1977 Johnson 35hp overheated

psmccall

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I am new to the forum and have a 35hp Johnson 1977 that overheated today. I was on the lake running top speed and noticed that the engine was losing power and slowing. When I looked back the tell tale or pee stream as I have heard it called was no longer streaming. I Immediately turned the engin off, took off the cowling and sure enough the engine was very hot. In fact I dropped some water on top of the engine and it boiled off immediately. I was towed in and sure the engine was destroyed.

When I got home I could turn the flywheel so I decided to pull the top spark plug. The plug looked good so I put the muffs on with water and the motor starts fine. At first there was no water coming out of tell tale, so I immediately shut it down. I took off the lower unit, looked at the impeller which looks ok (3years old). I used air to blow out the water intake tube and checked the supply hose from the block to outlet and found no blockage. I put the lower unit back on, started the motor and again it did not stream water. I tried it again to show my Dad the problem, but this time it streamed. On idle it is a little slow, but at half throttle in neutral with the muffs it is strong and the top of the engine is cool to the touch.

A little background. I have been trying to buy a new impeller for the last 3 weeks from my local dealer, but we finally determined that I have 77 motor with 78 foot so the impeller needed is different because between 77 and 78 they changed the impeller size/design. Once we figured that out I got the new impeller for a 78, but the slot/key mechanism is different than the one installed. It appears to be a type of slip key disign vs. a full cut slotted design. Anyway I was going to tackle that problem next week.

The engine paint is already gone so I can't tell if discolored. (a mouse built a nest on the engine a few years ago and his urine disolved the paint)

None of the wiring is melted.

The engine starts and sounds fine.

I run 50:1 Johnson/evinrude oil

Question:

Even though it sounds fine on the trailer could I still have damge and if so how would it show itself?

Has anyone ever run into this impeller issue for 77/78 Johnsons?

This boat/engine has much sentimental value to me. My Dad bought it new when I was 4years old and we have many memories of fishing together. I will keep it going as long as I can.
 

Daviet

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Re: 1977 Johnson 35hp overheated

First what is your model number? Run a compression test to see if there was internal damage done.
 

psmccall

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Re: 1977 Johnson 35hp overheated

The model number is 35EL677C. I will do compression test tomorrow (I don't own the testing tool so I will go and borrow one from an auto parts store)
 

psmccall

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Re: 1977 Johnson 35hp overheated

Not sure if this could cause the low water pressure, but the bottom steel plate in the waterpump housing is worn with grooves, I assume from the spinning impeller.
 

Daviet

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Re: 1977 Johnson 35hp overheated

Water pumps between the 77 and 78 are completely different. One has a metal housing and the other uses a plastic housing with a stainless liner. The 77 has akey for the impeller and the 78 uses a pin. Which do you have? I seem to remember that some replacement pumps were the plastic type, maybe some installed a new style pump.
 

psmccall

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Re: 1977 Johnson 35hp overheated

The waterpump housing is plastic and the impeller is small in comparison to the 77 example I first got. The key appears to be a brass key pressed into the shaft. It seems like it would be tough to get out. The supposed 78 impeller that I got last week is the right size, shape and the shaft hole is correct, but the key set up seems to be for a shaft that would have a flat side to allow for this key to fill the space in the circular impeller. The impeller I have on the engine has a slot that is designed to fit over a key like the one on the shaft coming out of the lower unit.
 

psmccall

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Re: 1977 Johnson 35hp overheated

When you say pin, do you mean a piece that slips beside the shaft in the impeller to keep it stable vs a key that is pressed into the shaft itself?
 

wilde1j

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Re: 1977 Johnson 35hp overheated

I would only repair with a complete pump kit. If there is any grooving in the wear plate or pump body/liner, they are junk, and the pump either won't pump or will pump poorly.
 

psmccall

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Re: 1977 Johnson 35hp overheated

Could someone have installed a 1978 waterpump kit onto my 1977 lower unit? Would that even work?
 

wilde1j

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Re: 1977 Johnson 35hp overheated

The impeller key has to be consistent with the driveshaft machining.
 

psmccall

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Re: 1977 Johnson 35hp overheated

The key that is pressed into the shaft sticks out in way to engage an impeller that is slotted (like the larger 77 impeller) but the waterpump housing is smaller with a steel insert that holds a smaller impeller. The impeller that is currently in the waterpump has that slot, but the one that I was sold has a offset cut and came with a plastic slide in piece that would only make sense on a shaft that was machined to have a flat side.

Does anyone know if the water pump housing bolts lined up the same on a 77 lower unit as they do on a 78 lower unit?
 

Haffiman

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Dec 17, 2009
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Re: 1977 Johnson 35hp overheated

There are two options, change the shaft which is rather expensive, or grind a flat surface on the shaft and use the 'new' type wedge or pin locking for the impeller.
 

psmccall

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Re: 1977 Johnson 35hp overheated

I did the compression checks today and the top cylinder is 80 and the bottom is 85. I took the head off and the head gasket is fine but the cylinders are scored and scratched. I am giving up on the old motor and looking for a newer one. I have found a 1995 or 1996 48hp SPL that appears to be in good shape. I like the added horsepower and of course the mere fact it is newer.

Does anyone have any feedback on the Johnson 48hp SPL?
 
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