lower unit removal 61 johnson 75 hp

[steamking123]

I am trying to disassemble my lower unit to get to the clutch dog and the gears. I read over the manual and then tried to do it it. Reading that manual is reading a language that I don't speak. I swear they are giving instruction for a different lower unit so I thought I would ask you guys for some help.

Here are some pics to where I got.
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I started by draining the oil, and loosing screw to the shift rod connector behind triangular plate half way up the shaft. Then I removed the 8 bolts that connect the lower unit. Lower unit slip down about an inch and a half to expose the drive shaft and the shifter rod. I also tried to remove the 8 bolts the connect the middle section of the shaft but 4 of the bolts broke off at the head.
What do I do next to completely disconnect lower unit from motor.
I also tried to get to them from the propeller with no success. There appears to be a clamp of some sort.
Which way should I be going to examine the clutch dog and the forward gear.

Thanks for your help

Derek.

More pics on the way

 

[steamking123]

Re: lower unit removal 61 johnson 75 hp









More pics. Apologies for being so small. hope you can see what going on

Derek

 

[F_R]

Re: lower unit removal 61 johnson 75 hp

"Loosening" the screw in the shift rod connector doesn't get it. You need to completely remove that screw. Then the lower unit will come down and away. Remove the water pump. Then you will find two locknuts, fore and aft of where the water pump was. Remove them and you can separate the upper part of the gearcase from the lower part. The clamp you referred to holds the shift rod to the fork in the bottom of the case. You will be able to remove the bolt and nut from that clamp, then get all that stuff out of the way. The phillips screw down near the skeg holds the shifter fork. Then it is just a matter of shucking all the parts out.

Good luck, it sounds like you are going to need it. Study that manual.

 

[steamking123]

Re: lower unit removal 61 johnson 75 hp

I got the bottom end to come off. I undid the bolts like you said that were behind the water pump. I cannot get the bottom and the middle portions of the shaft seperated. I believe I have everything undone, but before I apply more pressure I just wanted to make sure I was going to break something. is there a proper tool or process to pry these apart.









thanks

Derek

 

[F_R]

Re: lower unit removal 61 johnson 75 hp

Pictures are so small I can't tell, has it separated any at all? If it has, it should continue to come down. But if it won't budge even a little bit, congratulations you have just discovered a major PITA concerning those gearcases. The two long studs get corroded in there so badly that sometimes they may even have to be disassembled with a hacksaw. I hate it when that happens.

 

[steamking123]

Re: lower unit removal 61 johnson 75 hp

I finally got it all disassembled. I am so relieved. I didn't even break anything...to my knowledge. After reading the manual about the gears and clutch dog I examined them. There is definately some wear on the forward side of the clutch dog. I am not sure if its bad though. here are some close ups. The bottom and the top picture are the forward side, and the middle one is the reverse side.






Is this bad? Can I turn it around so that the reverse side of the clutch dog meets the forward gear.

Pics of forward and reverse coming up.

Derek

 

[steamking123]

Re: lower unit removal 61 johnson 75 hp

Here are some close up of the gears. These seems to be in good condition, but if I was sure, I wouldn't be posting pics for a second opinion. I can't believe how much parts cost.
I also notice that the shift rod was bent. would this need to be replaced is is a slightly bent shift rod work.

 

[F_R]

Re: lower unit removal 61 johnson 75 hp

Somebody has already replaced the clutch dog at least once. That shows the futility of replacing the dog and not the gear. Turn the dog to the best side against the forward gear. It takes surprisingly little wear to make it jump out of gear. You can also swap the forward and reverse gears by swapping the bushings inside them. I don't see any hole/spring/balls in the prop shaft--were there any? If it were mine, I'd drill the shaft and install the detent balls. You will have to get somebody that is properly equipped to drill the shaft, don't try it at home. If it still jumps, well you know the story.

EDIT: The shift rod is supposed to be bent. It bends away from the water pump, then back again. For clearance.

 

[steamking123]

1961 johnson super sea horse 75

1961 johnson super sea horse 75

I don't have the parts catalog for this motor.
Johnson 61, super sea horse 75 horsepower

Does anyone know that part numbers All seals in the lower unit. (do they come as a kit or individual?)



Thanks

Derek