Tollycraft 40 Sundeck
Built 1985–1994 by Tollycraft Yacht Corp. (Kelso, WA)
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About the Tollycraft 40 Sundeck
Researched from public sources for this model. Any individual boat may have been modified or repowered — confirm before relying on any figure.
- Built
- 1985–1994
- Builder
- Tollycraft Yacht Corp. (Kelso, WA)
- Length
- 40.17 ft
- Beam
- 14.67 ft
- Draft
- 3 ft
- Displacement
- 26,000 lb
- Hull
- fiberglass
- Hull / keel
- planing
- Propulsion
- inboard
- Fuel
- 398 gal
- Water
- 140 gal
- Holding
- 40 gal
- Stern thruster
- not fitted
Tank capacities — where the figures come from
-
Fuel 398 gal
“Fuel Tank (Gallons)796” — broker listing (1985), yachtr.comNo builder figure was found. The only listing checked says 796 gal, which looks like two tanks counted twice (2 x 398), so it was not used.
-
Water 140 gal
“Fresh Water (Gallons)140” — broker listing (1985), yachtr.comOne listing agrees.
-
Holding 40 gal
“Holding Tank (Gallons)40” — broker listing (1985), yachtr.comOne listing agrees.
-
Water heater unknown (Torrid)
“11 gallon torrid stainless steel water heater” — broker listing (1988), boatsdata.comOnly a broker listing for a 1988 boat gives a size, and it may be a replacement. Tollycraft's 1979 line brochure said every Tolly had a 12 gal heater as standard, but that predates this 1985 model, so we don't apply it here.
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 unknown
No builder list for the 40 Sundeck was found, and neither the PowerBoat Guide entry nor any other source found gives thruster information.
-
Stern thruster not fitted
No source was found either way. A forum post mentions a Tollycraft 40 with a stern thruster (the model isn't clear), so our earlier figure of none is unproven.
-
Steering unknown
No builder document for the 40 Sundeck was found. Tollycraft's 1979 catalog and 1992 45-foot sheet show hydraulic steering standard across its cruiser line, which suggests hydraulic here too, but no source names the 40 Sundeck's system.
Thrusters and steering are often replaced — check the units on your boat before ordering parts.
Fuel was 300 gal until the 1991 increase to 398 gal. Modified-V (10 deg) with shallow keel. Floorplan revised mid-1992 (larger forward cabin and salon). All-teak interior; lower helm optional. Many are diesel powered per PassageMaker.
Engines fitted
-
Crusader 350 (gas V8 inboard) — 350 hp, gas, twin
standard
Standard power; 17-18 knots cruise, about 25 top. A 1985 boat for sale still has its original twin Crusader 350s.Sources: hmy.com · yachtr.com
-
Caterpillar 375 hp diesel (model not named in source) — 375 hp, diesel, twin
factory option
Optional diesel; cruise in the low 20s (25-26 top). Source does not name the model (375 hp matches Cat's 3208 TA rating, unconfirmed for this boat).Sources: hmy.com
-
Detroit Diesel 6V53 — 400 hp, diesel, twin
factory option
Fastest option; 24-25 knots cruise.Sources: hmy.com
Boats of the same model can differ — check which engines yours actually has before ordering parts.
Generator
No builder document, review or owners' association page naming a generator for the 40 Sundeck was found; a Powerboat Guide-style summary on a broker site covers only engines and tanks.
Known problems for this model
No well-sourced problem reports found yet.
Engines & parts
Crusader 350 / 454 inboard gas V8 parts: good
Factory standard engine — you entered “Crusader 350 (gas V8 inboard)”
GM-based inboard engines; Crusader (now part of Pleasurecraft Marine Engine Co.) still publishes illustrated parts manuals and sells through distributors. Go2marine stocks Crusader manifolds, risers, raw water pumps and ignition parts; Osco and Barr make aftermarket manifolds, and new GM/Crusader base engines are sold by rebuilders.
Parts sources: Crusader Engines, Go2marine (Crusader parts), 1-800-RUNS-NEW (GM & Crusader base engines)
Common problems (1)
-
Clogged or failing manifolds/risers exhaust
Owners find individual risers running much hotter than the others (a sign of internal blockage) and debate replacing vs. flushing; Osco manifolds are often preferred as closest to OEM.marineengine.com · marineengine.com
Maker’s service schedule (14)
| Engine oil & filter change 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 50 hrs or 1 yr | “Change engine oil and filter — After 1st 25 Hrs / Every 50 Hours of Operation / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Fuel filters & water separator 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 50 hrs or 1 yr | “Fuel Filters - Service or replace — After 1st 25 Hrs / Every 50 Hours / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Raw-water pump impeller 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 1 yr | “Cooling System - Inspect/Replace raw water pump impeller — Every 100 Hours of Operation / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Drive belts inspect / replace 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 1 yr | “Drive Belt - Inspect condition and check tension — After 1st 25 Hrs / Every 100 Hours / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Spark plugs inspect / replace 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 1 yr | “Ignition System and Spark Plugs - Clean and inspect condition — After 1st 25 Hrs / Every 100 Hours / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Exhaust mixing elbow inspection 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 4 mo | “Exhaust System - Check condition and tightness of all hose clamps — After 1st 25 Hrs / Every 100 Hours(1) / Once Each Ye” — manufacturer (2013), crusaderengines.com |
| Coolant replacement & freeze-point test 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 5 yrs | “Fresh-water cooled models - Change coolant — Every five years” — manufacturer (2013), crusaderengines.com |
| Engine pencil zincs 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 1 mo | “Zinc Anodes - Heat exchanger and cooler - check condition — Every 30 days” — manufacturer (2013), crusaderengines.com |
| Transmission fluid change 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 1 yr | “Transmission and "V" Drive - Change fluid and clean strainer, if equipped — After 1st 25 Hrs (Hurth Only) / Once Each Ye” — manufacturer (2013), crusaderengines.com |
| Flame arrestor & crankcase ventilation - clean and inspect 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 1 yr | “Flame Arrestor and Crankcase Ventilation System - Clean and inspect — Every 100 Hours / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Engine alignment check 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 1 yr | “Engine Alignment - Check and adjust if necessary — After 1st 25 Hrs / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Inspect all hoses (and cooling hose clamps) 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 1 yr | “Hoses (all) - Inspect for cracks, swelling, weather checking or other signs of deterioration — Every 100 Hours / Once Ea” — manufacturer (2013), crusaderengines.com |
| Shift & throttle cable linkage - inspect and lubricate 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 100 hrs or 4 mo | “Shift and Throttle Cable Linkage - Inspect and lubricate — Every 100 Hours(1) / Once Each Year” — manufacturer (2013), crusaderengines.com |
| Electrical system - check connections and wiring 2013 MPI 5.0L/5.7L (350 CID)/6.0L | 50 hrs or 2 mo | “Electrical System (complete) - Check for loose or dirty connections and damaged wiring — Every 50 Hours(2) / Once Each Y” — manufacturer (2013), crusaderengines.com |
Service part numbers (18)
| Oil filter remote-mounted oil filter (MP7.4L and 2013 5.0/5.7/6.0L MPI) |
Crusader 22679 | “Oil Filter 22679 (MAINTENANCE ITEM PART NUMBERS)” — manufacturer, crusaderengines.com |
| Fuel filter MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008 |
Crusader 47038 | “Fuel Filter 47038 (MAINTENANCE ITEM PART NUMBERS)” — manufacturer, crusaderengines.com |
| Fuel filter 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13 |
Crusader RP080026 | “Fuel Control Cell (FCC) Fuel Filter Element RP080026” — manufacturer, crusaderengines.com |
| Fuel pre-filter / separator MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: engine-mounted Racor water-separating filter 47046 |
Crusader 47047 | “25 47047 Element, Racor fuel filter (Not Shown) 1” — manufacturer, crusaderengines.com |
| Fuel pre-filter / separator 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13: primary fuel filter |
Crusader R080033 | “Primary Fuel Filter Element R080033” — manufacturer, crusaderengines.com |
| Raw-water impeller MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008 (raw water pump RA057031) |
Crusader RP061017 Replaces R061017 |
“Replaces Crusader R061017 (Impeller Kit with Gasket & O-Ring | Crusader RP061017)” — dealer, marinepartssource.com · “Replaces Crusader R061017 (Impeller Kit with Gasket & O-Ring | Crusader RP061017)” — dealer, marinesuppliesdepot.com |
| Raw-water impeller 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13 |
Crusader RP061022 | “Impeller , Raw Water Pump (1) RP061022 (ON-BOARD PARTS KIT 5.7L)” — manufacturer, crusaderengines.com |
| Raw-water pump kit MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008 (raw water pump RA057031) |
Crusader 40064 | “40064 Overhaul Kit, Major (includes items 2, 3, 11, 14 and 15)” — manufacturer, crusaderengines.com |
| Drive belt MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: alternator drive |
Crusader 98210 | “Alternator Drive Belt 98210” — manufacturer, crusaderengines.com |
| Drive belt MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: raw water pump drive |
Crusader 10258 | “Raw Water Pump Drive Belt 10258” — manufacturer, crusaderengines.com |
| Drive belt 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13, left-hand (LH) rotation: serpentine |
Crusader R066028 | “Belt , Serpentine (1) R066028 (ON-BOARD PARTS KIT 5.7L (LH))” — manufacturer, crusaderengines.com |
| Drive belt 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13, right-hand (RH) rotation: serpentine |
Crusader R066029A | “Belt , Serpentine (1) R066029A (ON-BOARD PARTS KIT 5.7L (RH))” — manufacturer, crusaderengines.com |
| Spark plug MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: platinum plug |
Crusader 49078 × 8 | “Spark Plugs (platinum) 49078” — manufacturer, crusaderengines.com |
| Spark plug 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13: platinum plug set |
Crusader RP030010 | “Spark Plug , Set, (Platinum) (1) RP030010 (ON-BOARD PARTS KIT 5.7L)” — manufacturer, crusaderengines.com |
| Thermostat MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: raw-water (standard) cooling, 143 F |
Crusader R026002E | “6 R026002E Thermostat (143-degree) 1 (Raw Water Cooling Components - Figure 18)” — manufacturer, crusaderengines.com |
| Thermostat MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: fresh-water (closed) cooling kit, 170 F |
Crusader 98203 | “5 98203 Thermostat (170-degree) 1 (Fresh Water Cooling Components 1)” — manufacturer, crusaderengines.com |
| Zinc / anode MP7.4L / MP454 XLi (454 MPI) - illustrated parts manual L510008: oil cooler / transmission cooler / heat exchanger |
Crusader R168005 | “24 R168005 Zinc, sacrificial 1 (Raw Water Cooling Components - Figure 18)” — manufacturer, crusaderengines.com |
| On-board spare parts kit (belt, cap, rotor, fuses, relays, plugs, impeller, fuel filters) 5.7L (350) MPI with FCC fuel system, 2007 on - 2013 owner manual L510001-13, LH rotation |
Crusader RK173089D-07 | “ON-BOARD PARTS KIT 5.7L (LH) 2007 TO PRESENT, FCC FUEL SYSTEM RK173089D-07” — manufacturer, crusaderengines.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.
Detroit Diesel 6V-53 (N / T) parts: good
Factory optional engine — you entered “Detroit Diesel 6V53”
Two-stroke 53-series V6; complete overhaul kits and service parts are still sold (Diesel Pro Power, Heavy Duty Pros), and used 53-series parts circulate among owners.
Parts sources: Diesel Pro Power (6V53 overhaul kits), Heavy Duty Pros
Common problems (1)
-
Heavy, leaky, smoky and noisy engine
Classic Bertram owners sum up the 6V53 as heavy and hard to install, prone to leaks, smoke and noise, but with good service parts support.bertram31.com
Maker’s service schedule (18)
| Engine oil & filter change | 150 hrs | “Industrial & Marine 53, 71, 92 2-Cycle 150 Hours (oil drain interval, Table L-3)” — manufacturer, archive.org |
| Fuel filters & water separator | 300 hrs | “Install new elements every 300 hours or when plugging is indicated” — manufacturer, archive.org |
| Coolant replacement & freeze-point test | 1,000 hrs | “Clean the cooling system every 1,000 hours using a good radiator cleaning compound” — manufacturer, archive.org |
| Engine pencil zincs | 500 hrs | “Every 500 hours, drain the water from the heat exchanger raw water inlet and outlet tubes ... [remove the zinc electrode” — manufacturer, archive.org |
| Heat exchanger & oil cooler cleaning | 1,000 hrs | “remove the retaining cover every 1,000 hours and inspect the heat exchanger core” — manufacturer, archive.org |
| Drive belts inspect / replace | 200 hrs | “check the tension of the drive belts every 200 hours” — manufacturer, archive.org |
| Air filter / intake silencer dry-type air cleaner | 1 yr | “[replace] with new elements after one year of service or when the maximum allowable air intake restriction has been reac” — manufacturer, archive.org |
| Transmission fluid change Warner marine gear (and the other gear covered in Item 41) | 200 hrs | “WARNER MARINE GEAR: ... Change the oil every 200 hours” — manufacturer, archive.org |
| Clean crankcase breather | 1,000 hrs | “[Remove the crankcase breather] assembly every 1,000 hours and wash the steel mesh pad” — manufacturer, archive.org |
| Inspect blower screen | 1,000 hrs | “Inspect the blower screen and gasket assembly every 1,000 hours” — manufacturer, archive.org |
| Check / clean air box drain tubes | 1,000 hrs | “[check for flow of air from the] air box drain tubes every 1,000 hours” — manufacturer, archive.org |
| Check thermostats and seals | 5,000 hrs or 1 yr | “Check the thermostats and seals at 5,000 hours or once a year” — manufacturer, archive.org |
| Inspect all hoses | 500 hrs or 1 yr | “should be thoroughly inspected at least every 500 operating hours (1,000 hours for the fire-resistant ...) and/or annual” — manufacturer, archive.org |
| Drain water/sediment from fuel tank | 500 hrs | “Open the drain at the bottom of the fuel tank every 500 hours to drain off any water and/or sediment” — manufacturer, archive.org |
| Coolant filter/conditioner element (if fitted) | 500 hrs | “the filter element should be changed every 500 hours” — manufacturer, archive.org |
| Check emergency (air) shutdown | 700 hrs | “[check the] operation of the emergency shutdown every 700 hours” — manufacturer, archive.org |
| Check engine and transmission mounts | 2,000 hrs | “the condition of the mounting pads every 2,000 hours” — manufacturer, archive.org |
| Replace fresh-water pump seal | 6,000 hrs | “[Replace the water pump seal after it has been in service] for 6,000 hours” — manufacturer, archive.org |
Service part numbers (11)
| Oil filter full-flow cartridge element, 9 in. (shell-type filter) |
Detroit Diesel 5573014 Also: AC Delco PF132 |
“4.2250 - ELEMENT, OIL FILTER 3A 5573014 ELEMENT (9") (AC TYPE PF-132)” — manufacturer, archive.org |
| Oil filter spin-on element (engines with spin-on adaptor 5104419) |
Detroit Diesel 25010495 | “4.2250 - ELEMENT, OIL FILTER 25010495 ELEMENT . 1111 25011106 ELEMENT” — manufacturer, archive.org |
| Fuel filter secondary filter, spin-on (3/4 in. thread base) |
Detroit Diesel 23530707 Replaces 25010778 Also: AC Delco TP916 |
“25010778 Superceded by DN 23530707” — dealer, powerlinecomponents.com · “Detroit Diesel Secondary Fuel Filter - 23530707 - Series 60 Series 53 Series 71 Series 92 Series 149” — dealer, industrialtecsupply.com |
| Fuel pre-filter / separator primary fuel strainer, spin-on (1 in. thread base) |
Detroit Diesel 25010776 Also: AC Delco T915 |
“25010776 * CARTRIDGE (SPIN ON) (T-915)” — manufacturer, archive.org |
| Fuel pre-filter / separator primary fuel strainer, shell type (8 in. felt sock element) |
Detroit Diesel 5575032 Also: AC Delco T552 |
“3C 5575032 ELEMENT (8", FELT SOCK TYPE, T-552)” — manufacturer, archive.org |
| Raw-water impeller smaller raw-water pump (manual fig. 8A, 2/3/4/6V-53), synthetic rubber |
Detroit Diesel 5193602 | “5.6230 - IMPLELLER, RAW WATER PUMP ... 8A 5193602 IMPELLER, 2,3,4,6V53 (SYNTHETIC).” — manufacturer, archive.org |
| Raw-water impeller larger raw-water pump (manual fig. 8B, 6V/8V-53), synthetic rubber |
Detroit Diesel 5193553 | “8B 5193553 IMPELLER, 6,8V53 (SYNTHETIC).” — manufacturer, archive.org |
| Raw-water pump kit smaller raw-water pump (2/3/4/6V-53) |
Detroit Diesel 5197225 | “5.6025 - RECONDITIONING KIT. RAW WATER PUMP 5197225 RECONDITIONING KIT, 2,3,4,6V53” — manufacturer, archive.org |
| Raw-water pump kit larger raw-water pump (6V/8V-53) |
Detroit Diesel 5197224 | “5197224 RECONDITIONING KIT, 6.8V53” — manufacturer, archive.org · “Detroit Diesel Marine Water Pump repair kit 6V53, 6V71, 6-71, 6V92 5197224P For 2 1/2" impeller height” — dealer, dieselpro.com |
| Zinc / anode heat-exchanger electrode assembly, 3 3/8 in. |
Detroit Diesel 8515850 | “5.5010 - ELECTRODE, HEAT EXCHANGER 6AB 8515850 ELECTRODE ASSY., 3, 4, 6, 8V53 (INCLUDES 3 3/8" ELECTRODE)” — manufacturer, archive.org |
| Thermostat 170 F, full-blocking (seal 5134269 separate) |
Detroit Diesel 5143210 × 2 | “5.2050 - THERMOSTAT ASSY. ... 6A,B 5143210 ... THERMOSTAT ASSY., 3,4,6,8V53 (170 DEG. OPENING TEMP.)” — manufacturer, archive.org · “Detroit Diesel Thermostat for engines 6V53 and 8V53 5143210 170 degrees” — 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 (4)
Own a Tollycraft 40 Sundeck? Add her to your boats, then share a photo — names, numbers and faces are blurred before it appears.
Other Tollycraft models
- Tollycraft 26 Sedan 1973–1987
- Tollycraft 34 Tri-Cabin 1975–1985
- Tollycraft 44 / 45 Cockpit Motor Yacht 1986–1996
- Tollycraft 48 Motor Yacht (48 Cockpit MY) 1976–1998
Researched from public sources. Spotted an error? The sources are listed above — tell us what they got wrong.