9.9 Johnson lower unit re-assemble - HOW?

[fishon71]

How do you re-assemble the gears and shaft back into the lower unit of a 1985 Johnson 9.9 hp. The main problem I'm having is the detent balls & spring and the alighnment of the balls to the clutch dog, not sure how to get it all back in there.

Thanks

 

[fishon71]

Re: 9.9 Johnson lower unit re-assemble - HOW?

Any ideas, I need to get this back together today, thanks

 

[5150abf]

Re: 9.9 Johnson lower unit re-assemble - HOW?

Uh ya, apparently you don't have a manual?

A lower unit is a transmission and needs to have very precise tolerances, chances are if you did get it back together it would last a couple hours and break.

Did you take it apart and why??

Pretty sure you won't be getting that going today, asemling alower isn't something that can be answered in a post, you really need to get a manual, OMC not Clymers or Seloc or any CD.

 

[fishon71]

Re: 9.9 Johnson lower unit re-assemble - HOW?

It was taken apart because it failed due to a snapped drive shaft - All I need to know is how to get everythig back in with out loosing the detent balls - eveything else is common sense.

Now someone must have more advise then get a manual, please - this is a OMC forum, right?

 

[wilde1j]

Re: 9.9 Johnson lower unit re-assemble - HOW?

but not a substitute for a shop manual!

 

[fishon71]

Re: 9.9 Johnson lower unit re-assemble - HOW?

I wish I could buy a manual for every different outboard I work on but can't afford that, If I had a manual I would not be asking here. I'm just looking for a little guidance on the detent spring & balls, must be a trick someone knows so the balls don't shoot across the shop or fall in the LU.

 

[fishon71]

Re: 9.9 Johnson lower unit re-assemble - HOW?

Okay this is not brain surgery, I got the spring & balls in place, just need a tip on if you leave the shift fork in the lower unit to assemble or take fork out and put on the dog gear then slide into lower unit. Neither way is easy but I'm assuming the fork comes out and is put on dog gear then you try to align shifter to fork inside the lower unit.

 

[fishon71]

Re: 9.9 Johnson lower unit re-assemble - HOW?

Not to worry, all together works like new again. Next guy that needs help I will tell you how without the manual, just need to use your brain a little, thanks

 

[preet083]

Re: 9.9 Johnson lower unit re-assemble - HOW?

Not to worry, all together works like new again. Next guy that needs help I will tell you how without the manual, just need to use your brain a little, thanks

Please help me i have no idea how the shift link and dog leg work with the spring and balls. I tried putting in of course the balls were missing, and the prop was locked in both directions. I have the balls and springs now, but how do i re-assemble please help.

 

[gozierdt]

Re: 9.9 Johnson lower unit re-assemble - HOW?

This article over on LeyRoy's Ramblings gives a lot of small tricks about how to
get these '70's, '80's, early '90's small Johsonrudes back together:

http://www.leeroysramblings.com/Lower_unit.htm

LeyRoy's Ramblings is a great source for almost anything about these engines.

 

[the machinist]

Re: 9.9 Johnson lower unit re-assemble - HOW?

Thank you GOZ, I try to help