exhaust corrsion and warranty

[ronnie301]

I have a 2005 Sea Ray Sundeck with 4.3 mercruiser Alpha One. 4 years old, kept dry, cleaned profusely everytime it comes out of the salt water.
I have a bad port side Exhaust manifold that my dealer says is not covered... even under my extended warranty . He wants $3500 plus to repair. He also says Mercury want do anything. They say it is a maintenance item. I say "if its a maintenance item, What can you do to maintain it????

This is BULL after having this boat for 4 years. Do I have a leg to stand on or am I just screwed by Merc and my dealer??

 

[skolbe]

In salt water that is a typical maintenance item every 5 years or so. I am sure others will chime in.

 

[ronnie301]

Thanks for the experienced reply. ....even though it doesnt make me feel any better. Just doesnt seem right to have to spend that kind of money after four years and less than 300 hours!! And it was just serviced by my dealer less than 6 mos ago and has been in the water less than 5-6 times since.... they said nothing.??
Any advice on where to go to get less expensive parts. I have a good mechanic that I trust but would like to find parts at a discount, remanufactured etc..???

Thanks again

 

[rcknecht]

I run my 190, 2001, in salt water, and it has 4.3 with the original manifolds and exhaust... I think 4 years is too short.... Although, I has same problem with my 250, with a passport extended warentee, I ended up paying for the exhuast repair after 3 years, out to of pocket... They told me that anything that can rust is not covered...

 

[Alex F]

Although I don't have first hand experience with the warranty comp replacing the exhaust manifolds, but one of the selling points while I was purchasing my 320 was the fact that exhaust manifolds were replaced under the warranty. I was told that while Merc techs were there perfoprming some work (don't recall what exactly) they check the manifolds and advised that it'll be a a good idea to replace them. The boat was only 3 years old (she came from FL). So, it sounds like it all depends on the company policy, mine was Passport from Legacy.

....if its a maintenance item, What can you do to maintain it????..

I'd say the only thing you can do is flush your engines with fresh water after each use. I do it all the time.

 

[BahamasBlair]

I'm replacing 4 exhaust manifolds on my 8.1S Horizons. Only 390 hours on the clocks! Mercury Marine made the 8.1s for 4 years with Aluminum exhaust manifolds. Can you believe it Aluminum! Nothing corrodes faster in salt water than raw aluminum castings. They have since switched back to cast iron. Dumbest thing i have ever seen.
The entire replacement for parts, labor and haulage will hit $6,000 here in the Bahamas.
NO HELP FROM SEA RAY NOR MERCURY MARINE - NOTHING!
Buyer beware.

 

[Jimmy Buoy]

Nothing corrodes faster in salt water than raw aluminum castings.

I replaced all 4 of mine 2yrs ago when I noticed water dripping from a pinhole on the outside (luckily) of one of the manifolds.

To be fair, these aluminum manifolds due have some kind of "ceramic coating" so they are not "raw aluminum". Still, the coating is not very reliable. Only one of my 4 were leaking, but why risk an engine.

Didn't know about the cast manifolds, and got an ok deal on a new set of Merc Aluminum's - in fresh water they should last as long as cast iron and I plan on having the boat long term.

What does B-O-A-T mean again???

 

[fwebster]

ronnie301,

You say your boat was "4 years old, kept dry, cleaned profusely everytime it comes out of the salt water."

Does that mean that you flushed the engine with freshwater?

Also, where you are, it is considered standard preventitive maintenance to remove risers(elbows) and check the risers and manifolds for corrosion after the 3rd year, then every year thereafter until you replace them. Once replaced, you should be good for another 3 years at which time you start the process all over. Consider yourself luck that you re only replacing manifolds. More times than not, failing to follow the "3 year then annual checks" ends up filling an engine full of sea water.

Now.......if you are dealing with the Sea Ray dealer where you are, they have a great relationship with the extended warranty company and it is unusual for them to not be able to get some help from them. Are you dealing with the service manager or just a service writer? If you are with a service writer, you might want to call the service manager and talk to him directly.

 

[tobnpr]

^^DITTO^^.

It is on the "short side" of the expected longevity, but definitely not unusual.
Now, you know.

Funny how manifold/riser maintenance seems lost on a lot of owners.
Last year I noticed my next door neighbor, who had used his Mariah almost every weekend (bastard) hadn't had his boat off the lift in months. I finally asked him what was going on and he told me the engine was shot- he went to start it one day and found the cylinders full of water.

I naturally inquired "When did you change your manifolds and risers?" (7 or 8 year old boat) He looked at me like I was speaking Chinese- for real...

To make matters worse, he just assumed that the engine was shot. I told him that he should have gotten me as soon as it happened and we could have gotten the water out of the cylinders, filled them with Mystery Oil, changed the oil and we might have been able to save it. Oh well, I think he wanted a new boat anyway...

 

[TMK988]

How do you flush the manifolds (Bravo 3, 4.3) with fresh water while the boat is in the water?

 

[Chris Dauth]

One sure way around this problem is to install a fresh water cooling kit. About $1100 in Australia. The kit will pay for itself in a few years.

It was about a days work to do the job myself.

On my 270 WE, the exhausts are over 10 years old and no sign of corrosion when I had them off for the engine rebuild when I took the 5.7L out to 383 cdi (6.5 L).

 

[Bridog]

I'm looking into getting the extended product protection plan from Mercury and it list's "Intake and Exhaust Manifolds" as a covered component? I'm a bit confused as to why they are saying it's not covered. Is it different from the Passport plan? I thought they would be similiar because Mercury is owned by Brunswick.

 

[C-SIDE]

$3,500 is criminal. I have a 2000 270 with the 7.4L. I'm literally in the process of having it replaced - paying someone to do it due to the rust and those pesky bolts that just don't come off.

Anyway, the manifold itself is $423 - that is a Mercrusier manifold too. I can't imagine your manifold is much more, unless it is aluminum.

Something doesn't seem right or there is more repairs needed that you didn't tell us or your marina didn't tell you

 

[Jack F]

I'm looking into getting the extended product protection plan from Mercury and it list's "Intake and Exhaust Manifolds" as a covered component? I'm a bit confused as to why they are saying it's not covered. Is it different from the Passport plan? I thought they would be similiar because Mercury is owned by Brunswick.

I thought so to until I read the normal wear and tear section.

Mercury Marine,
Division of Brunswick Corporation
PLAN BENEFITS & PROVISIONS


Covered Parts - Those parts, components, or systems designated in the section of this
Contract entitled ENGINE, DRIVE & TROLLING MOTOR COVERAGE as eligible for replacement or
repair pursuant to the terms of this Contract.



COMPONENT COVERAGE: This Contract covers only those components of eligible
product set forth herein under ENGINE, DRIVE & TROLLING MOTOR COVERAGE. If the component
is not listed as a Covered Part, or is listed under Contract Exclusions, it is not covered.


ENGINE, DRIVE & TROLLING MOTOR COVERAGE:
Engine: Cylinder block and internally lubricated parts contained within the cylinder block, to
include: Engine head(s); rocker covers; timing gear cover; crankshaft; main bearings; and connecting
rods; rod bearings; pistons; piston rings and wrist pins; camshaft and bearings; rocker arms; valves;
valve springs; guides and seats; supercharger; valve push rods; lifters; flywheel and ring gear;
harmonic balancer; reed valve, reed blocks, timing chain or belt; timing gears; distributor housing,
shaft and gear; oil pump; oil pan; intake and exhaust manifolds; and circulatory water pump.
Transmission, Gear Cases, and Drive Shaft Housings: Internally lubricated
parts contained within the transmission or gear case; the case, if damaged beyond use as a
result of a Covered Part breakdown; universal joint yokes; socket, cross and bearings; internally
lubricated parts contained within the drive shaft housing, if damaged as a result of a Covered Part
breakdown.
Steering: Power steering cylinders and pumps; Mercury Precision Parts, Quicksilver, or Mercury
supplied cables, steering control helm, rack, and yoke.
Transom Assembly: Inner transom plate; Gimbal bearings; Gimbal housing, Gimbal ring,
bell housing, if damaged as a result of a breakdown of a Covered Part.
Electrical and Ignition: Wire harness; starter; solenoid; circuit breaker; alternator;
voltage regulator; Mercury Precision Parts or Quicksilver instruments; switches; ignition coils;
stators; triggers; switch boxes; ECU box; temperature and pressure sensors, warning horns and
signals; EFI electrical components.
Trim System: Trim pump; trim motor; cylinders; solenoid; limit switch; wiring harness; trim
position senders.
Fuel System: Carburetor body; fuel delivery pump; compressor, fuel cooler, fuel injection
pump; fl ame arrestor, fuel injectors, and manifold body.
Mercury Precision Parts or Quicksilver Accessories: All Mercury Precision
Parts or Quicksilver engine related accessories, except propellers, required to operate the engine
and purchased at the time of sale of the eligible Product, and attached to and used with the eligible
Product but only for the duration of the Contract.
MotorGuide Trolling Motor: Major components, to include: Circuit board(s); steering
motor/transmission and components (non-wear items only); pinion or steering gears; shaft;


This is the gotcha part…


NORMAL WEAR AND TEAR: Cost of maintenance and repairs such as tune-up,
adjustments, and carburetor rebuilding to correct performance loss and/or repairs required
as a result of normal wear and tear. By way of example, this includes, but is not limited to,
internal carburetor/vapor separator parts such as needles, seats, and fl oats; reduction or loss
of compression due to worn pistons, cylinders, rings, valves, head gasket(s), water pumps and
impellers, jet pump impellers, engine couplers and wear rings, spark plugs, high tension spark plug
wires, brushes, etc. Replacement of seals and gaskets due to seepage or overheating. Minor loss
of fluids is not a mechanical Breakdown. Corrosion to any Product or Covered Part is considered an
environmentally-caused condition and is specifically not covered by this Contract.

 

[Alex F]

Brian,

I don't know if this going to help you, but when I was purchasing my 320 one of the selling points was that the manifolds were changed under the warranty just few months prior the sale. The boat had LEGACY extended warranty.

 

[Loneranger]

$3500 seems very expensive. I have not replaced mercury manifolds but i have replaced volvo penta manifolds and i believe the parts were <$300 and the replacement is just bolts and gaskets. Not very technical. Granted this was maybe 5 years ago and iron maybe more expensive but even if they are $450 then you could do it for less than 1000.

BTW mine were bad because i messed up winterizing them one year. In fresh water they seem to last a very long time.

John

 

[C-SIDE]

I just got my bill and it was $1,222, which includes new bolts, gaskets, a mercrusier manifold, and they had to pull her out of the water to do it.

 

[swift1]

Those gaskets are very skinny at the webs on those 4.3's
Yes they should be pulled by 4 years or sooner if any leaks/rust showing. Last time for me on a 350 V8 it was about $ 2200. for two manifold,risers,elbows at an independent (merc) shop. Much cheaper than water in cyl. which does not compress like air, just bends rods and blows motor.

 

[260 Sundancer]

I just got my bill and it was $1,222, which includes new bolts, gaskets, a mercrusier manifold, and they had to pull her out of the water to do it.

They just pulled my engine (bolts rusted) to replace both manifolds.. $2,500.00 1999 260DA 454 7.4L