1985 Johnson 6HP Prop Shaft

cruiserbill

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Hello everyone, first post here. I am rebuilding a J6RCOB 1985 Johnson 6hp lower unit. The lower unit was run out of lube and the pinion gear is toast. I am trying to remove the prop shaft, but it will not come out. I can turn it and it seems loose, but it will not budge to come out. Just wondering if anyone has experience getting it out. I attached some pics.

Thanks,

CB
 

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Chinewalker

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Does it turn within the gear, or does the gear turn with it? Judging by the rust elsewhere, I'd say the shaft has rusted into the gear. A shot of your favorite penetrating oil and brute force might be needed to get it apart. Placing the propshaft in a padded vice, and gentle persuasion on the housing with either a rubber mallet or a block of wood and a hammer might pop it free. Go easy with the hammers/mallets - it's a cast aluminum housing and they have been known to crack when too much force is applied...
 

cruiserbill

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Does it turn within the gear, or does the gear turn with it? Judging by the rust elsewhere, I'd say the shaft has rusted into the gear. A shot of your favorite penetrating oil and brute force might be needed to get it apart. Placing the propshaft in a padded vice, and gentle persuasion on the housing with either a rubber mallet or a block of wood and a hammer might pop it free. Go easy with the hammers/mallets - it's a cast aluminum housing and they have been known to crack when too much force is applied...

Thanks for the reply. The forward gear turns with it, but the pinion turns as it should, sort of, for being torn up so bad. I was considering that same method - using a padded vice and rubber mallet. I will spray it first though.
 

racerone

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After you check availability of parts and the price of parts , you will likely begin looking for a used unit on this !!
 

Chinewalker

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The propshaft should turn free of the forward gear - unless the clutch dog is engaging the gear. There is a flat bearing under the pinion, sandwiched between two thrust washer/races. Check those for wear, too...
 

cruiserbill

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OK, got the prop shaft out. Now to figure out how to get to gears out. The pinion is really bad. Ironically though, the bearings all seem to be OK so far. I have a Clymer manual, but it is the wrong years (1966-1984).
 

cruiserbill

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After you check availability of parts and the price of parts , you will likely begin looking for a used unit on this !!

I have been looking for one, but they are all just a bare housing, no guts in them. I priced everything out though and it comes in under $175. A good used one is a whole lot more than that.
 

cruiserbill

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Trying not to damage anything; can't seem to figure out how to get the pinion and forward gear out. Any advice here? Thx
 

racerone

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That lower unit was first used in 1980 so that manual you have covers it !-----But some of those after market manuals are best used to wipe up the shop floor.
 

cruiserbill

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That lower unit was first used in 1980 so that manual you have covers it !-----But some of those after market manuals are best used to wipe up the shop floor.

All this manual says though is: "Remove the forward and pinion gears from the gear case." That is it. Nothing telling how to do it. :confused: Also, this manual does not cover many aspects of this exact motor. They didn't start making it until 1985, so 1984 and earlier have many differences.

I did, however, find a real manual that gives instructions on how to remove the gears. It says to remove the propshaft, remove the pin and spring, then put the propshaft into the forward gear and using your hand "rap" it towards the cavitation plate to dislodge the forward gear and bearing. That makes sense to me, but I haven't got out to the shop yet today to try it.

I will let you know and thanks for the help here. I really appreciate it!! :)
 

racerone

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Sorry , but that lower unit was offered in 1980 !------It was the 7.5 hp model.-----That had the exact same gearcase !
 

cruiserbill

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Sorry , but that lower unit was offered in 1980 !------It was the 7.5 hp model.-----That had the exact same gearcase !

Correct - I agree - however, even though it is the same gear case, my book doesn't show the newer model parts breakout; as a matter of fact, the 1-piece gear case it shows for the 4.5-15hp outboards is not what I have. I have the OMC parts catalog and some of the parts are very different from what they are showing. It is one of those that are useful for wiping up the floor with.

The other service manual I found has it all exactly so I am using it now. Not sure where Clymer went wrong on this, but it hasn't been very useful and frankly it has been a bit frustrating trying to figure it out.
 

racerone

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I repaired / resealed 3 of those units last winter.--Nothing to them and easy to work on.
 

cruiserbill

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I repaired / resealed 3 of those units last winter.--Nothing to them and easy to work on.

Thanks; to be honest I have never worked on one before. That is probably apparent, but I am mechanically inclined though. It is a simple set up and once you get to know how things work and go together they are easy to work on.
 
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