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Yeah we have been through what work was done and how this can happen over the winter. I suspect you will find either water got in bellows or water got in the gear lube and corroded a bearing in the drive.

Agreed something is not right. Would also verify firing order is correct. I thought on the SBC there are two cylinders that can get swapped wires and still run ok ish. Has tach been verified for accuracy ?

My 65 Pontiac had a factory windage tray also not a real high Revving engine 5200 was about it before the rods left the building …

Yeah no way a 5.0 would do that. Answer depends on what u want out of the boat and how much you want to spend. as mentioned you would be better off getting a 96 and up vortec engine . If it were me I would get a new long block and exhaust and intake manifolds . Drop in would be the same vintage...

Yeah Sierra is a better respected aftermarket supplier, but you never hear I bought the OEM part and it failed or was SOL in the box.. Also there are so many counterfeit parts suppliers online now. There is a toyota mechanic on you tube called Car Care Nut, he did a whole video on how to spot...

Hope the check out ok. Its rare that folks actually represent them in actual condition!

What size boat is it , I think you’d be better off not loosing displacement and power

Had to typically pry them out with screw driver, so do t come out without breaking them. If you go through the work to get in there dont just test it just replace no sense screwing around

Not a problem to mix them in a non catalyst engine, as stated the blend is a blend of synthetic and conventional oil , so mixing blend and full synthetic will be a blend when combined . Use them all interchangeably

Yes upper gear case seal you should definitely inspect or do a pressure test when you reassemble. Can get damaged reassembling so be careful. o change that upper seal gear and vertical drive shaft come out, seal is like first thing that goes back in .

if you get the quicksilver merc impeller kit with the base plate and gaskets + orrings its in there its #25 in this dwg- the kit comes with a tool to install it- its just a cup you use as a gauge to slide the slinger seal down the driveshaft while lifting up on drive shaft. I think it just...

So are you swapping this engine into original boat ?

yes likely happened prior to this change out. In salt the rubber I believe doesn't last quite as long but in fresh I changed my neighbors original to the boat 11-12 yr old impeller, looked new. Did mine after 6 years also looked new. OEM bellows lasted 18 years. Sounds like you are on right...

That melting is due to lack of water flow from impeller at some point. There is some water flow into exhaust at all times to cool it. This is indicative of problems with water flow or impeller lost a vane I have never put anything on the screws although using perfect seal/ permatex #3 can help...

When you say there is a gash in there do you mean tear in the bellows? If so need to replace them, they are clean enough. last pic yes that is where the annode goes

One thing to try have you done the same revving but at different drive angles via both trim and steering. Willing to bet it changes pitch which would be an indication of gimbal and or u joint issues despite the previous work

Volvo outdrives for us market are made in TN and the engine is a chevy so not as imported as you think.

No elegant but zip tie will be fine for years to come , it just sits there. I had a rubber band on my Datsun Z years ago, metal spring clip broke off.

Depends on where your current WOT rpm is compared to max WOT range for engine. As stated above 19" pitch if similar style prop would probably increase WOT rpm about 800 rpm. that may put you over. Generally when propping such that you can hit the upper end of rpm range or a tad over will give...

Normally the Hand stamping like that are done when it goes to the prop shop for rework or repitching . Probably only way to tell is to put it in a pitch block, maybe side by side comparisons vs other black max type props sitting on the shelf. With a pressed in hub you can tell that prop has some...