Mercury KE4 Assembly

[goldmember]

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 ?

[green-thumbs]

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.

[goldmember]

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

[green-thumbs]

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

[green-thumbs]

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

[goldmember]

Wow. Interesting. Thank You

[green-thumbs]

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.

[garry-in-michigan]

But interesting (and educational) none the less –

[Author]

Posts