1996 Johnson 175hp Ocean Runner Developed a Rattle

E1 Toro

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1996 Johnson 175 hp Ocean Runner (unknown hours)

Motor has developed a chinka-link rattle at about 3800-4000 RPM. The sound is like a large steel chain being dragged across a pile of chains.

Before my most recent trip, I changed out the fuel bulb and hoses up to the hose connector on the left side of the engine. I run high-octane fuel and Pennzoil Marine Premium TWC-3 oil using the VRO.

I have taken this motor on 6 trips this season for approximately 40-50 hours of saltwater fishing. Last Sunday after running out for about 45 minutes at 4000 rpm we headed back. Ran for about 20 minutes at 4000 rpm and began to hear a low drone sound. I noticed the change in engine droning right away but kept same speed. After 5 minutes, I started to hear the chinka-link noise and immediately dropped the throttle down to 1500 rpm. Noise ceased right away and engine sounded fine, no missing or sputters. Took it back up to 3000 rpm and it didnt sound or feel right. Went up to about 3800 rpm and the chinka-link sound returned. Limped home for an hour and a half at 2000 rpm and 7 knots. When I got into the harbor, I had to idle at the ramp and it seemd to be a rough idle. After pulling out of the water, I noticed dark oil seepage and streaks between the mid-section and lower along the cavitation plate. some oil was coming out the prop exhaust too. I didnt check if it was fuel mix or gear oil and just got her home. At home, I ran clean water and salt away through the engine. It peed just fine and sounded great at idle.

Friday will be my first chance to run compression tests and check for water in the lower.

Any advice or experience would be appreciated.
 

E1 Toro

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UPDATE 08/05​
Ran compression on all 6 cylinders 1-3 had 100 psi, 4-6 had 110 psi​
Placed a wooden dowel in each cylinder and applied pressure on the top of each piston. No wobble or movement.​
Changed Lower gear oil. Still blue-green with a haze, wouldnt call it milky. Old oil sat in water glass for a few hours and got no separation - so no water​
Pulled prop and removed 20-30 feet of 30lb monofilament from around shaft. Visually inspected outer seal and it looked good, no cuts.​
Checked fuel filter full of crud. Changed out the filter and replaced the feed line.​
Fair amount of fuel/oil residue in the front of the engine cover. Noticed carbs 1 and 4 had some fuel/oil drips on the lip. ​
Cleaned up the powerhead and looked for damaged wires but saw none.​
In summary: ​
1. compression good​
2. piston fit good​
3. Lower gear oil clean, now changed​
4. Prop has no wobble, removed some fishing line.​
5. Lower prop seal looks good. No water in gear case.​
6. Definitely a fair amount of fuel/oil leaked from ??? when last run. Carbs probably the source.​
7. Ran at idle very nice.​
Plan to find a barrel and run up the RPMs for a brief land test. If good then back out to the ocean and run up to 3000-3600 rpm.​
Still perplexed about the chink-alink noise under load. Hope I find its something easy and not a fatal problem.​
Any ideas?​
 
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