1991 Johnson 3HP lower unit replacement

[bluefish52]

hello, I could use some help from someone knowledgeable about JOhnson 3 HP motors,

bought it and the mechanic that owned it replaced most parts but had the impeller left to do, he gave that to me and said it was a simply two bolt s to drop lower unit and three to replace impeller.

I have dropped the lower unit on the new to me 1991 3HP and replaced the impeller, all that went smoothly but I am having a heck of a time trying to get the lower unit back on.

the gear shift rod is a pain but the real trouble is the copper tube, the water line I am assuming? Is there an easy way to get that back into the rubber boot of the water pump?
and somehow I moved the prop so the drive shaft is fighting me and wont line up in the head....

Big aggravation and I figured I would take a break and ask if there is a secret or shortcut to making all these three things line up correctly?

Thanks for the help and please hurry, Im starting to think I cant get this together and will have to junk this great motor.

 

[Monte1961]

Re: 1991 Johnson 3HP lower unit replacement

hold on and ill send you a pic of that l/u

 

[bluefish52]

Re: 1991 Johnson 3HP lower unit replacement

Thank you Monte!

Im really stumped how to make this line up:facepalm:

 

[Monte1961]

Re: 1991 Johnson 3HP lower unit replacement

Hope this helps ya!

 

[bluefish52]

Re: 1991 Johnson 3HP lower unit replacement

thank you Monte, I think I am overtired and will tackle it in the AM...what a headache.

thanks for the help!

 

[Monte1961]

Re: 1991 Johnson 3HP lower unit replacement

Good luck and dont hesitate to ask us for help thats what were here for!

 

[bluefish52]

Re: 1991 Johnson 3HP lower unit replacement

nope still cant get it to fit together.

is there a trick of the trade in sliding this lower unit back into place?

like turn the motor upside down or >??

I can not get the drive shaft back into the head and the one time it did go I couldnt keep the copper waterline straight into the waterpump so had to back it out and now its a lost cause again.

tips tricks?

thanks

 

[raczekp1]

Re: 1991 Johnson 3HP lower unit replacement

i did repair on 4 models similiar like yours.
the best is to stand motor up side down(lie motor on the power head, so midsection is facing stright up.

put in lower unit with drive shaft and try to fit drive shaft in crank shaft but try tp ply with shift rod, the end of this shift rod is bent like"S"

this shift rod must fit into small hole in gear case
to fit drive shaft into crank shaft spines pull a litle pul starter(but first take out spark plugs)

 

[Haffiman]

Re: 1991 Johnson 3HP lower unit replacement

1: Get the shift rod into the hole in gear case.
2: Just enter the drive shaft into the crank. Wiggle the fly wheel to be sure it is entered.
Be sure you use original O-ring at drive shaft. If too thick will not enter! Grease on splines ONLY,
3: Get water tube into the rubber grommet on the pump.
Push together and install screws