Re: 1989 Johnson 40hp clunks when shifting to forward?
You can try to adjust the shift shaft. You should get a manual to walk you thru it. Do a search on "clutch dog". It is the cog that engages the gear on the prop shaft.
I would remove the Brg carrier and inspect the internal workings of the Gearcase before you do anymore damage. You might be able to save either the clutch or the frwd gear. You may have to disasseble the entire gearcase to see the frwd gear and clutch.
But first disconnect the shift cable and shift it into forward manually at the engine and see if the problem persists. If it does, gear work is in your future. If not, make sure the control box is in neutral, spin the prop and make sure the gear case is in neutral. Adjust the thumb knob on the shift cable to knob retainer with just a little forward tension....just a little. This should put the shift cable in the right place. Also.....Have you checked the gear lube for any bits of metal or just to see if it was good?
