side and I had to shut it down and limp home (8 hours!) on one engine due to 3 of the 4 coupler bolts shearing off, so the shaft was vibrating at the coupler. I had no idea what the problem was since the engines seemed to be running fine and I couldn't see any problem (no leaks or obvious problem). So could it be a problem at the coupler/transmission, not with the engine and plugs?

La Maddalena is spot on! Had the exact same symptoms as mentioned resulting from the exact Same exact problem with my 2006 44 DA this summer. All 4 coupler bolts sheared and bent the driveshaft. 14 hours of labor saved the transmission. $10k repair bill. Saved 9k-12k by saving the transmission. Good luck
 
Just thought I would report back with what my issue was.
.

Do I go the genuine leads or aftermarket? If aftermarket does anyone have any suggestions?
.

MSD 8.5mm wire set would be my choice. Check Summit Racing; they will have a set to fit your motor
 
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Thanks ttmott,

I got a quote from my local mercruiser tech today and it came in at AU$825.00 per set!!! I rang around and my usual mercruiser tech was actually the cheapest!!!

Whilst I do prefer OEM those prices are a joke. I'm sure gold is cheaper per ounce. The AU$5.99 for the single auto plug lead got me home with no problems.

So I've found these alternatives - including the OEM from the US.

http://www.ebay.com/itm/New-Mercury...Part-84-881698-WIRE-KIT-SPK-PLG-/261528026734

http://www.raylarengineering.com/spark-plug-wires.html

http://www.amarket.com/imwo808.htm

http://www.cpperformance.com/p-2686...mercruiser-496ho-496mag-and-81l-standard.aspx

https://www.rockauto.com/catalog/moreinfo.php?pk=3881043&jnid=299&jpid=0

Any comments on the above or any other alternatives?
 

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