Mercury Manifold Stud 49545

Mercury MerCruiser 49545 is a genuine OEM manifold stud used on a wide range of older MerCruiser engine manifold and exhaust-related assemblies. Current Mercury dealer references list it as 16-49545 Stud, (3/8 x 1.75), Manifold (1-3/4″) and show it superseded to current replacement part number 8M0204664.

Key Features

• Genuine Mercury Marine OEM part number 49545 / 16-49545.
• Current replacement part number is 8M0204664.
• Size listed by Mercury as 3/8 x 1.75 in.
• Mercury description identifies it as a manifold stud.
• Current dealer listing shows GTIN 745061157149.
• Related cross-reference sources connect it to exhaust manifold / elbow / riser service layouts on older MerCruiser engines.

Engine Compatibility

The strongest supportable fitment for 49545 is older MerCruiser manifold / exhaust hardware service across many legacy gas engine families. Current Mercury where-used references include 140 GM 181 I/L4, 470 / 470 MIE Mercury 224 I/L4, 160 / 165 GM 250 I/L6, 200 GM 292 I/L6, 260 GM 350 V8, 300 Tempest GM 350 V8, 370 / 400 / 440 / 460 TRS big-block applications, 420 / 425 GM 454 V8, and 5.7L ski / competition ski applications across listed serial ranges.

Serial Number Fitment Notice

Verify fitment by exact engine serial number and the correct manifold / exhaust elbow / riser parts diagram before ordering. This stud appears across many older MerCruiser engine families, so serial-based confirmation is the safest way to match the correct manifold hardware and superseded replacement number.

When This Part Needs Replacement

Replace this stud when the original is corroded, seized, stretched, damaged, broken during manifold service, or no longer provides reliable clamping. Manifold studs are commonly renewed during exhaust manifold, elbow, or riser work when existing hardware is deteriorated or difficult to remove.

Installation Notes

Install 49545 or current replacement 8M0204664 only after confirming the correct MerCruiser manifold assembly and hardware layout. Mercury lists the original as a 3/8 x 1.75 in. manifold stud, so thread size, length, and assembly location should all be matched before installation.

Alternate/Superseded Part Numbers

Current Mercury references show 8M0204664 as the active replacement for 49545 / 16-49545. Related cross-reference sources also associate AM16-49545, GLM22391, and OMC/Johnson/Evinrude 0509516 with this manifold stud application.

Parts Desk Insight

With manifold studs, the important match is the thread size, length, and exact manifold location. A quick serial-number and exhaust-diagram check usually avoids mixing up similar studs used around the manifold, elbow, and riser area.

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