Ok, after all winter of getting the box installed and issues with the mechanic I finally get the boat back today (hoping and crossing my fingers there would be no issue) wrong. I put the boat in water and check the bilge for leaks....problem 1.....water flowing in at an alarming rate so I assume it is a very bad seal around box and transom. I still wanted to take it out to see if there were any other issues and just keep the bilge pump on. I get engine up to temp and take off....it does fine till about 2700-3000 RPM's and feels like it is starving for fuel...sputters a bit and almost wants to stall. I did this several times and varied the rpm's, slow take off, fast take off, mixture of both with same results. I then put the boat in neutral and no issues at any RPM all the way to 4500. So........I have heard the stellings shaft can set off the knock sensor? Would an alarm sound if this was true as no alarm sounded. Anything else I can check for?
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Carrier Bearing?

Sorry about your problems. I have heard good things about the stellings boxes. Maybe post in the Drives section and get better replies. Let us know your outcome.

I agree, pics would be very helpfull.

I had stellings and friends of mine did as well,,NO PROBLEMS...wonder what he did ?!

pics....

There are several things that could cause water intrusion. Where the ears are attached, your water intake hose to your sea pump could be loose, your inspection covers could be loose or not sealed, you could have a bad transom asym, or you could have a bad seal around the box. You could eliminate around the box by running a bead of 4200 around the outside of the box and make and external seal.

What ever it is u do, do NOT use 4200 or 5200 ,,just use clear marine silicon...it will seal and hold up just as good...but come off flawless if needet !!!!!!
Any pics from the inside of the box maybe and of the transom inside the boat ???

If your driveshaft is knukeling due to a to high instalation ..that can cause the engine to not give power and other things..like u said , check the bearing carrier and make shure greased well,,and such .

The angle of the drive shaft should not be less then 2 degree and not more then the u joints allow ( at the most u want to get a pencil in between the knuckles ) ~ 1/4 " at the absolute min, if the knuckles are facing each other !!!

Hope that helps.

PS. the way it looks on the pictures he did not seal between the transom and the box, i just had this on a costumers boat with 2 boxes..lol
Did u get it done in texas ???

Wayne looking at these pics now I'm guessing your leak is where the notch is in the transom...That box is hanging down and depending on where the seal on the box is which I disagree about putting 4200 on the box unless you plan on playing with adjustment you want a seal. I put 4200 on mine and then the seal between the transom assembly and the box I used black silicone as well as a "new" Mercury gasket. The engine issue you'll have to get someone that has experience with the 496 and the Stelling box with the shaft. Mine is direct replacement for the factory shaft so I can't help you there. Other thing you should look for is a possible loose wire on a plug all that moving around pulling the engine as well as putting in could've knocked one loose. Hope you figure it out and if you want to boat this weekend just go to Walmart and buy you come silicone and put a bead around the outside of the transom assembly as well as the bolts...You can clean it off as obviously he'll have to pull the box off to seal it...

So, I will take the access plates off in the morning and check for leaks there first and silicone around the entire box to transom to try to stop the leak.