Clutch dog linkage reassembly

[Jair Amorim]

I disassembled the lower unit of a Johnson 1990 - 25 HP to change the oil seals and make a internal inspection of the gears, and now I?m not be able to put back the linkage on the clutch dog.

I have seen some service manuals, but no one can show a correct disposition to reassemble this unit, the correct sequence of mounting or the use of an apropriates tools to do this job more easy. Any kind of help will be very
mutch gratefully.

Jair Amorim

(This thread was posted in an old post, but I was warned to create a new thread)

 

[Jair Amorim]

Re: Clutch dog linkage reassembly

please, I really need this help !!!

thanks a lot ...

 

[wilde1j]

Re: Clutch dog linkage reassembly

Have you looked at the parts list on BRP's website?

 

[Jair Amorim]

Re: Clutch dog linkage reassembly

I?m still with this problem. Was tried all the ways to put back the shift lever into the clutch dog groove. There is an special tool to hold the detents and spring in his place, and then put back the propeller shaft, or just patience is the main tool?

Thanks for any information to a desperate newbee !!!!

 

[wilde1j]

Re: Clutch dog linkage reassembly

You really need to get an OEM shop manual, if you don't have one.

 

[Jair Amorim]

Re: Clutch dog linkage reassembly

Hi Jim ! Thank?s for your opinion !

I already have an OEM Service manual (Johnson 90-01 Service Manual ), but even full of pictures, diagrams and helpfull hints, don?t show any information wich can help me. At a first look, it is impossible to assembly the parts outside, and then put all together back (the pinion gear it?s an interference).
For me, an amateur, it seems a very hard job, but with the helps I have found in this forum, perfectly possible to do.

 

[Jair Amorim]

Re: Clutch dog linkage reassembly

Hi Jim ! Thank?s for your opinion !

I already have an OEM Service manual (Johnson 90-01 Service Manual ), but even full of pictures, diagrams and helpfull hints, don?t show any information wich can help me. At a first look, it is impossible to assembly the parts outside, and then put all together back (the pinion gear it?s an interference).
For me, an amateur, it seems a very hard job, but with the helps I have found in this forum, perfectly possible to do.

Thank?s again !

Jair Amorim

 

[wilde1j]

Re: Clutch dog linkage reassembly

I haven't worked on a small gearcase like you have in a long time, but looking at the parts breakdown on BRP's website, it looks like you must assemble in the same right to left order as in the PL, and do the assembly internally. It doesn't look like any more the the the roller bearing, fwd gear and dog with the detent stuff can be slid in as an assembly, but the other stuff may have to go in sequentially. It's not clear whether or not the shift lever, cradle, etc. can go in the the other stuff or not. I would reread the shop manual to see if it has any more detail. Most of the small motors I've worked on had split gearcases, which made all of this easy.

 

[Jair Amorim]

Re: Clutch dog linkage reassembly

Hi, Jim!

The OEM Service Manual is exactly as you told, it?s not so clear about this topic. Seems as this job (assembling the parts in a no-split gearcase), was so easy that it does not need more information. It?s impossible engage the clutch dog linkage with the shaft in his final position, or at least without any special tool (wich it never saw by me).
As I said to myself, "patience is the last tool to be rejected", let?s to exercise it...

Thanks for your attention, and sorry my english !

Jair Amorim

 

[wilde1j]

Re: Clutch dog linkage reassembly

A possible suggestion: try positioning the motor or lower unit if off the motor so the skeg is facing upward. I think this might get gravity helping hold things in position.

One more thought: use Triple Guard or similar sticky grease to hold the shift parts in place during re-assembly.