Exhaust Elbow Fit Problem

[76SeaRay]

What happened here (pics below)? I assume I have the wrong elbow to Y pipe. Anybody know what part I need to fix this issue?

 

[tmagyar]

A little hard to tell if this is maybe all it is, but...maybe you are just missing the rubber collar, like mine has to act as the go-between?

Just coincidentally I took this photo today of my almost-ready-to-install 4.3MPI rebuild.


Tom

 

[76SeaRay]

Thanks, I have the rubber couplers but the one that connects to the Y pipe isn't long enough and the other one doesn't seem to fit the manifold elbow. Notice how the elbow is larger on one end. I assume that is supposed to go towards the manifold elbow but not really sure.

 

[achris]

There are 2 different dry-joint elbows, and they use different intermediate elbows.
Can you supply the casting numbers on the exhaust elbows and the intermediate elbows?

Chris.......

 

[achris]

Also going to need the casting number on the y-pipe.

 

[achris]

Ok, done a bit of research for you...

That intermediate elbow (casting #94444) was used with 15° down angle 3" exhaust elbows and a -99877A10 Y-pipe...

Never intended for a 7° 4" exhaust elbow (need the HGE number to confine what you have).

What you appear to have is a 7° 4" exhaust elbow, so you are going to need a -11086T and a -14343T intermediate elbows (one port, one stbd)... And that should be going into a -807130A4 Y-pipe (you may find casting #44266 on it. If you find #99877, that's the wrong one).

Chris.....

 

[76SeaRay]

My Y pipe is the older 3 inch round version. The existing intermediate elbows with the Y pipe are 94443 and 94444. They are too short vertically and I don't see how they attach to the new elbows/riser even though one end is about 4 inches. I bought new dry joint HGE Exhaust Manifolds (5735) and Exhaust Elbows/Risers (4309). These are interchangeable between port and starboard.

 

[76SeaRay]

I can't get at the Y pipe casting number since I have the engine set in place. I can pull it tomorrow, however, it appears I may have to get a new Y pipe based on your description. I think the -11086T and -14343T are oval on the outlet end.

 

[achris]

My Y pipe is the older 3 inch round version.

And that'll be the problem.

The existing intermediate elbows with the Y pipe are 94443 and 94444.

Which corresponds to the 3" Y-pipe.

They are too short vertically and I don't see how they attach to the new elbows/riser even though one end is about 4 inches. I bought new dry joint HGE Exhaust Manifolds (5735) and Exhaust Elbows/Risers (4309). These are interchangeable between port and starboard.

HGE-4309 is a 4", 7° dry joint elbow...

Looks like you're going to need a new Y-pipe, intermediate elbows (as you said), and the interconnecting rubbers.

Exhaust elbow to intermediate elbow rubber: 32-14358001
Intermediate elbow to Y-pipe rubber: 32-44348001

Chris.........

 

[76SeaRay]

Thanks, I was afraid of that. I have seen a few of the Y pipes for sale that show multiple casting numbers for them. Some have the part number 807130 with just A (instead of A4), some have a C and others claim they work as a 807130 but have cast number 861229-C. Any idea about the compatibility?

 

[Lou C]

It almost looks as if the elbows are too long to mate with the Y pipe.
Back when I replaced the heads on my 4.3 I also had to change the exhaust since I was on my last set of OMC bat wings. I REALLY wanted to convert to the Merc dry joint system because it is a better design no doubt. But the heights, lengths and angles of each system is different enough that it can be a real headache to make it work. So I wound up going with the later 2 piece wet joint style used by both OMC & Volvo because I know it would fit judging by Y pipe casting #. And it did fit like factory no leaks either. Still would like the Merc exhaust on my engine lol!

 

[76SeaRay]

I have found two Y pipes that are listed as 807130A4. One of those has the casting number 861229-C and the other has casting number 44265C1. Will either of these work?

 

[achris]

I have found two Y pipes that are listed as 807130A4. One of those has the casting number 861229-C and the other has casting number 44265C1. Will either of these work?

I believe either of those will fit. Just check the shutter configuration. One may be the original design and the other the updated design. Have a look at this thread -> EXHAUST SHUTTERS EXPLAINED to see the differences. You want the updated design...

Chris...

 

[76SeaRay]

Thanks for all the info. It appears that the 44265C1 uses the old style shutters and the 861229-C uses the new style shutter.

 

[76SeaRay]

Ok, so hit a wall here and getting nowhere fast. My old 3 inch Y pipe which matches my gimbal housing is the offset bolt pattern. It appears that the 807130A4 that is needed to connect to the HGE dry joint exhaust risers is a non-offset/non-symmetrical bolt pattern. Is there a different part number for the Y pipe that fits the offset bolt pattern and the dry joint risers? Pics below of my existing gimbal housing bolt pattern, existing Y pipe bolt pattern and the 807130A4 with casting 861229C symmetrical bolt pattern. Do I have to get a new gimbal housing or get rid of my new exhaust manifolds?

 

[nola mike]

Is the issue that only 3 of the bolts will mate with the housing, or does it not fit at all?

 

[76SeaRay]

Yup, only three holes line up. I see in 90 to 92, Mercruiser added the additional top hole to the gimbal housing apparently so that either Y pipe will fit but I have the older gimbal housing with the offset. So, to put in 4 bolts, I either have to find a Y pipe with the old bolt pattern that works with my new dry exhaust/closed cooling (if it exists) or get a newer gimbal housing that has the bolt pattern for the newer Y pipe. Worried if I go for the expense of the newer gimbal housing then something else might not fit (gimbal ring or bell housing?).

 

[nola mike]

I ran into this problem as well. Scoured the web and found people that only used those 3 holes without issue, so I did the same. No leaks after 1.5 years...

 

[achris]

Yup, only three holes line up. I see in 90 to 92, Mercruiser added the additional top hole to the gimbal housing apparently so that either Y pipe will fit but I have the older gimbal housing with the offset.
So, to put in 4 bolts, I either have to find a Y pipe with the old bolt pattern that works with my new dry exhaust/closed cooling (if it exists)

Doesn't exist.

or get a newer gimbal housing that has the bolt pattern for the newer Y pipe.

Expensive, and you don't know what compatibility problems you'll be kicking down the road.

Worried if I go for the expense of the newer gimbal housing then something else might not fit (gimbal ring or bell housing?).

Exactly.

There shouldn't be a great deal of load on those bolts anyway, I'd do as Mike suggests, use the 3 holes that do line up. I may also consider a few things. 1) Run stainless steel thread inserts into the holes to improve strength. 2) fab up a clamping bracket that pushes on all 4 mounting points, and is held on by the three screws that do line up.

Chris.....