Heads Up.....early Mercruiser 8.1's w/ aluminum manifolds

[osd9]

Oh...I thought it was Four Thousand.....:grin:

 

[fwebster]

John,

It won't work that way with Shelli if your kids just started driving...she'll be at home by the phone "in case something happens".

Jeff,

Nobody's talking but yours is a good guess, i.e. weight and cost. I supposed this is kind of a latent event since it takes a while for the aluminum to corrode, but Mercruiser has had salt water test facilities for years, and this isn't the first aluminum corrosion issue they've seen. I just get a slow burn when I consider how many products Mercruiser rushes to the market only to set a serious financial trap for unsuspecting buyers like CSR members. For example, the last thing Hampton was expecting weas for some guy (me, not Mercruiser) to tell him to check his manifolds and then find he's looking at a $5K repair for something he wouldn't be dealing with if the manufacturer had kept his eye on the ball.

Never is a long time, but I'm not sure I'd ever buy a Mercruiser powered boat unless it had a tried and proven drive train about 5 years down the technology curve.

On your freshwater application question, I think you aren't quite as subject to failure, but this would put the risers and manifolds up on my check annually list.


rmilian340,

Sorry you had the problem but at least you had warranty coverage and only lost the down time.

Risers on these engines are a whole "nother" issue and also an unknown since that are a new design.....not cast iroon or stainless, but a formed weldment from stainless tubing. There is kind of an upside down funnel in the exhaust passage to keep water from flowing back into the motor. The weld attaching the funnel to the tubing seals off the water jacket from the exhaust passage and that weld does seem prone to faiure. your isnt the first one we've heard about. The god thing about this design is that the riser to manifold joint is a dry joint and it should solve the gasket failuere problems inherient in older designs. However, the risers are something else I'd start checking annually.

 

[Hampton]

John - Until I read your entire post, I thought you might be thinking of a word that rhymes with "trucking" ;-) It certainly would apply!

I'm sorry. You are right. I misspelled the word.

BOAFFT!

 

[carterchapman]

John,

It won't work that way with Shelli if your kids just started driving...she'll be at home by the phone "in case something happens".

Jeff,

Nobody's talking but yours is a good guess, i.e. weight and cost. I supposed this is kind of a latent event since it takes a while for the aluminum to corrode, but Mercruiser has had salt water test facilities for years, and this isn't the first aluminum corrosion issue they've seen. I just get a slow burn when I consider how many products Mercruiser rushes to the market only to set a serious financial trap for unsuspecting buyers like CSR members. For example, the last thing Hampton was expecting weas for some guy (me, not Mercruiser) to tell him to check his manifolds and then find he's looking at a $5K repair for something he wouldn't be dealing with if the manufacturer had kept his eye on the ball.

Never is a long time, but I'm not sure I'd ever buy a Mercruiser powered boat unless it had a tried and proven drive train about 5 years down the technology curve.

On your freshwater application question, I think you aren't quite as subject to failure, but this would put the risers and manifolds up on my check annually list.


rmilian340,

Sorry you had the problem but at least you had warranty coverage and only lost the down time.

Risers on these engines are a whole "nother" issue and also an unknown since that are a new design.....not cast iroon or stainless, but a formed weldment from stainless tubing. There is kind of an upside down funnel in the exhaust passage to keep water from flowing back into the motor. The weld attaching the funnel to the tubing seals off the water jacket from the exhaust passage and that weld does seem prone to faiure. your isnt the first one we've heard about. The god thing about this design is that the riser to manifold joint is a dry joint and it should solve the gasket failuere problems inherient in older designs. However, the risers are something else I'd start checking annually.

Thanks for this info Frank,

I just happened to find this older thread, but it may apply to my "new" boat. I've asked my dealer to check my boat before delivery. He really wants to sell me the extended warrenty ($6200 for two years). I'll see if he will cover these before I decide to buy it or not (the extended warrenty)...

 

[carterchapman]

The value of this forum has been great for me so far.

Thanks to the info provided by Frank and John I was able to get my aluminum manifolds replaced prior to delivery and get the 2 year warranty extended to 3 years - at no extra cost.

Thanks guys!

 

[Alex D]

I have the early 8.1S with aluminum manifolds. Remember the first 8.1S engine packages were installed in 2001, with 2002 being the first year were they completely replaced the old 454s.

I still have the original manifolds. My boat is a 2002, but was comissioned in 2003 into salt water marshes in Savannah, GA. We bought and put her back into fresh water in June 2006, so she has been in fresh water since. No problem so far but better check this fall.
Frank, is there any info on the recall or is there absolutely no factory bulletin or recommendation in print?

Please advise and thank you as always!

 

[Hampton]

I think I can help. I'm 99.99% sure that there is nothing in writing available to the public regarding these manifolds. With the age of yours, even ceramic coated cast manifolds would be subject to replacement after having spent time in salt. I think you made the call - time to get them inspected. As far as getting some help from Merc, I'd be really surprised, but, as long as you don't burn credibility points, it couldn't hurt to ask.

 

[fwebster]

Nothing has been published, but every dealer close to salt water knows about the problem and how to get them fixed. It is one of those deals where every case is handled individually, so pay the cost to get your manifolds inspected and find out if you have a problem then go from there.

The price of ignoring this one is usually the cost of a new engine so the goal is to first find the problem then avoid the major expense for everyone by replacing the bad manifolds. Mercruiser usually steps up. They aren't stupid.....manifolds are cheaper than crate motors.

 

[carterchapman]

My boat was located on a river in CT (so they tell me) for its 150 hours, so it should have received a "natural" fresh water flush after each outing in salt water. MM here in Atlanta (Buford - Lake Lanier) told me my aluminum manifolds were fine, but they got Mercruiser to pay for the cast iron replacements anyway - I popped for the labor. I felt it was woth it to be done with the aluminum ones.

Anyone if CT know anything about a 2005 340 Dancer that was named "Lucky One"? (probably a little late to be asking!!).

 

[fwebster]

The boat was documented to a Gary S. Sutcliff then to a Michael J Havrilko in Shelton CT. the last documentation was issued on 5/28/08......which probably means the boat had a lein on it at that time.

 

[Jimmy Buoy]

Just got my 2001 Amberjack last August and found that one of the exhaust manifolds had a corrosion hole (thankfully on the outside) so I decided to have all 4 replaced. Always thinking that the manufacturer knows best, I replaced them with OEM Aluminum (part cost $500 x 4 including water rail) to be safe.

Any guesses on how well the aluminum will last in fresh water??

I'm in the Great Lakes, but the boat had been purchased in New Jersey then sold and moved to Florida. If it won't last even in fresh water, anyone know of a bypass sytem to cool the manifolds with glycol along with the block??

 

[carterchapman]

Just got my 2001 Amberjack last August and found that one of the exhaust manifolds had a corrosion hole (thankfully on the outside) so I decided to have all 4 replaced. Always thinking that the manufacturer knows best, I replaced them with OEM Aluminum (part cost $500 x 4 including water rail) to be safe.

Any guesses on how well the aluminum will last in fresh water??

I'm in the Great Lakes, but the boat had been purchased in New Jersey then sold and moved to Florida. If it won't last even in fresh water, anyone know of a bypass sytem to cool the manifolds with glycol along with the block??

Jim,

My boat was originally docked 7 miles up the Connecticut River and operated in LI Sound. It got a "fresh water flush" after each outing - just by going back to the mairna. As I stated earlier in this thread, I had mine replaced under warranty - when I took delivery of the boat, they showed me the replaced 4 year old aluminum manifolds - they looked brand new inside.

So I would say they would last many years in fresh water.

 

[Hampton]

If it won't last even in fresh water, anyone know of a bypass sytem to cool the manifolds with glycol along with the block??

No, and that includes Mercruiser.

 

[carterchapman]

John,

Even though fresh water doesn't affect them as badly as salt water, if I were going to replace them, I would use the porcelain cast iron ones rather than aluminum. Then you are covered - even for a possible re-sale...

 

[Wanchaiwarrior]

Howdy all.

I've been a Sea Ray owner for almost 10 years now. My Sundancer was re-powered with twin 8.1 Horizon inboards in October 05. Cost for re-power was pushing $40k. Right before the warranty expired, I had my local dealer come down and do a once over on the engines. I had notices some paint chips on one of the manifolds and ask the mechanic to look them over. Unfortunately he was in a rush to get to his next job, never looked them over and reported all system in good working order. Last week I had my head down in the engine compartment and felt raw exhaust gas on my cheek. On closer inspection, I found water weeping from under the paint on all 4 manifolds and exhaust gasses leaking out from between the manifolds and risers.

Two frustrating weeks later, I'm getting no joy from Mercruiser. I'm 6 months out of warranty with 50 hours on my engines. The treatment I've received from my local dealer and Mercruiser customer support has made me feel like a second class citizen.

I know that manifolds go bad, particularly in salt water environments. I've replaced several sets in the past. But in this instance, I feel Mercruiser should offer some level of assistance for their poor design.

 

[my3sons]

My 360 has the 8.1's and I assume the aluminum manifolds. The parts schematics I found for my serial number range shows a "water rail" which I do not have on my engines. Would anyone know why? Do some manifolds have water rails and some not? Could this mean they were changed by the PO? any info would be much appreciated. Thanks

 

[Hampton]

John,

Even though fresh water doesn't affect them as badly as salt water, if I were going to replace them, I would use the porcelain cast iron ones rather than aluminum. Then you are covered - even for a possible re-sale...

Merc gave me Cast/Porcelain ones last year.

 

[Hampton]

Howdy all.

Two frustrating weeks later, I'm getting no joy from Mercruiser. I'm 6 months out of warranty with 50 hours on my engines. The treatment I've received from my local dealer and Mercruiser customer support has made me feel like a second class citizen.

I know that manifolds go bad, particularly in salt water environments. I've replaced several sets in the past. But in this instance, I feel Mercruiser should offer some level of assistance for their poor design.

Read the entire thread. Go to your Sea Ray dealer, especially since they gave you a clean bill of health on exactly this. Don't be confrontational. You need to convince them to make a lot of money from Merc by supporting you in this issue. Read the entire thread, save $4,000.