1996 Johnson gearcase

[brandon200317]

Hi all, new to the forum. I have a 1996 Johnson Fast strike 115hp v4 60deg. Couple years ago i have the impeller replaced by a "marine guy". Since then I've been battling water getting into the gear case. This year i finally decided to just reseal everything in the lower unit. I got a complete water pump kit and gearcase reseal kit. Got everything torn apart and found a couple small chunks missing from the pinion gear and the forward gear is starting to wear bad. Reverse gear looks good still. Genuine OMC/BRP gears sets (pinion and forward gear only) are in my opinion ridiculously priced at $650 roughly. I see the sierra marine brand is just as expensive. I don't have alot of experience in marine repairs so curious what thoughts are on some of the aftermarket suppliers out there for gear sets: WSM, SEI, etc... I've also seen quite a few used in good shape gearsets but those make me nervous. I'm an automotive technician and using used gear sets is unheard of in vehicle differentials because gear wear patterns are set base on how they're initially setup. try to swap it to a different vehicle/diff and you can get gear whine or excessive wear. It also upsets me because i can get a complete OEM differential rebuild kit for my 3/4 ton chevy for the same price or cheaper than 2 stupid gears for this Outboard.
Sorry for the long post. Looking for Opinions as i wasn't expecting to run into this discovery.
Also with new gears, any tricks to setting up pinion gear depth without the special tools? I may just take it to a former dealer assuming they have the tooling to do it properly

Thanks!

 

[Chris1956]

SEI likely makes an entire new replacement gearcase for your motor. I have heard good stuff about these. You might check it out.

 

[flyingscott]

Hi all, new to the forum. I have a 1996 Johnson Fast strike 115hp v4 60deg. Couple years ago i have the impeller replaced by a "marine guy". Since then I've been battling water getting into the gear case. This year i finally decided to just reseal everything in the lower unit. I got a complete water pump kit and gearcase reseal kit. Got everything torn apart and found a couple small chunks missing from the pinion gear and the forward gear is starting to wear bad. Reverse gear looks good still. Genuine OMC/BRP gears sets (pinion and forward gear only) are in my opinion ridiculously priced at $650 roughly. I see the sierra marine brand is just as expensive. I don't have alot of experience in marine repairs so curious what thoughts are on some of the aftermarket suppliers out there for gear sets: WSM, SEI, etc... I've also seen quite a few used in good shape gearsets but those make me nervous. I'm an automotive technician and using used gear sets is unheard of in vehicle differentials because gear wear patterns are set base on how they're initially setup. try to swap it to a different vehicle/diff and you can get gear whine or excessive wear. It also upsets me because i can get a complete OEM differential rebuild kit for my 3/4 ton chevy for the same price or cheaper than 2 stupid gears for this Outboard.
Sorry for the long post. Looking for Opinions as i wasn't expecting to run into this discovery.
Also with new gears, any tricks to setting up pinion gear depth without the special tools? I may just take it to a former dealer assuming they have the tooling to do it properly

Thanks!

Yes it takes a special tool set the pinion height.

 

[racerone]

No surprise that gears are damaged.-----These gearcases are not as robust / long lasting as earlier V-4 models.-----A shop should have the universal tool kit to set this up in minutes.-----Gears are much smaller than automotive.----They are made precision made with top quality material.----Properly set-up with the factory shimming kit you will not have any whine from good used gears !

 

[stresspoint]

being that it is such an old motor i would suggest to source a used gearbox, there should be plenty around (i have one sitting up in the shed i would gladly hand over for cheap).
even if you get a couple of years out of a used one its still cheaper than the cost of replacement new parts and the time and tools involved setting the one you have up properly.

 

[racerone]

In my area a 1996 is NOT considered to be an old motor.

 

[stresspoint]

In my area a 1996 is NOT considered to be an old motor.

2006 is considered old around here when it comes to boat stuff !, but that's fine, as i prefer the older stuff rather than the later models so it makes boating cheaper for me.

with that said ,I'm happy to put stuff that is harder to come by or expensive in some areas in the mail or ship parts that i have collecting dust in the sheds for not much more than the cost to post.

OP , feel free to PM me if you want , if the part numbers on the gearbox i have match what you need ill be only too happy to see it go where it will be used.

 

[Crosbyman]

old is only a false perception of the young...they eventually change their minds. 1949 version myself.

 

[racerone]

Gears and bearings were more robust in some 1960's motors than typical same power motors today.----If I had a 60 degree 4 cylinder I would contemplate / modify and install a pre 1995 model V-4 gearcase.

 

[stresspoint]

old is only a false perception of the young...they eventually change their minds. 1949 version myself.

exactly , when all this newer stuff starts needing repairs the owners will wish they stuck with their older stuff.

one boat 1999 4.3 vortec, the other 1992 hull with a 500 hp vortec both carbed motors.

 

[Chris1956]

Gee, what could be easier than installing a new SEI gearcase? You need to reuse the upper driveshaft from the old gearcase, but that is easy.

At least check out the prices of the SEI product, as they are usually just a bit higher than some unknown quality used gearcase.