Outdrive still leaking water

[udm328is]

Mercruiser Alpha One Gen II. Replaced the water pump, replaced tube that connects to copper water intake and to the coupler at the top of the pump housing. I then replaced the o ring at the top of the outdrive under the top, hooked up the hose and water leaked from in between the cap and the upper unit (this was without the motor on). Did some research and realized there is supposed to be a "stuffer plug" installed just behind the gears where the O ring is, I have now replaced that and hooked the hose back up and it still leaks water, just maybe now as much. Anyone have any ideas? This is driving me crazy and I can't find any other posts that help.

Thanks,
Eric

 

[achris]

Re: Outdrive still leaking water

Merc stopped putting that stuffer plug in as it held water after the boat was removed from the water and caused huge corrosion problems there. Just remove the top cover again, pull the stuffer plug out and run a THIN bead of silly sealant around the edges. Put the cap back on and tighten the screws to 20 lb. ft....

Chris.......

 

[udm328is]

Re: Outdrive still leaking water

thanks Chris. I have Permatex 2 form gasket sealant, could not find the 2 Aircraft sealant by Permatex or the Quicksilver Perfect Seal, should the one I have work? Also I just realized when I redid my water pump I also did not use sealant on the bottom gasket of the three gaskets as shown in the service manual, but I was watching a how to video from some "Eddie" from Long Island Boaters Club on Youtube and he didnt use the sealant there which is why I didnt only because I did not realize until after that the manual says to. Should I take the whole thing apart and do that as the manual suggest or just do what you said to the top cap?

Thanks again

 

[udm328is]

Re: Outdrive still leaking water

also another question, how long do I have to wait before going in the water after applying sealant?

 

[achris]

Re: Outdrive still leaking water

I've watched a few of Eddie's videos, and I must say I'm not the least bit impressed... The guy is as rough as guts... I wouldn't let him within 50 feet of my boat! That said, he does show how to do things, just be a little more gentle than he is.

As for the sealant under the water pump gaskets, I always put them on dry... It makes it so much easier to get them off on the next service. The one thing I am very particular on is using the alignment pins when reassembling the housing, plate and gaskets. That's critical.

Ok, sealant under the top cap. I use silicone because of its flexibility , and I wouldn't use a Permatex. I prefer the Loctite one, max blue I think it's called, and you have to wait 24 hours...

Chris........

 

[udm328is]

Re: Outdrive still leaking water

Thanks Chris,
the waiting part sucks, but I really appreciate the insight. Have a good day!

Eric

 

[ktbarrentine]

Re: Outdrive still leaking water

All that "fun" trying locate a source for the stuffer plug, and now you dont need it!!! (sounds about like the drive shaft o-ring issue on the older Alpha drives)... Aren't Mercs Wonderful! (I actually have a lot of fun with mine and learn something new just about every day!).

 

[udm328is]

Re: Outdrive still leaking water

I am definitely learning something new everyday, however it would be a lot more fun and wonderful out on the water. It is a big week in the Baltimore area, they are having various celebrations for the 200th anniversary of the war of 1812 with the tall ships coming in and the Blue Angels and I am hoping to get out on the water for all of it, crossing fingers, not to mention for the 4th. One day at a time I guess, coming from know absolutely nothing I sure have learned a lot!

 

[achris]

Re: Outdrive still leaking water

All that "fun" trying locate a source for the stuffer plug, and now you dont need it!!! (sounds about like the drive shaft o-ring issue on the older Alpha drives)... Aren't Mercs Wonderful! (I actually have a lot of fun with mine and learn something new just about every day!).

And just to pep up the fun, neither of those issues are mentioned in the service manuals...