1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

[Caseyuconn]

Nightmare day with my 1995 Johnson 88 SPL. (Just bought the boat/motor)

I have a factory service manual for this engine and am attempting to rebuild water pump before the season.

Problem: The shift rod is not disengaging from the power head making the lower unit impossible to remove.

The manual specifies to put the engine in reverse, remove cotter pin from shift lever than push shift lever attachment in toward the center of the motor to disengage the shift rod. After multiple tries it is NOT disengaging.

The lower unit drops +/- 2 inches and will not come off even after much wiggling and pushing on this shift lever during removal attempts.

Any good advice for getting this thing off?

As a follow question can I attempt to remove the lower unit in forward or neutral without risking harm?

 

[JWhit]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

Is the shift lever moving toward the center once the pin is out? It should separate from the linkage going to the controls and once that happens can slide down and out. no risk in forward/neutral except that it's harder to reattach as that lever will move down under the powerhead more

 

[Caseyuconn]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

The shift rod is not disengaging from the pin. From scouring the web I will try to pull on the shift rod towards me with some needle nose pliers. Im not sure what the issue is but it seems that the shift lever is not moving far enough toward the powerhead center to disengage the rod. tried it 3 different times, each time bolting the lower unit back up to relieve pressure and trying again.

 

[boobie]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

One thing you could try is, shifting it in forward and disconnecting the shift cable from the linkage.

 

[Caseyuconn]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

Got home, shifted it to forward. Pulled cotter pin, pushed shift lever, than grabbed the shift lever with some needle nose pliers and pulled toward me. Had lower unit off in 7minutes from the start time.
Miles away from where I was yesterday.
Thanks for the helpful posts.

 

[nedelmann]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

Hello: I was reading this thread b/c I'm having the exact same issue:I can't get the shift rod to release. I disconnected the cable while in reverse, pulled the cotter pin and pushed the lever in towards the block but it won't release. Casey ststed that he did the same process but in in forward and pulled the lever "towards him" with needle nose pliers. Did he mean forward or starboard. This thing is kicking my butt.

 

[allmuckmojo]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

@nedelmann, I could not get mine off either by using needle nose but I ended up unscrewed the screw in the pic and pushing it away further while in the forward position.

 

[Chaser73]

Re: 1995 Johnson 88 SPL - Lower Unit removal - Shift rod not disengaging

I did mine this weekend. Disconnected the shift cable, removed the keeper pin, pushed the arm in while jiggling it, had been well greased, so easily came apart. With the cable off it is easier to ensure the holes and pin are in alignment. Must be done before touching the lower unit.

I made a 12 inch "tool" from a coat hanger, with a 3/8" bend on one end...round bend on the other for a handle. I used that to twist and position control rod for reassembly. Make sure shift rod moves easily up and down before assembly; be careful about turning it; you want it to be able to turn freely...quarter of turn either way, but not unthread it...or change the length. If you can turn it easily, alignment is not critical during reassembly...just get linkage hole 90 degrees to front of engine. It will likely get jarred when you push it back into place...I did final alignment with the coathander tool.