Sea Ray 380 Sundancer (1999-2003)

Built 1999–2003 by Sea Ray Boats

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About the Sea Ray 380 Sundancer (1999-2003)

Researched from public sources for this model. Any individual boat may have been modified or repowered — confirm before relying on any figure.

Illustration of a Sea Ray 380 Sundancer (1999-2003) — **Illustration, not a photo of this model.** AI-generated illustration of a typical flybridge motor yacht.

Built: 1999–2003
Builder: Sea Ray Boats
Length: 40.08 ft
Beam: 13 ft
Draft: 3.33 ft
Displacement: 18,300 lb
Hull: fiberglass-cored
Hull / keel: planing
Propulsion: inboard
Fuel: 275 gal
Water: 70 gal
Holding: 42 gal
Water heater: 6 gal · AC + engine · standard
Generator: standard
Bow thruster: factory option
Stern thruster: not fitted
Steering: hydraulic

Tank capacities — where the figures come from

Fuel 275 gal
“Fuel capacity 275 gal 1,040.9 L” — brochure (2000), rnr-marine.com · “a 275-gallon fuel capacity” — search excerpt (2001), boatsonly.com

Sea Ray's 2000 spec sheet (a PDF posted by a dealer) confirms 275 gal.
Water 70 gal
“Water capacity 70 gal 265 L” — brochure (2000), rnr-marine.com · “Water tank capacity is 70 gallons” — search excerpt (2001), boatshed.com
Holding 42 gal
“Holding tank 42 gal 159 L” — brochure (2000), rnr-marine.com

The builder gives a 42-gal holding tank, reduced to 28 gal on boats fitted with the optional gray-water system.
Water heater 6 gal · AC + engine · standard
“Pressure Water System & 6-Gallon Water Heater w/Exchanger” — builder (2000), rnr-marine.com

Technical section of the 2000 standard-equipment list. Small for a 40 ft boat but that is what the builder sheet states.

Tanks are often replaced or added on older boats — check the tank labels or a survey for yours.

Thrusters and steering — where this comes from

Bow thruster factory option
“Individual Options: ... Bow Thrusters” — brochure (2000), rnr-marine.com

Listed as an individual factory option on the 2000 builder spec sheet; the make and size are not given.
Stern thruster not fitted
“Standard equipment ... Options/Accessories ... Individual Options (bow thruster listed, no stern thruster)” — brochure (2000), rnr-marine.com

The 2000 option list offers a bow thruster but no stern thruster.
Steering hydraulic
“Hydraulic Steering w/Tilt Wheel” — brochure (2000), rnr-marine.com · “a wood-accent tilt wheel with hydraulic steering” — brochure (2000), rnr-marine.com

Hydraulic steering with tilt wheel is standard on the 2000 builder spec (standard power twin 454 Mag V-drives); helm brand not named.

Thrusters and steering are often replaced — check the units on your boat before ordering parts.

Top-selling big express of its day. Deep-V (19.5 deg). Most sold with gas engines (18 kt cruise); Cat diesels cruise about 25 kt. LOA includes platform.

Engines fitted

MerCruiser 7.4L MPI (V-drive) — gas, twin standard
Owners on Boatered say 2001 boats had MerCruiser 7.4L MPI gas V-drives before the switch to the 8.1L. Rating not stated in the sources read.

Sources: boatered.com · hmy.com
MerCruiser 8.1S Horizon (V-drive) — 370 hp, gas, twin standard
2002-03 boats moved to the 8.1L; HMY says most 380s were sold with 370 hp MerCruiser V-drive gas engines (18 kn cruise, mid-20s top); a 2003 listing has twin 8.1S Horizons at 370 hp.

Sources: hmy.com · harbortownemarine.com · boatered.com
Caterpillar 3116TA — 340 hp, diesel, twin factory option
Sea Ray's 2000 spec sheet (quoted by an owner) lists twin Cat 3116TA V-drives at 292 hp or 340 hp; HMY says 340 hp Cat diesels cruise about 25 kn.

Sources: clubsearay.com · hmy.com
Caterpillar 3126TA — 350 hp, diesel, twin factory option
A 2000 380 Sundancer examined by an owner had Cat 3126 engines plated at 350 hp, although the spec sheet listed 3116TAs; owners explain Cat replaced the 3116 with the 3126 around then.

Sources: clubsearay.com

Boats of the same model can differ — check which engines yours actually has before ordering parts.

Generator

standard

“Generator - Remote Start w/Muffler, Freshwater Cooling, Fuel Filter & Seawater Strainer: 120V/60 Cycle 7.2 kW Westerbeke” — builder (2000), rnr-marine.com

A sound box for the gas generator was a separate option.

Westerbeke — 7.2 kW, gas standard
US 120V/60 Hz standard set; export boats listed a 6.0 kW Westerbeke gas set.

“120V/60 Cycle 7.2 kW Westerbeke Gas” — builder (2000), rnr-marine.com
Westerbeke — 8 kW, diesel factory option
Offered instead of the standard gas set, with sound box; export boats listed a 6.0 kW Westerbeke diesel.

“Generators (in lieu of Std.) ... 120V/60 Cycle 8.0 kW Westerbeke Diesel w/Sound Box” — builder (2000), rnr-marine.com

Generators are often replaced or added — check the unit's own plate before ordering parts.

Manuals and brochures online

Document Sea Ray Documents & Manuals library (spec sheets and owner's manuals searchable by model and year) — searay.com

Hosted by the builder or an owners' association; they own the copyright.

Known problems for this model

Balsa-cored bottom hull
The bottom is balsa cored, and HMY notes Sea Ray had problems with some cored hulls built 1995-2002; a moisture/percussion survey of the bottom is essential.
hmy.com · yachtsurvey.com

Engines & parts

MerCruiser 7.4 (454) V8 gas parts: good

Factory standard engine — you entered “MerCruiser 7.4L MPI (V-drive)”

GM big-block base; Marine Engine Depot and others sell 7.4 L engines and parts, and cast-iron riser kits run a few hundred dollars. Manifold and riser replacement is the main recurring expense.

Parts sources: Marine Engine Depot, Power Boat Supply

Common problems (2)

Manifold and riser corrosion exhaust
As with other gas marine V8s, internally rusted manifolds and risers can let water into the engine; periodic replacement is standard practice.
powerandmotoryacht.com
Rough running and won't rev under load fuel
Common troubleshooting threads trace this to fuel delivery (filters, pump, carburetor) or ignition timing problems.
justanswer.com · youtube.com

Maker’s service schedule (8)

Engine oil & filter change	100 hrs or 1 yr	“Most four-stroke outboards and sterndrive engines require an oil change either annually or every 100 hours of operation.” — manufacturer, mercurymarine.com
Fuel filters & water separator	100 hrs or 1 yr	“The fuel filter on your engine should be inspected or replaced per the maintenance schedule in your owner's manual, usua” — manufacturer, mercurymarine.com
Raw-water pump impeller	300 hrs or 3 yrs	“How often should my seawater pump impeller be serviced? Every 300 hours or 3 years, whichever comes first.” — manufacturer, mercurymarine.com
Spark plugs inspect / replace	300 hrs or 3 yrs	“How often should spark plugs be changed? Every 300 hours or 3 years, whichever comes first.” — manufacturer, mercurymarine.com
Coolant replacement & freeze-point test closed (freshwater) cooling only	5 yrs	“How often should coolant be changed on engines with closed cooling? Every 5 years.” — manufacturer, mercurymarine.com
Transmission fluid change sterndrive gear lube	1 yr	“Gearcase lubricant in outboard and sterndrive lower units should also be changed annually or at the service interval spe” — manufacturer, mercurymarine.com
Lubricate steering linkage and check power-steering fluid sterndrive	100 hrs or 1 yr	“Mercury Marine recommends lubricating the steering linkage and checking the power steering fluid level in ... MerCruiser” — manufacturer, mercurymarine.com
Check power trim fluid level sterndrive	100 hrs or 1 yr	“Power trim and tilt fluid level should be checked annually or every 100 hours.” — manufacturer, mercurymarine.com

Service part numbers (4)

Oil filter	Mercury Quicksilver 35-866340Q03	“Part number: 866340Q03 ... for MerCruiser sterndrive and inboard engines except V6 engines with the oil filter mounted o” — manufacturer, mercurymarine.com · “14957 FILTER, Oil (1 required per assembly) ... 35-866340Q03 - Oil Filter” — dealer, marineengine.com
Fuel filter carbureted engines (Rochester 4-barrel): filter inside carburetor fuel inlet	Mercury 53336T	“For use on MerCruiser 3.0L, 4.3L, 5.0L , 5.7L and 7.4L engines with Rochester 2- and 4-barrel and MerCarb” — manufacturer, mercurymarine.com
Raw-water impeller Bravo sterndrive / inboard with pre-2000 engine-mounted plastic sea water pump	Mercury Quicksilver 47-59362Q01 Also: Sierra 18-3087	“For MerCruiser engines with engine mounted, 2-piece, plastic sea water pumps.” — manufacturer, mercurymarine.com · “Included water Pump Impeller 59362Q01 fits Pre-2000 plastic seawater sea pumps. WILL NOT work on newer (2000+)” — dealer, midnightmarine.net
Thermostat standard cooling, 160 F	Mercury Quicksilver 807252Q5	“Thermostat 807252Q5 is for V6 and V8 MerCruiser engines ... made by General Motors (model year 1987-2016)” — manufacturer, mercurymarine.com

From the engine maker’s parts lists, or two independent parts dealers. Numbers change with serial number and get superseded — check yours before ordering.

Caterpillar 3116 parts: limited

Factory optional engine — you entered “Caterpillar 3116TA”

Supported by Cat dealers by serial number; aftermarket rebuilders (e.g., Big Bear Engine) sell parts and address known problems. Some 3116s built in France ('soft block') were problematic and owners are told to check serial numbers with Cat.

Parts sources: Big Bear Engine Company, Diesel Pro Power

Common problems (4)

Failures in high-load use engine
3116s generally do fine in trawlers but problems show up in fast boats run near full power for long periods; poor propping that overloads the engine ages it quickly.
trawlerforum.com
'Soft block' engines engine
A batch of French-built blocks had a reputation for early failure, sometimes within a few hundred hours.
trawlerforum.com
Injectors, fuel rack and heads fuel
Owners and rebuilders report injector/injector-cup, fuel rack and cylinder head problems; good maintenance history matters when buying.
4btengines.com · facebook.com
Low turbo/exhaust mixer height exhaust
The low-mounted turbo and exhaust mixer make it harder to get adequate exhaust riser height, so the exhaust installation needs care to avoid water backflow.
trawlerforum.com

Maker’s service schedule (18)

Engine oil & filter change	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Engine Oil and Filter - Change” — manufacturer, oxfordyachtagency.com
Fuel filters & water separator	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Fuel System Primary Filter/Water Separator Element” — manufacturer, oxfordyachtagency.com
Raw-water pump impeller	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Auxiliary Water Pump - Inspect” — manufacturer, oxfordyachtagency.com
Engine pencil zincs	50 hrs	“Every 1500 L (400 US gal) of Fuel or 50 Service Hours ... Zinc Rods - Inspect/Replace” — manufacturer, oxfordyachtagency.com
Valve clearance check / adjust	2,000 hrs	“First 7500 L (2000 US gal) of Fuel or 250 Service Hours ... Engine Valve Lash - Inspect/Adjust” — manufacturer, oxfordyachtagency.com
Coolant replacement & freeze-point test Cat DEAC / conventional coolant	1,000 hrs or 2 yrs	“Every 30 000 L (8000 US gal) of Fuel or 1000 Service Hours or 2 Years ... Cooling System Coolant (DEAC) - Change” — manufacturer, oxfordyachtagency.com
Coolant replacement & freeze-point test Cat ELC (extended life coolant)	6,000 hrs or 4 yrs	“Every 182 000 L (48 000 US gal) of Fuel or 6000 Service Hours or 4 Years ... Cooling System Coolant (ELC) - Change” — manufacturer, oxfordyachtagency.com
Turbocharger inspection	1,000 hrs or 2 yrs	“Every 30 000 L (8000 US gal) of Fuel or 1000 Service Hours or 2 Years ... Aftercooler Core - Clean/Test” — manufacturer, oxfordyachtagency.com
Turbocharger inspect	1,000 hrs or 2 yrs	“Every 30 000 L (8000 US gal) of Fuel or 1000 Service Hours or 2 Years ... Turbocharger - Inspect” — manufacturer, oxfordyachtagency.com
Heat exchanger & oil cooler cleaning	2,000 hrs	“Every 60 000 L (16 000 US gal) of Fuel or 2000 Service Hours ... Heat Exchanger - Inspect” — manufacturer, oxfordyachtagency.com
Drive belts inspect / replace	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Belt - Inspect” — manufacturer, oxfordyachtagency.com
Fuel injection timing check	2,000 hrs	“First 7500 L (2000 US gal) of Fuel or 250 Service Hours ... Fuel Injection Timing - Check” — manufacturer, oxfordyachtagency.com
Thermostat (coolant temperature regulator) replace	3,000 hrs or 2 yrs	“Every 91 000 L (24 000 US gal) of Fuel or 3000 Service Hours or 2 Years ... Cooling System Water Temperature Regulator -” — manufacturer, oxfordyachtagency.com
Sea water strainer clean/inspect	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Sea Water Strainer - Clean/Inspect” — manufacturer, oxfordyachtagency.com
Jacket water pump inspect	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Water Pump - Inspect” — manufacturer, oxfordyachtagency.com
Coolant SCA test/add	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Cooling System Supplemental Coolant Additive (SCA)” — manufacturer, oxfordyachtagency.com
Hoses and clamps inspect/replace	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Hoses and Clamps - Inspect/Replace” — manufacturer, oxfordyachtagency.com
Crankcase breather clean	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Engine Crankcase Breather - Clean” — manufacturer, oxfordyachtagency.com

Service part numbers (3)

Oil filter	Sources disagree: 1R-0658 / 324-2598	“Oil Filter CAT 1R-0658 \| 3126B C7 3306 3304 3116 C4.2 3046 3066” — dealer, marineenergy.com.au · “Caterpillar 324-2598 Advanced Efficiency 3116 and 3126 Diesel Engine Oil Filter” — dealer, marineengineparts.com
Fuel filter	Caterpillar 1R-0751 Also: Baldwin BF7632, Fleetguard FF5324, WIX 33626	“Caterpillar 1R-0751 Advanced Efficiency 3116 and 3126 Diesel Engine Fuel Filter” — dealer, marineengineparts.com · “the secondary fuel filter Cat specifies for the 3114, 3116, 3126/B/E, C7, and C9 family” — dealer, allprodiesel.net
Raw-water impeller keyway-shaft Sherwood seawater pump	Sherwood 17000K	“\| Impeller \| 17000K KEY WAY \|” — dealer, marineenergy.com.au · “Caterpillar Marine Engines ... Common applications include: ... CAT 3116” — dealer, marisolmarine.com
Zinc / anode	Caterpillar 6L-2283 × 3	“Anode kit CAT3116 \| 3 x 6L2283 2 x 6L2281 1 x 6L3104” — dealer, marineenergy.com.au · “Zinc Anode for Caterpillar Marine Engines 6L2283 NPT: 1/4”” — dealer, dieselpro.com

From the engine maker’s parts lists, or two independent parts dealers. Numbers change with serial number and get superseded — check yours before ordering.

Caterpillar 3126 / 3126B parts: good

Factory optional engine — you entered “Caterpillar 3126TA”

Electronically controlled HEUI engine that evolved into the C7 (around 2003); Cat dealers support it and released upgraded aftercoolers/cores. Aftercooler replacement is costly (owners cite thousands per engine).

Parts sources: Diesel Pro Power

Common problems (3)

Aftercooler leaking seawater into the engine cooling
Early 3126s had seawater-cooled aftercoolers that corroded from dissimilar metals and could leak salt water into the engine; Cat later offered upgraded aftercoolers, and surveyors check for this specifically.
trawlerforum.com · samsmarine.com · clubsearay.com
HEUI pump, hose and spool valve problems fuel
The high-pressure oil (HEUI) pump can fail, early 3126B high-pressure hoses were prone to failure (a steel-tube conversion exists), and sticky injector spool valves cause hard starting or rough running.
trawlerforum.com
Power loss and sooting engine
Owners troubleshoot engines that will not reach rated rpm and soot heavily at cruise, checking air filters, aftercooler condition, turbo and injectors.
facebook.com

Maker’s service schedule (18)

Engine oil & filter change	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Engine Oil and Filter - Change” — manufacturer, oxfordyachtagency.com
Fuel filters & water separator	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Fuel System Primary Filter/Water Separator Element” — manufacturer, oxfordyachtagency.com
Raw-water pump impeller	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Auxiliary Water Pump - Inspect” — manufacturer, oxfordyachtagency.com
Engine pencil zincs	50 hrs	“Every 1500 L (400 US gal) of Fuel or 50 Service Hours ... Zinc Rods - Inspect/Replace” — manufacturer, oxfordyachtagency.com
Valve clearance check / adjust	2,000 hrs	“First 7500 L (2000 US gal) of Fuel or 250 Service Hours ... Engine Valve Lash - Inspect/Adjust” — manufacturer, oxfordyachtagency.com
Coolant replacement & freeze-point test Cat DEAC / conventional coolant	1,000 hrs or 2 yrs	“Every 30 000 L (8000 US gal) of Fuel or 1000 Service Hours or 2 Years ... Cooling System Coolant (DEAC) - Change” — manufacturer, oxfordyachtagency.com
Coolant replacement & freeze-point test Cat ELC (extended life coolant)	6,000 hrs or 4 yrs	“Every 182 000 L (48 000 US gal) of Fuel or 6000 Service Hours or 4 Years ... Cooling System Coolant (ELC) - Change” — manufacturer, oxfordyachtagency.com
Turbocharger inspection	1,000 hrs or 2 yrs	“Every 30 000 L (8000 US gal) of Fuel or 1000 Service Hours or 2 Years ... Aftercooler Core - Clean/Test” — manufacturer, oxfordyachtagency.com
Turbocharger inspect	1,000 hrs or 2 yrs	“Every 30 000 L (8000 US gal) of Fuel or 1000 Service Hours or 2 Years ... Turbocharger - Inspect” — manufacturer, oxfordyachtagency.com
Heat exchanger & oil cooler cleaning	2,000 hrs	“Every 60 000 L (16 000 US gal) of Fuel or 2000 Service Hours ... Heat Exchanger - Inspect” — manufacturer, oxfordyachtagency.com
Drive belts inspect / replace	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Belt - Inspect” — manufacturer, oxfordyachtagency.com
Fuel injection timing check	2,000 hrs	“First 7500 L (2000 US gal) of Fuel or 250 Service Hours ... Fuel Injection Timing - Check” — manufacturer, oxfordyachtagency.com
Thermostat (coolant temperature regulator) replace	3,000 hrs or 2 yrs	“Every 91 000 L (24 000 US gal) of Fuel or 3000 Service Hours or 2 Years ... Cooling System Water Temperature Regulator -” — manufacturer, oxfordyachtagency.com
Sea water strainer clean/inspect	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Sea Water Strainer - Clean/Inspect” — manufacturer, oxfordyachtagency.com
Jacket water pump inspect	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Water Pump - Inspect” — manufacturer, oxfordyachtagency.com
Coolant SCA test/add	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Cooling System Supplemental Coolant Additive (SCA)” — manufacturer, oxfordyachtagency.com
Hoses and clamps inspect/replace	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Hoses and Clamps - Inspect/Replace” — manufacturer, oxfordyachtagency.com
Crankcase breather clean	250 hrs or 1 yr	“Every 7500 L (2000 US gal) of Fuel or 250 Service Hours or 1 Year ... Engine Crankcase Breather - Clean” — manufacturer, oxfordyachtagency.com

Service part numbers (3)

Oil filter	Sources disagree: 1R-0658 / 324-2598	“Oil Filter CAT 1R-0658 \| 3126B C7 3306 3304 3116 C4.2 3046 3066” — dealer, marineenergy.com.au · “Caterpillar 324-2598 Advanced Efficiency 3116 and 3126 Diesel Engine Oil Filter” — dealer, marineengineparts.com
Fuel filter	Caterpillar 1R-0751 Also: Baldwin BF7632, Fleetguard FF5324, WIX 33626	“Caterpillar 1R-0751 Advanced Efficiency 3116 and 3126 Diesel Engine Fuel Filter” — dealer, marineengineparts.com · “the secondary fuel filter Cat specifies for the 3114, 3116, 3126/B/E, C7, and C9 family” — dealer, allprodiesel.net
Raw-water impeller keyway-shaft Sherwood seawater pump	Sherwood 17000K	“\| Impeller \| 17000K KEY WAY \|” — dealer, marineenergy.com.au · “Caterpillar Marine Engines ... Common applications include: ... CAT 3126 / 3126B” — dealer, marisolmarine.com
Zinc / anode heat-exchanger anode	Caterpillar 6L-2283 × 2	“Replaces Caterpillar 6L2283, / 6L2282 (With the plug) Used on Caterpillar 3126, 3208 diesel marine engines. Qty 2 on Hea” — dealer, marineenergy.com.au · “Zinc Anode for Caterpillar Marine Engines 6L2283 NPT: 1/4”” — dealer, dieselpro.com

From the engine maker’s parts lists, or two independent parts dealers. Numbers change with serial number and get superseded — check yours before ordering.

Model sources (6)

hmy.com · yachtsurvey.com · boatered.com · harbortownemarine.com · clubsearay.com · rnr-marine.com

Own a Sea Ray 380 Sundancer (1999-2003)? Add her to your boats, then share a photo — names, numbers and faces are blurred before it appears.

Other Sea Ray models

Sea Ray 270 Sundancer (1994-97, 1999) 1994–1999
Sea Ray 300 Sundancer (1994-97) 1994–1997
Sea Ray 330 Sundancer (1995-99) 1995–1999
Sea Ray 340 Sundancer (1999-2002) 1999–2002
Sea Ray 370 Sedan Bridge 1991–1997
Sea Ray 400 Sedan Bridge 1996–2003

Researched from public sources. Spotted an error? The sources are listed above — tell us what they got wrong.