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    Johnson 150 Rebuild/Remanufacture Guidance

    Faztbullet, Thanks for suggesting Jay's Block Shop and giving me the contact information. Jason, did a great job on my block and was able to clean it up going .020" oversize. Jason fixed me up with WSM pistons, gaskets and seals. Jason is great to work with and I told him I got his name from...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Does the same hold true for the connecting rod big ends, or do you definitely leave them alone? Inspecting my connecting rod big ends, they seem to have even less discoloration than the crankshaft journals.
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    Johnson 150 Rebuild/Remanufacture Guidance

    So if I understand correctly, polish up the crank journals by wet sanding with a 220 silicone carbide strip of abrasive and work up through finer abrasives? Honestly, I would have no idea how to put a crosshatch pattern over that narrow journal and the rod bores. If you could point me to...
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    Johnson 150 Rebuild/Remanufacture Guidance

    I now have this powerhead pulled apart and I am waiting on return of the block. I have a question in regard to the crankshaft bearing journals. All 6 are very smooth with no uneven wear, scoring, or pitting. However, the surfaces have some tan or light brown surface coloration. Should these...
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    BTW I got that alternator installed on my 40 Rudy

    Congratulations! That is an impressive retrofit! What was the output on the OEM flywheel alternator? I never liked the fact that my 1986 Johnson 150 (J150TXCDC) flywheel alternator only put out 9 Amps. The same year J150STLCD put out 35 Amps. I wonder if I could swap out flywheels? Cheers...
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    Johnson 150 Rebuild/Remanufacture Guidance

    ct1762, racerone, Faztbullet, thanks for all your help in getting me through this powerhead removal. So I'm at a crossroads, do the rebuilt myself or send the powerhead out? Mechanically, I am thinking I could get through the rebuild. The big question I have is, how hard is it to get the...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Well, late Sunday evening we had a minor miracle occur here and the powerhead popped off after cutting the two bolts approximately 1/2" below the powerhead mating surface, lots of various penetrating oils, and some heat in the area above the cuts. I utilized my Dremel motor tool with the Heavy...
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    flywheel removal

    My 1986 Johnson 150 HP uses 5/16-24. I just purchased a few grade eights 2 inches long. I am thinking yours are the same given the puller was a single OMC part number used across all engine sizes.
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    Johnson 150 Rebuild/Remanufacture Guidance

    OK, I was able to get the "Frame and Seal Assembly" bolts removed and I slid it out the front of the powerhead and above the "Lower Housing Cover". This seems to give me a little bit of access for a Dremel. I'll have to research the Dremel Cutting Wheels for one that will cut...
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    Johnson 150 Rebuild/Remanufacture Guidance

    How do you get your Dremel and blade close to the powerhead mating surface? Is there a way to drop the "Lower Housing Cover" and/or the "Frame and Seal Assembly" (p/n 0392494) ? I currently have everything free except the two long bolts that snapped. I'm trying to pull the powerhead with a...
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    Johnson 150 Rebuild/Remanufacture Guidance

    I'll pick up some Free All at Auto Zone. I twisted the head off two of the six bolts. I'll try and pull the powerhead first, but I am thinking these two bolts may have to be cut off a half inch below the powerhead to get the head to pop off. Thanks for the quick response!
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    Johnson 150 Rebuild/Remanufacture Guidance

    Were you able to fill the slot/slit you opened up with the Dremel motor tool and reuse the Adapter Plate, or did you buy a new/used adapter plate and replace?
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    Johnson 150 Rebuild/Remanufacture Guidance

    racerone, I believe you confirmed below that the wee hole would be drilled in the Adapter and close to the powerhead. NOT in the powerhead as I describe in item 1 above. Is my understanding correct? Secondly, in item 2 above I believe you are telling me that if I am not successful in removing...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Lectro88, Is a breaker bar the same as a "pull handle"? If so, i have been using a 3/8" breaker bar that is approximately 12" long. I have an 18" long 1/2" breaker bar, but I am a bit reluctant to put more torque on the bolt heads. In addition to more penetrant, I may try a little heat today...
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    Johnson 150 Rebuild/Remanufacture Guidance

    So if I understand correctly: 1. You are telling me to measure the bolt length (I successfully removed 3), from below the head to the end of the thread. Then from the exhaust housing bolt head surface, measure vertically (the bolt length) and drill a small hole into the powerhead. The goal...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Three of the six long exhaust housing to powerhead stainless screws are frozen. I got them to move a little, but I don't like the way it feels. It's hard trying to get PB Blaster penetrant to run uphill 3 or 4 inches to the threaded area. I have been tapping the top of the heads and also...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for your comments regarding my Johnson 150 V6 crossflow. I pulled my boat last weekend. I plan on attempting to break free the key powerhead bolts this weekend. The powerhead was off 17 years ago and I boat in brackish water. I am hoping they break free for me. Any guidance on this...
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    Johnson 150 Rebuild/Remanufacture Guidance

    ct1762, You mentioned that you are going with Vertex pistons. What does your comment, "Vertex are rare for crossflows" mean? Does it mean that Vertex does not cast pistons for crossflows? Possibly due to the piston top/dome ?
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for all the comments. I am reaching out to a few of the individuals mentioned for additional information. Of course, I have more to learn about which piston to go with. Wiseco (forged) or WSM (cast), and now Vertex (cast). Jason at Jays Block Shop seems very nice and knowledgeable...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for the help with the rebuild shop names (Carson's Marine and Jay's Block Shop). Let me know if there are any other reliable rebuild shops out there, or additional comments for these two shops. Faztbullet mentioned Jason can short block it for me. Is that a complete rebuild of my...
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