135 merc gasket problem

[link 1]

i have a 94 135 that the powerhead to the exhust plate will
not seal keeps blowing the gasket without tearing the whole
motor down and having the block surfaced what type of problem would i have if i used liquid aluiminum around the gasket seat to fill any voids
thanks for any replies

 

[Chris1956]

Re: 135 merc gasket problem

Why not try some high temp silicone? make sure the bolts are correctly tightened.

 

[link 1]

Re: 135 merc gasket problem

tried that on both sides of the gasket and still blow out
infact i tried it twice

 

[emckelvy]

Re: 135 merc gasket problem

Well that's not gonna work, eh? If you are using the original covers, it's probably time to replace (at minimum) the inner exhaust baffle as I expect it's warped.

You may need to replace the outer cover too, but you can probably get that surfaced (or at least check it for warpage).

The last place I'd look to for a problem is a warped block, but if you've already eliminated covers as a cause of the problem, and silicone won't seal the voids, that's a pretty bad leak and there may be no other solution than pulling the block apart for milling.

But if you haven't done the covers yet, it's time!

HTH & keep us posted.........ed

 

[Chris1956]

Re: 135 merc gasket problem

Ed, Excuse my ignorance, but what covers are you referring to? The exploded parts diaghram shows an exhaust extension under the block and a single exhaust divider on the back of the block. I did not see any reference to inner baffle.

 

[emckelvy]

Re: 135 merc gasket problem

Chris, yeah I see what you mean, this has a one-piece combination divider and cover assy.

What I was thinking of are earlier models where the divider and outer cover are separate. Somewhere in the 'split' of serial #'s is where this happened from what I can see by checking in BAM.

In that case looks like a new divider might be in order, eh? Unless you have a really really good machine shop that could mill the sealing surface and take the divider down a commensurate amount (provided that's even possible). Probably easier to get a new divider!.....ed

Ed, Excuse my ignorance, but what covers are you referring to? The exploded parts diaghram shows an exhaust extension under the block and a single exhaust divider on the back of the block. I did not see any reference to inner baffle.