Trying to repair an old 40HP electric shift johnson (1963) with a leaky lower unit that doesn't shift into forward. Motor came with an old starcraft I bought late last summer and now getting to fixing motor. Motor runs and PO claims to have had carb kit, needles, coil done, but said motor doesn't go into gear. I tested and indeed it runs but didnt go into gear. I repaired faulty electric shift (control box issue) and changed lower unit oil with Type C OMC premium blend oil (old oil was dirty milkshake) and motor ran well for 30minutes pushing the old girl down the lake pretty good! Got back to shore and went to take another trip, and motor wouldn't go into forward (just reverse). Checked oil and it was a milkshake again. It appears lower is leaking at the shaft and between upper and lower gearcase, and maybe elsewhere? Coils check out ok and are getting powered when shift lever shifted, but lower unit won't engage into forward (reverse only).
I have a OEM service manual for this motor and an exact same model 'parts' motor (it doesn't run, but lower gearcase looks really good compared to my 'running' engine and coils also check out OK, so I am thinking about swapping the parts motor's 'good' lower unit to my 'running' motor with a 'bad' lower unit.
To that end, I pulled off lower unit and separated lower and upper gearcase (yes i also dropped one of the pinion bearings into the lower gearcase!). I pulled gearcase head off, removed everything except the front coil and bearing. Found missing pinion bearing, cleaned out goopy oil best I could with front coil/bearing in place.
Questions on lower gearcase: 1) should I try and remove front coil/bearing to ensure there isn't any grit in the nose of the bullet. It seems ok from what I can tell, but then one never knows unless it is out, right? If I should get them out, how do I do it without special tools? Do I heat the front of the gearcase and see if the parts 'drop' out or do I need to improvise a puller of some sort?
2) the springs on clutch hubs seem a bit gritty, should I disassemble clutch hubs to clean or simply clean with solvent/brake cleaner while the are assembled (eg spring not removed, bearing and bushings not out of clutch hubs). If I should disassemble, any pointers/gotchas from the pros?
3) i pulled out the propeller shaft seal from gearcase head, but left bearing in place and cleaned bearing while bearing was still in the head. Any reason I should remove/replace bearing if it looks ok?