1981 Johnson 25hp difficulty shifting from forward to neutral

Model J25RWCIM

I re-did the lower unit seals on this and am having trouble about 50% of the time getting it to shift from forward to neutral. Reverse to neutral seems fine. I've checked and double checked the shift rod linkage, and that seems to have helped some, but the problem persists and I'm pretty certain at this point that the connection is correct. Seems to shift fine when the motor isn't running - i.e. when I try it by hand. It also shifts better if I throttle down and shift immediately - I think the momentum of the boat is turning the prop and taking tension off of the clutch dog/forward gear engagement.

I've thought of two theories:

1. I didn't have the required special tool, so I didn't preload the bearings in the gearcase. Maybe the whole assembly is just a hair too far forward or back, so then the action of the clutch dog lines up a bit too far toward the forward gear.

2. I lost one of the detent balls (Ping!) during dissasembly so I had to order a replacement. Seemed to reassemble fine, but maybe there's some issue there.

Any ideas on this? I don't exactly want to pull apart the gearcase again if something else might be causing the problem.

Re: 1981 Johnson 25hp difficulty shifting from forward to neutral

2manband,
I reviewed your other thread to refresh my memory.

Are you sure the gearcase is the problem and not the plunger (#42) getting in the way? Just a thought.

http://www.marineengine.com/parts/j...urer=Johnson&section=Cylinder+&+Crankcase

Another thought. When assembling the gearcase, did you insert the pivot pin through the shift lever (#22)? Also, made sure the cradle (#23) was properly in place?

http://www.marineengine.com/parts/j...25RWCIM&manufacturer=Johnson&section=Gearcase

Just grasping for straws here. Hang in there.

Re: 1981 Johnson 25hp difficulty shifting from forward to neutral

jasper60103 said:

2manband,
I reviewed your other thread to refresh my memory.

Are you sure the gearcase is the problem and not the plunger (#42) getting in the way? Just a thought.

http://www.marineengine.com/parts/j...urer=Johnson&section=Cylinder+&+Crankcase

Another thought. When assembling the gearcase, did you insert the pivot pin through the shift lever (#22)? Also, made sure the cradle (#23) was properly in place?

http://www.marineengine.com/parts/j...25RWCIM&manufacturer=Johnson&section=Gearcase

Just grasping for straws here. Hang in there.

Click to expand...

Thanks Jasper

There's definately a possibility that it could be your first suggestion - I had to replace the starboard bracket, which required removal and reinstallation of the plunger. I thought that I had it correct but maybe not. I'll have another look.

As far as the shifter yoke, pivot pin, etc. - I'm pretty sure that I got those right.