Mercury KE4 Assembly

Home Forum Ask A Member Mercury KE4 Assembly

This topic contains 7 replies, has 3 voices, and was last updated by Avatar garry-in-tampa 1 month, 3 weeks ago.

Viewing 8 posts - 1 through 8 (of 8 total)
  • Avatar
    goldmember
    US Member - 1 Year
    Replies: 36
    Topics: 15
    #173488

    Finally putting the finished product together and I want to double check the power head mounting.
    My outboard had a metal shim under one end and under the gasket on top of the lower unit. I assume I need to put that back.
    Also I have a round gasket with a flat end that is for the copper water tube. Does that go under (on top of the metal shim) or over the main gasket ?

    Attachments:
    Avatar
    green-thumbs
    US Member - 1 Year
    Replies: 302
    Topics: 35
    #173595

    It is a Mercury thing, apparently Mercury decided the rectangular metal plate served no
    purpose so they left it out. My Mercury Illustrated Parts Catalog does not show the plate
    nor is it mentioned in parts list for combined KE4/Mark7
    Probably a hold over from KD series used on some KE4 but not on Mark 7
    I have several of the rectangular plates in parts drawer…
    For what it is worth I believe plate (when used) goes on top of gasket as otherwise the
    holes are not effectively sealed
    One thing is certain, the plates are not used on singles…lol
    Louis

    Did you find a copper stamping as part of the old gasket? I believe the metal plate
    and the coppper gasket are used together. Mercury seemed to be continualy
    looking at product for ways to reduce costs. Just my opinion and i have been in error
    at times.

    Avatar
    goldmember
    US Member - 1 Year
    Replies: 36
    Topics: 15
    #173596

    The old gasket had the plate under the gasket up against the lower unit. No copper stamping on my 1947.

    Avatar
    green-thumbs
    US Member - 1 Year
    Replies: 302
    Topics: 35
    #173619

    Mr Grubb or Mr. Thurwachter may know for sure. As for me, I would leave plate out entirely
    if the copper stamping is not used. I use Permatex # 2 gasket sealer with the two gaskets
    laying down the large gasket first then positioning the smaller water tube gasket before joining powerhead to driveshat/exhaust housing.
    That may seem to be leaving out items , but, that is how the Mercury Parts Manual for KE4/Mark7 illustration shows it. No * indicating a change, so it seems fair to assume
    it will work.

    The copper stamping bonded to gasket and the cover plate were used ,but, from what
    parts manual shows they were later made without either of them. The water jackets
    show no change. Very early production KE4 use KD4 cylinders, pistons and rods
    with the 4 leaf reed block and later crankshaft. Using up old stock parts is another
    Mercury thing.

    Louis

    Avatar
    green-thumbs
    US Member - 1 Year
    Replies: 302
    Topics: 35
    #173620

    Mr Grubb or Mr. Thurwachter may know for sure. As for me, I would leave plate out entirely
    if the copper stamping is not used. I use Permatex # 2 gasket sealer with the two gaskets
    laying down the large gasket first then positioning the smaller water tube gasket before joining powerhead to driveshat/exhaust housing.
    That may seem to be leaving out items , but, that is how the Mercury Parts Manual for KE4/Mark7 illustration shows it. No * indicating a change, so it seems fair to assume
    it will work.

    The copper stamping bonded to gasket and the cover plate were used ,but, from what
    parts manual shows they were later made without either of them. The water jackets
    show no change. Very early production KE4 use KD4 cylinders, pistons and rods
    with the 4 leaf reed block and later crankshaft. Using up old stock parts is another
    Mercury thing.
    Some lower cylinders are not machined on face that contact driveshaft/exhaust housing
    so that may be how the cover plate fits in. Mercury is also known for listing later
    parts and not mentioning earlier patterns that were No Longer Available.

    Louis

    Avatar
    goldmember
    US Member - 1 Year
    Replies: 36
    Topics: 15
    #173625

    Wow. Interesting. Thank You

    Avatar
    green-thumbs
    US Member - 1 Year
    Replies: 302
    Topics: 35
    #173986

    A little further checking. Revise prewar parts list shows a cover M-40-100 as part of drive shaft housing assembly for twins kB4 and kB5. I also went thru old cylinders to find a lower cylinder that did not have the machined flat lower side. I fitted the cover plate over the bosses and fitted a water jacket. Lower edge of water jacked matched level of bottom side of cover.
    My conclusion is the cover you found on your KE4 was added during a prior service and
    it does not belong to a KE4 or Mark 7 with the smooth machined lower surface of
    lower cylinder. The cover in my opinion belongs to a twin that used the rough cast
    lower cylinder which would benefit from a flat surface to press gasket to seal the exhaust
    holes in drive shaft housing used for a single .
    Up to KD4 Mercury used same basic drive shat housing for both singles and twins. All had the opening for single cylinder exhaust which were banked off when used as a twin
    drive shaft housing. The side opeing were machined for exhaust when used with twin
    powerhead. For what it is worth I have a KE3 singlele mounted on a drive shat housing
    that was machined for a twin. A cover is bolted over exhaust ports. I acquired it that
    way and I do not know if factory or clever native craftsman.

    The need and purpose of the copper stamping is now clear…with the cover plate over
    the exhaust holes the power head was raised and not contacting gasket to seal area where drive end of power head enters the drive shaft housing.

    At least that is the way it seems to me.
    Parts Manual shows some of first run of KE4 used old design cylinders which may mean
    some early KE4 would have a cover plate and copper stamping. I am not sure how rare
    or common those are. Serial # range 214324- 258226

    Louis more than you want to know I know and probably not what you need to know.

    Avatar
    garry-in-tampa
    Lifetime Member
    Replies: 3065
    Topics: 29
    #174157

    But interesting (and educational) none the less –

Viewing 8 posts - 1 through 8 (of 8 total)

You must be logged in to reply to this topic.