55hp 1977 Evinrude stuck gear case

[bea413]

Trying to check/change water pump on this 55773D.

I have removed the 4 bolts holding the gear case to the exhaust case (actually all 4 twisted off about ? in below the head so have a lot of drilling to do if I ever get it off). Removed the trim plate and bolt and removed the long bolt underneath in the middle (these two both came out hard and had a lot white corrosion powder) and disconnected the shift rod below the carbs. The gear case will only separate about 1/16 inch from the exhaust case. Managed to break part of rib off the gear case above the cavitation plate beating on it with wood and a hammer. Reading another post sounds like I should beat on the cavitation plate with a bigger hammer.

Motor is still on the boat at this point. Used in salt more than fresh water. Has not been serviced in more than 15 years. Very light use and a few years not at all. Motor almost always runs well. I ruined my 7.5 HP gear case 5 or so years ago when the drive shaft stuck in the crank, so I am starting to get worried. Will the shaft pull though the WP like the 7.5 did?

Any suggestions would be appreciated.

Thanks, Bruce

 

[Panhead Jim]

Re: 55hp 1977 Evinrude stuck gear case

If you are committed to reviving this old warrior, I would remove the powerhead. You can do it in about 30 - 45 minutes, and you will save the driveshaft/crankshaft connection, if it's saveable. You can wiggle that powerhead to loosen the shaft/shaft connection, you can't wiggle that drive shaft with the lower unit. Of course this brings all of those upper bolts into play as well; you may well break some or all of them off, too. What a mess. I hate it for you. It's more work than you planned to do, but there's a bunch of stuff that could be cleaned, lubed, serviced in the process. My two cents...

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Thanks for the tips Jim.

I am committed at this point to repair, although maybe I shouldn't be, as I did notice very light creamy colored oil drained out of this gear case, which indicate water, of course. Maybe different story after another day or two of work on this. I am pretty sure something will give, whether it is the motor, or me!

I have a lot of time now since I retired a couple months ago, but I would probably rather shore fish than work on the motor. Cant travel too far with just the kicker! The motor has always run very well except for the time the spring on the electric choke broke and it was really hard starting till I figured that out. Guess I won't order the water pump kit just yet till I spend some more effort getting it apart to see what all parts I need to order besides bolts and water pump kit.

I am thinking of wedging the prop and jiggling and shaking a bit with a wrench on the flywheel nut first, before I take off the power head. I am assuming the only likely thing holding the gear case up is the drive shaft to crank connection. Do you think that is worth a try first?

I guess I will spend at least today messing with it. I have an old Mark 55E Kiekhaefer (1956 I think) in the garage that my son traded work for, a few years ago. Not sure what it would take to get that thing running (it is not frozen, is all I know at this point, and shifter seems to work). I believe I read that you need some special tools to work on these also. I think I better give the old Evinrude a little more effort first, before I make a desperation move like that. More later.............. Bruce

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Still stuck gear case after quite a bit of work yesterday. I have the power head read to come off now also, but only about 1/4 inch separation between ph and exhaust housing. I only twisted off two more small screws one of which was on the exhaust relief port, which I probably didn't need to take off.

Is my only option more force using some good fabricated oak wedges and a bigger hammer?

Will the drive shaft pull through the water pump and out of the gear case like it did on my 7.5HP a few years ago?

I cant really hang it upside down yet, like some have, as I cant get to the shaft yet to flood with pb blaster or atf-acetone.

I have a few photos, but don't really show much except rib on gear case broken off a lot on both sides, from pounding. I think I must need to make smaller so they will actually show up as an image here. I will try to do that later.

http://i1291.photobucket.com/albums/b544/bea413/IMG_3629_zps23aa4aee.jpg
http://i1291.photobucket.com/albums/b544/bea413/IMG_3630_zpsfc2db79f.jpg
http://i1291.photobucket.com/albums/b544/bea413/IMG_3633_zps2bcda0af.jpg
http://i1291.photobucket.com/albums/b544/bea413/IMG_3634_zpseafe14b1.jpg
http://i1291.photobucket.com/albums/b544/bea413/IMG_3635_zps8d4a6a1f.jpg
http://i1291.photobucket.com/albums/b544/bea413/IMG_3638_zpsc0743c01.jpg

I would appreciate any additional advice.

I am less committed to saving this motor than I was yesterday. I see a few on CL that might work. I believe I can use up to 85 HP on this StarCraft super sport 16. Sounds more fun than the 55HP! Ha, ha.

Thanks, Bruce

 

[pn]

Re: 55hp 1977 Evinrude stuck gear case

whats wrong with the motor, if its still pumping water, put the motor back together.

 

[Joe Reeves]

Re: 55hp 1977 Evinrude stuck gear case

For future reference.... when removing tight bolts, use a hand help propane torch to heat the aluminum surrounding the bolts. This will force the aluminum to expand somewhat which will help free the bolts.

Also, in lifting the powerhead... apply lifting power straight up. If you tilt the powerhead, you risk breaking off the bottom sealing edge area of the crankshaft which to my knowledge cannot be repaired.

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

To PN, I wasn't sure it was pumping water, and I haven't touched in 17yrs so I thought should check water pump. Then I found creamy colored oil in the gear case, so I thought it had to come off anyway to reseal. Now that I have twisted off about 6 bolts, I will need to get it apart just to drill bolts, if I cant get ahold of them with vice grips or something. This motor doesn't have a pee hole, and I didn't ever install one of those either.

I should have used heat on the casting too, like Joe said, but I didn't. I didn't work on it at all today.

Maybe later......... Thanks for the comments though. Bruce

 

[Panhead Jim]

Re: 55hp 1977 Evinrude stuck gear case

Where you have the flat bar is the break between the adapter plate and the exhaust housing. The power head comes off clean from the adapter plate, one level above that. Have you removed the little nut, think it's a half-inch or 9/16", from the back under the cowl? That is the final release from the adapter. Also, I'm assuming you've released the shift shaft under the bottom carb?
Jim

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Thanks for being gentle, Jim! I am feeling pretty dumb now! I went down and looked again and you are right, I have been trying to get power head to separate in the wrong spot. Unbelievable! I can do a lot of things myself, but none very well, that is for sure! I like trying though (sometimes)!

I had to remove all the oak wedges that I drove in there yesterday. I see the little nut in the back that you are talking about. I guess I better get to work.

Hope I have not done too much more damage, if I ever can get it apart. I see a copper tube through the gap which I crimped with a wedge. Assume that is the water tube from the pump. Hopefully I can fabricate or find one, if I can get the gear case off, one of these days. I will see how bad the damage is one of these days. I might have to find a rebuilt gear case at least.

There was a place in Portland that had a huge inventory of used and rebuilt boat and motor parts but I cannot remember the name of it. I remember having a choice of about 3 gear cases for my 7.5 HP a few years ago, when I had similar troubles. I don't know how I could forget the name of that place, but I did. If anyone knows the location, let me know.

I wasn't able to locate anything like that in the Seattle area.

Okay, back at it till I get tired. Thanks again Jim! Bruce

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Thanks to the two Jims and Joe, made a little headway on this disassembly.

Once I got the power head totally disconnected I shook and rattled the thing a lot. I was about to give up and decided to pry on the gear case one more time. Clunk, down came the gear case.

Lots of corrosion powder on the drive shaft and in the end of crank. Hard to believe this welds it together so well.

I thought the water pump looked pretty good for 17yrs. It had set in the vanes, but was still flexible and didn't seem worn that much. Maybe I didn't let the engine run long enough when I was testing. I don't have a telltale on this anyway. I have never felt comfortable with it, but never installed pee hole on it anyway. I suppose I better check the thermostat too while I am this far into it.

I think I should drill the four or so bolts that are broken off flush. I used heat as Joe suggested and got some broken ones out, but some broke flush the second time round (4 I think). I will drill tomorrow and see what happens. How do you get broken easy outs out again?

Only one of the bolts is the larger gear case to exhaust or mid section. the others are smaller screws which I think will be challenging to drill and remove.

I still need to get the exhaust tube off, too, to fix the copper tube that I kinked up top, with a wedge. Not exactly sure how to do that. Two the screws that I sheared of flush are on the cover plates for midsection mount to lower part of transom. I am worried about th bolts in here too.

Once I get a few of these things done I will be able to decide if she is salvageable, and what parts I need to find, or order.

A few pictures of todays progress are attached (although I am still having trouble with pictures, just attached the link).

Motor7-15-13 Photos by bea413 | Photobucket

I wonder If I could just run the gear case with fresh oil and check the oil every week or so to see how much water is in it. At least I should be able to get it apart this winter. The oil was definitely creamy, but I couldn't see any water separating out. Can an amateur get the gear case resealed??

Any additional advice or comments are welcome. I am just plugging along on this.

Thanks, Bruce

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Motor7-15-13 Photos by bea413 | Photobucket



Exhaust tube mount lower. This ruined screw was drilled and removed with heat. Two on other side are broken off flush, even using heat. How does the mid section come off? I will drill the other two screws today.

Got the picture, but the description from photobucket does not seem to come over to the post.

Testing the picture thing again. Bruce

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case



Exhaust tube spacer captured bolt at rear. How did evinrude get this bolt in here anyway? At least it didn't twist off. I do need to get this spacer off though, to fix the copper tube that I damaged with a wedge, under this spacer. Not totally sure how this comes off. I did remove the three bolts at the top rear that hold this spacer to the upper part of the transom swivel mount. Need to work on the lower attachment which is pictured in previous post.

I need to go get after it again. Any comments or advice on this will be appreciated. Thanks, Bruce

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

I guess that bolt above is probably just a stud with a nut on it. It just struck me as odd in the heat of battle yesterday..... more stuff........



I meant to post a picture of the drive shaft corrosion. I am amazed a little bit of corrosion can weld things together so tightly. Is axle grease or white lithium okay to use on this, if I ever get to put back together????




Three of the four broken off bolts came out with heat and Vice Grip. The fourth broke off flush with heat and VG. Wife is out looking for some reverse twist drill bits, which seem to be recommended by many in other threads.. I do not want to remove broken eze out. Failed before at that. I will go see if I have a heli coil or two. Seems like I bought some a few years ago. Looking at the forum threads this seems to be a pretty common problem especially on salt outboards. Still doing Research today. I should have done a little more of that before I started this project.

Shoulda, woulda, coulda!

Later, Bruce

 

[Panhead Jim]

Re: 55hp 1977 Evinrude stuck gear case

So many questions to answer! First, congratulations on a winning attitude.
Piece of advice: Look on eBay and get the manual for THAT PARTICULAR year and model. Wait for it to arrive and read the disassembly sections at least twice before you attempt to separate the exhaust housing from the stern bracket or perform any other major disassembly. I've just been through this whole mess with my '73 50HP and the manual can't be overstressed.
Yes, it's a stud. And it needs to be a stud again. It'll come out when you separate the adapter plate from the midsection. Replace with a stud.
Replace the whole pump, no matter what that one looks like. Get the kit that includes the housing, liner, everything you need. Use Genuine OMC.
Install a tell-tale. Plenty of details here about how to do that. I did it, so anybody can. USE GREASE and GO SLOW.
That water tube is grommetted into the exhaust adapter, and it will become obvious how it is removed when you separate the exhaust housing. Take the whole housing off (MANUAL), then separate the adapter from the midsection. Be careful with that tube as it is no longer readily available. It's available, just not readily. Replacement attitude is critical - the tube, not you...it must stuff into the discharge grommet on the pump on reassembly, and you can't see it if doing it alone. GO SLOW.
Replace all those rubbers, one upper and three lower. Expensive, but critical. Readily available.
Remove the swivel/steering arm and replace all the soft parts and thrust washers. Remember to lip the upper seal IN and the lower seal OUT. Absolutely do not fail to use Loctite 660 at the steering tube splines on reassembly. Expensive but critical.
Get that manual, the genuine original article so you can find all the soft parts hiding in that midsection. Buy genuine parts where you can, they just fit right. Buy genuine replacement bolts and screws.
By the way, you're fixin' to get into a BUNCH of money. That's even if you do nothing to the lower unit. I went into mine to replace the water pump and put over $1,000 worth of parts on it. Never got deeper than the shift shaft cap, which I did replace. In fairness, I did replace the transom bracket in that money, mine was the old clamp style and I upgraded to the bolt-up so I could raise it up on the transom. You will never get your money back out of that motor. I'm just sayin'. You might want to consider your options before you do that.
Did you break off any bolts in the powerhead?

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Thanks again Jim! I do tend to ramble and spray random questions though out. Makes it kind of messy. Sorry!

None of the bolts broke off in the power head. Broke two #10 screws on that cover for the mid section mount and one 1/4 inch in the top of mid section that holds that transition piece on to the exhaust tube (the part I should not have taken off, at all) and one 3/8 in on the bottom of the exhaust tube where the long bolts hold the gear case on.

All others that I broke off. have already been removed using heat and VGs.

I hear you loud and clear about the Manual. The Clymer's that I have is not too helpful for a lot of the specifics of my engine. There is minimal info about the midsection that I can find.

I am up and down with the commitment to getting this thing running. I have been doing a little shopping too. My level of commitment was tested again today as I tried to drill the 3/8 bolt piece out of the bottom of the midsection this afternoon with a couple left hand twist bits that I found today (suggested in other threads on this amazing forum). It did not spin out, like I fanaticized that it would. I am slightly off center and nothing is budging. Using a lot of various penetrants and heat too. I bought a heli-coil this size, but I am worried that I am a little off center and the heli-coil will not line up with the gear case holes. Maybe it will be okay, as I think you could safely wallow out the hole in the gear case just a little. Haven't hit the threads yet though. I am thinking the #10s and the 1/4 in will be as hard if not harder to do. I could return the $100 of helicoils to help pay for the machine shop..........

If I could get the mid section off, I would try to find a machine shop to do this. Tomorrow I will concentrate on get the mid section out instead of drilling. Seems like the two bolts that point inward toward the drive shaft (one on each side) would release the mid section along with the three on top that capture the rubber yoke thing on top of the transom swivel (which I already took out). Those two side bolts seem awful tight. I didn't heat that area yet as I can see there is a rubber mount in there.

Can anyone confirm that those two bolts will release the midsection? There is a picture above of one side, where the cover is still attached by one washed out screw (which was later drilled off and heated to remove stub). Comments?

I don't know if I can wait for a manual, ha, ha. I just get impatient. I should just get a motor, if I could find one and do this in the winter. I would rather fish now than work on this, but.............. Sort of pathetic how the water pump turns into this disaster along with a little water in the gear case oil. I am pretty sure many would say I should have the lower unit rebuilt by pros.......Oh well, it is 36 years old, I guess.

Hind sight, I should have drilled a pee hole and changed the oil in the gear case and gone fishing. I just retired a couple months ago so I thought I would do it more like it should be done since I had the time. Now I don't have this much time skill or money. I will be back at it tomorrow though.

Thanks again for your help Jim. Later, Bruce

 

[Panhead Jim]

Re: 55hp 1977 Evinrude stuck gear case

It's the four bolts, two each side oriented front to back, that release the bottom end of the midsection. If you already have the top ones out, the midsection will swivel out from the bottom when you remove those four. The two laterals in the pic hold that rubber insulator assembly to the midsection. All of those fasteners were originally installed with a little OMC loctite, they are very tight and should have a little heat applied. Plus 35+ years of life. I say again, get that original OMC manual. You will be glad you did...

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Thanks Jim! You have been a great help and this Forum is really great resource for us rookies (or "cadets" as we are designated).

I ordered almost $400+ in parts last night, so there is less chance of turning away from my commitment now. I couldn't find the copper water tube yet, for the long shaft but will keep looking. I am sure I will need a few more parts, but will have to order when I discover or find locally.

They actually had the long shaft exhaust mid section for $90 so I jumped on that. I thought that was reasonable compared to the $5 or $6 bolts. For now I can forget about the heli-coils, since all my broken bolt stubs are in this piece (so far.....) unless something else bad happens. I will return the $100 worth of heli-coils assuming I don't need to open any of the three packages, which will help offset the cost of these parts. Ha, ha?

I notice from more reading myself to sleep at night, that stuck lower gear case is a very common problem. Many horror stories going way back. I probably wouldn't have needed a post, if I had spent a few days researching this forum. Takes so much time and I tend to get tired after a point......What a resource though! I did end up buying some of my parts right here. I did read a lot of your story too! Wow, you sure did a great job on yours it sounds like. Hope it is running well. I do not recall actually seeing the end of your story.

Okay, now to finish disassembly, clean stuff up, and wait for parts.

Is it the OEM SERVICE MANUAL that I want? found one on ebay but didn't buy yet. This is my motor only and "service".

http://www.ebay.com/itm/REAL-OEM-FACTORY-EVINRUDE-SERVICE-MANUAL-1977-55-HP-/321162569929?pt=Motors_Manuals_Literature&hash=item4ac6c7e8c9&vxp=mtr

More later, Thanks again! Bruce

 

[Panhead Jim]

Re: 55hp 1977 Evinrude stuck gear case

Yes, that is the correct manual. Push the buy it now button and you will be glad you did. I told you it would be a bunch of money, huh? You'll be lucky to get out of this without another $400. But all good, you will not only have a great motor when you finish, but you'll know every little thing about it. That's my favorite part about working on my own stuff, the piece of mind. Sounds like you are on the path.

And thank you, mine is finally running great. I wound up putting a pair of carbs on it, rebuilding them completely of course, and they adjusted out exactly like the manual suggests. My wife and I put about 50 miles on it last weekend!! On six gallons of gas! We bought this rig last winter, Jan or Feb, and I've been working on it ever since, right down the exact same road you are travelling. Thought several times that I should give up. I'm really, really glad I didn't.

 

[bea413]

Re: 55hp 1977 Evinrude stuck gear case

Now wasn't that fun? Finally got my gaskets and seals on 7/31 and other parts previous. Didn't do a great job, but finished up on 8/4/13, and it runs real nice in the barrel! I have a nice new telltale water indicator!

I ended up putting the telltale in the head, as it was thicker there than the cylinder jacket and I thought I could get a few more good threads there. New gaskets and thermostat. Ran the motor at least 45 minutes and re-torqued head bolts after in cooled. Could hold my hand on the head at least 6 seconds so I think the thermostat worked fine. I really like having the telltale now! It pumps almost half a gallon per minute.

I had no puller for the prop shaft seal/bearing carrier. If I have to, I will put some hooks on some bolts to catch the three web arms and use my puller, but the bolts seemed to be 9/32 and 28 threads which I couldn't match to pull that way. Anyway, I skipped the prop shaft seals and just did the drive shaft and shift rod, hoping they were the source of the water in the gear case. I had another twisted off bolt in the seal cap for drive shaft and made a repair with a helicoil that turned out badly, but is sealed with RTV high temp I hope. I will check the oil for water again before going on the water, but hoping I wont be taking in too much water. I think it has run about an hour now, and is still sitting in the barrel, so that is somewhat of a test. I think the film of oil on the water probably came from the exhaust and not the gear case, hopefully.

I think I ended up with 3 or 4 helicoils but not in heavily loaded areas, and believe they should be okay. This should end this story for now. Now I need to decide if I will repair my power tilt unit. This motor gets heavier and heavier every year!!

I think my total cost was around $500, but I did not replace the rubber leg mounts bumper and tilt or swivel bearings or seals or other items, that could have been replaced. (they did look pretty good and there is not much play in those two swivel points) I believe the tilt motor will still cost $200 if I decide to fix/replace.

Thanks to all who gave me advice and to this forum for providing a place to help us new guys out! I stuck up a few pictures and video of the completed job.

IMGP0033_zps0a60dfca.mp4 Video by bea413 | Photobucket

Adjusted the idle a bit. My new elbow leaked a little and when I put in gear the geyser trash bucket shot some water up into the motor housing, which explains the water in there. New gaskets were not leaking. Runs pretty good for 7 year old gas I think, even without stabilizer.

Motor Running With Telltale Video by bea413 | Photobucket






Thanks again. I didn't really know I needed more humility lessons, but..............hopefully it will run good for a while, now.

 

[bonz_d]

Re: 55hp 1977 Evinrude stuck gear case

Great outcome! I wasn't as lucky with the 1988 70hp Evinrude I aquired.