Merc 60 4 stroke problem

[Didley]

I've got some photos of the castings mentioned in my original post, I'd love to know peoples thoughts on the cause. The outboard mechanic believes the cause is probably the tin gasket in the 4th photo reacting with the cast aluminium. The new gasket supplied by Mercury, is of a different design, a sandwiched 3 layer type thing, where the tin bit is encased in fibre stuff I think. So I guess they're on to it, but if you've got a Merc with the older type it may be something to keep an eye out for. Its a 2002 motor

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[BM]

You can fix that with a tube of metal mend type epoxy (I believe thats what FNQ was hinting at early on in the piece). Build up the corroded areas and file back. Back in business very cheaply.

Also, I repaired a customers 02/03 60 Merc 4 stroke last season that had corroded through where the water tube joins into the adapter plate. Seemed an unusual place for it to occur to me. Had my alloy welding guru buddies weld it back up and one very happy customer back on the water for heaps less than it could have been. I think you have to replace the entire midsection which from memory was $1500.

I ran it by 2 mates who are Merc dealers and neither of them had ever heard of that particular problem.

As previously mentioned, you are out of warranty so by right why should a manufacturer do anything? I agree its an unfortunate incident but at the end of the day its bad luck for you. I would certainly try putting it through a Merc dealer as an odd problem like that may get some joy from Merc. Its a slim chance, but over the years Merc and other manufacturers have come to the party surprisingly in some instances. Some things they fix, others they provide the parts at no cost etc etc

In relation to the boat/engines condition (and I am not deliberately throwing a dart at the Ausfisher you bought it from) but regardless of how shiny it looks how many times did he actually get it serviced? Clean and shiny but no service history does not make for a cared for engine.

[Didley]

You can fix that with a tube of metal mend type epoxy (I believe thats what FNQ was hinting at early on in the piece). Build up the corroded areas and file back. Back in business very cheaply.

Thanks for the comments BM. Got it fixed with new parts, in the top photo the corrosion has gone right through, making a hole of around 8mm, ie. exhaust flowing out the side of the join between the adapter plate and the leg. I felt better with replacing with new parts.
I'd like to know why it happened to make sure it doesn't happen again! If it is the gasket then problem solved.

[Jabba_]

mate I feel sorry for you but I don't think you got anything to stand on, warentee is warrantee its like cars go one k over your 150 000 k or day past your three years you know exactly what a car dealer will say don't matter which one you deal with.

Actual... If your just a little over your warranty, such as a day or a week, there is a clause in the waranty law called a good will clause, or something like that....
I had a AU XR8 that needed a new engine mount, diff and window switch a month outside it's warranty, and it was all fixed for free......