[BayStYat]

I had to remove the block due to a broken bolt for the starter. Now after fixing that issue I cant get the block to seal at the base of the lower unit. I am getting exhaust blow back into the motor pan and shroud. I have tried 4 different gaskets of various thicknesses and permatex with no luck.
I was told that removing the motor after 20 plus years could cause some issues. Is this my problem? The motor never ran hot. Actually it runs perfect except for the exhaust blow back. It's not sealing at the base under the carb on the starboard side.

Any one ever fixed this issue?

 

[Brett]

Sounds like a pinched gasket or corrosion/chip causing a gap
between the inner exhaust tube and the block.

http://www.crowleymarine.com/johnson-evinrude/parts/46126.cfm

 

[BayStYat]

Thanks Brett,

I checked it and it looks fine. Any other suggestions?

 

[Brett]

Find the exact location of the leak, mark it, disassemble to determine cause.

Or

The ******* solution, find the exact location of the leak and fill it with hi-temp sealant.

Doesn't fix the cause, but it blocks the symptoms.