Can't attach shift rod or remove oil plugs on a 1991 Johnson 9.9

shepeard

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Jul 8, 2011
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2
I have a 1991 Johnson 9.9 and have two questions.
I put in a new water pump and now I am trying to re-assemble the lower unit and I can't attach the shift rod to the shift rod connector. When I put the screw in the connector first, the rod won't go through the connector opening and I can't find a way to fit the screw through the narrow opening of the extension unit to the shift rod connector after the shift rod is already inserted in the connector. Is there a special way this needs to be done?
I also cant remove the oil plugs from the lower unit-i tried PB Blaster and tapping on them but they still wont budge.
Any ideas from anyone on both questions would be greatly appreciated.
Thanks
George
 

AlTn

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Mar 9, 2010
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2,813
Re: Can't attach shift rod or remove oil plugs on a 1991 Johnson 9.9

whichever of these gets the 2 halves of the shift rod closetest together..lower rod pulled up and the upper shift lever in reverse or forward <I think it's reverse> then insert the lower shift rod fully into the connector before you put the connector screw back in < don't force the screw into the connector as it'll strip the threads and over time the lower connector rod will pull out of adjustment> if you'll then move the shift lever forward. it will pull the lower unit up and you can reinstall the screws...the fill and drain screws may require an impact driver to loosen, not unusual, I've used a hammer driven, hand held impact driver for this
 

shepeard

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Jul 8, 2011
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Re: Can't attach shift rod or remove oil plugs on a 1991 Johnson 9.9

Thanks for your advice- I'll try that next. Is there a way to expand the opening of the housing extender to make it easier to get the screw in the opening? Thanks
 

Rick.

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Jul 30, 2006
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3,740
Re: Can't attach shift rod or remove oil plugs on a 1991 Johnson 9.9

Good idea. Just use a flat blade screwdriver to open the brass coupling a bit. Makes it much easier. Best of luck. Rick.
 
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