Re: Merc 800 80hp L.U. problem.. (need advice)
Sounds like exhaust gasses might be flowing out the cracks in the gearcase and ventilating the prop upon takeoff.<br /><br />If the cracks aren't affecting the structural integrity of the gearcase, you may be able to patch them up with some Marine Tex or equivalent. The repair would need to be faired in properly so as not to cause more turbulence & ventilation.<br /><br />If you know a good welder, you may be able to get the crack welded up to keep it from spreading.<br /><br />However, usually when these crack it just gets worse, and then your shafts, gears, and bearings are in jeopardy.<br /><br />If you plan on keeping this motor for a long time, it might not be a bad idea to replace the lower unit.<br /><br />Ones run in a lot of salt seem to have more of these problems than freshwater motors, due to salt deposits building up in the threads of the gearcase cover ring, causing stress on the gearcase and eventually cracking the case.<br /><br />You may be able to find a decent lower unit on eBay or from one of the good folks at this forum.<br /><br />HTH and Good Luck.........ed