5 replies to this topic

[bstuke]

Hey guys,

There is a casting on the expansion part of the exhaust that is welded close, and is leaking a stream of water.

Can I just have it welded over?

Or do I need to replace it.

It sure is an easy way to make sure there is water flow!

Thanks in advance,

Bob

PS. 1999 Challenger 1800 twin 717's

[Kevin Leclair]

Probably would be best to have you local dealer take a look at it since we can't see the weld or how much it is leaking. Do you have any pics?

[Wild Goose]

I had the same problem with mine, and pulled both manifolds out to weld in new plugs.

You might be able to patch it until the end of the season.

When I ground down the other non-leaking plugs, they were about to go as well - thin and pitted. There's plenty of material in the casting, so if you have access to a tig welder, or a guy with a tig, and some material for new plugs, you're all set! Mine went at the end of the season last year, so I lucked out with the timing.

Getting them out and back in was a breeze, the torque and sealant specs are in the technical service manual.

[bstuke]

Thanks for the responses guys, I guess I don't have notification turned onn.. :-)

Kevin, it is the size of a spray bottle with a stream setting. It hits the starboard side of the gunwale. Like Wild mentioned, I suspect it is fine till I pull the boat. It is on a lift on the dock right now.

I am relieved to know that I shouldn't have to replace the manifold.

Bob

[GNickels]

Hey guys,

There is a casting on the expansion part of the exhaust that is welded close, and is leaking a stream of water.

Can I just have it welded over?

Or do I need to replace it.

It sure is an easy way to make sure there is water flow!

Thanks in advance,

Bob

PS. 1999 Challenger 1800 twin 717's

[brickslayer]

Bob,
I had the same issue with both of my engines (97 Challenger 1800 w/twin 787's) was leaking so bad I opened up the engine compartment and thought I was sinking. Here is what you can do to stop it quickly and get back on the water until the end of the season. Just buy some type of stick epoxy like JB Weld Stick. Hold a mirror down there so you can see the weld and hit it with a little sand paper just to knock the paint off (150 grit) pinch off a marble sized ball of the epoxy stick and mash it up until it is a uniform color then press it flat to about the size of a quarter and stick it over the leaky casting plug weld. My mechanic taught me this trick and I did it mid season last year. I haven't gotten around to yanking the pipes for re-welding yet, but the epoxy is still holding strong. No leaks at all. Will probably let it ride for the rest of the season then yank them. It is definitely jerry rigging it (which I am usually very against) but that stuff is amazing.

Jeremy