1981 Johnson replaced water pump and now no water and no forward gear.

[Paul Moore]

I know I should have checked more before I started replacing the rotor impeller in the water pump. I also had it in reverse when I pulled it apart. I pryed on unit before finding the linkage nuts at the water intake and then forced the lower unit back to gether by tightening the bolts. . I got some water spitting out of the two holes just below the motor housing but none from the hole it should have come from and I had no forward gear. Neutral was way forward from where it had been and if I went farther forward the engine just raced higher as that is the accelerator on this motor. I took the lower unit off again and looked up inside with a light. I see I missed lining up the copper water flow pipe to the engine case. A verry small spot to hit and I have bent and turned the pipe some. I disconnected the shift cable from the motor and found that even when I shift it manually the position is way off. It shows hardly in reverse at all(but it is) and way forward on neutral. I don't have a manual on how the shift lever converts to the downward shifting rod. My questions are 1: Is there a trick to lining up the copper water flow tube and 2: How do I get my gears back? Thanks in advance to anyone who can help me from this foolish situation I've gottem myself into.Paul

[OBJ]

Welcome aboard Paul!Paul it would help a lot to know what HP you have there. I'm sure it's just something you missed.

[Paul Moore]

Well, looks like I left off that it is a 35 hp Johnson, 1981. TKs. Paul

[newuserguy]

Hey Paul, I can't give you much advice but I am sure going to follow this posting 'cause I just bought a one-owner 1981 Johnson 35hp. READ AND FOLLOW THE MANUAL, saves lots of headaches (I have Seloc). The guys on this forum are super sharp. Listen to them and you'll be fine. Ezeke helped me tons with an old 1966 Johnson 9.5hp. Good luck. Jim Moore (newuserguy)

[alden135]

Really ought to part with the short $ and get a manual. At this point I'd take it apart and start over.

[Lubosleftboot]

In the uk you can get manuals for all the omc engines on cd that is what I have done.£6 about $10 on ebay

[HOU-CHAP]

Did you take the connector end of the shift rod off? The first time I did my water pump, I unscrewed the shift rod to change the gasket below it. I unknowingly screwed the connector/fitting all the way back not knowing it has to be an exact length. If you find your cables are not the problem, I would measure your shift rod to make sure it didnt get out of whack.

[Wakeboarder Tom]

PaulI had the same problem with the copper tube when doing my leg on a 70hp evinrude. It's just a case of perseverance to get it lined up - and DON'T force it! The problem with the water flow in the block is almost certainly down to the fact the tube wasn't in. Don't know how easy it is to replace the tube on the 35 I'm afraid!I suspect that you have got the cable reinstalled incorrectly for the shift to be that far out. You could have bent the control arm that runs under the carbs to the shift rod in the leg though???

[Paul Moore]

Much thanks to Houston and UK for your advice. I have friends from Ohio and Cal. in now but will try to fix it again on Sat.

[Paul Moore]

Hou-Chap--Do you mean the shift rod connection (with the lock nut at the water intake)==== screws into the foot to change gears? I may have unscrewed that without realizing and made the overall longer. tks.

[HOU-CHAP]

Paul,First off I am not familiar with the exact set-up of your 1981 35hp. I have a 1977 140hp. On mine there is a fitting on the end of the shift rod (that the shift cable attaches too). This fitting is threaded down on the shift rod coming out of the gearcase. If that connector is screwed in or out, it changes the length of the shift rod and will give you problems. Hopefully someone with knowledge of your particular motor will chime in, but if the shift rod's length was changed it could be your problem. OMC placed a pretty tight +/- 1/32" tolerance on the length of that rod.

[Paul Moore]

I will tell my friends about this site. I am glad to announce that I now have my water pump and gears working correctly less some minor adjustment to be made. I worked on the motor with the rear of the boat pulled to the edge of the lake and just out of the water so it was a bit awkward. The gear problem was I had unscrewed the shift arm too far from the foot. Screwing it all the way back down got me close enough to make the final adj. at the shift lever on the motor. I solved the water pipe problem by removing it from the pump and inserting it into the hole at the top of the housing and then was able to line it up with the hole at the top of the water pump with a screw driver to then push the foot unit back up into the housing. So Newuserguy, we now have success-- thanks to my new friends Jim Moore(say hey to my brother-in-law in Houston), and Wakeboarder Tom. I couldn't have done it without your help. Take care all. Paul Moore