Johnson 10 hp 1961 OD22 disassembly

[thb]

I was given an old Johnson which someone threw away at out local dump. Saved it from destruction. Previous owner told the dump man that it needed a new water pump.

Well I put in a new water pump and put back together and ran it the other day. Had compression and spark so put her foot in the water barrel and fired the baby up. Boy I could not believe it ran so smooth and idled down no problem.

After several minutes the engine head area was starting to get hot so I shut her down. Apparently something is plugged up in the powerhead water passages or in the water delivery tube. Seen this on other 60's vintage evinrudes.

Simple hey, take the power head off, remove head, water tube and exhaust cover plate, investigate and fix.

Well first off, two of the head bolts can not get loose. Most of them were very tight but eventually came loose.

OK lets take the power head off. Same deal with the SS screws on the bottom of the lower engine pan being seized. Got 3 or the 4 off and finally ground off the last one. The 4 rubber mount bushings for the lower cowl also removed after much work. most of them broken previously and new ones cost 65/each.

There are 3 nuts visible on the upper side of the lower pan which seem to be the last thing holding the power head onto the midsection of the lower unit. Problem is I see no way to get a wrench or socket on any of these three nuts which need 1/2" size wrench.

Any ideas on how to get these 3 nuts off??? Don't even think I can get a dremmel grinder down there to grind them off as the access is very small.

Is there some other way to get the power head off???

I guess I could grind the lower pan off in pieces and access the nuts that way.

Looking for suggestions
Tom In Steinhatchee

 

[levi_tsk]

Re: Johnson 10 hp 1961 OD22 disassembly

youve gotta pull the carb and the shifter linkage and pretty much everything else off the power head before you can get to those nuts and youll need a 1/2" open end box end wrench and ALOT of patience id spray the nuts down with pb blaster and let it ride for a day before i tried to take em off and maybe youll get lucky and once you break em loose theyll come off with your fingers

 

[thb]

Re: Johnson 10 hp 1961 OD22 disassembly

Thanks for the input. I have used a lot of pb blaster so far. Shift linkage is off but I haven't pulled the carb yet. Have the mount and steering tube off as well. Will keep going and see what happens.

I wonder if there are some cheap rubber bushings out there which would work rather than buying the OMC 377582 $65 jobbies???

 

[kfa4303]

Re: Johnson 10 hp 1961 OD22 disassembly

HI thb. I have the exact same motor. Great deal you got there. Are you sure you really need to remove the power head? Have you tried dropping the LU and then hooking a garden hose up to the copper, water tube to flush out any debris? Lots of folks have aso had luck getting things unclogged that way. I've also heard of folks removing the thermostart and running salt out throught the engine with good resulsts too. Just a few suggestions. I only offer them b/c removing the power heads on these guys can be such a pain. I've heard of floks bending whrenches with a torch to gain easier access to some of the hard to reach nuts and bolts. Look at post #3.

http://forums.iboats.com/showthread.php?t=452432

Keep us posted and let us know what you find. Good luck.

 

[levi_tsk]

Re: Johnson 10 hp 1961 OD22 disassembly

you may have to remove the recoil brackets also

 

[Chinewalker]

Re: Johnson 10 hp 1961 OD22 disassembly

Getting those powerhead nuts out gets MUCH easier if you have a bent 1/2-inch box-end wrench to reach in there. I have a long-handled cheapie one that I bent in a vice, using a propane torch and a hammer to effect the desired angle. You want the handle to be at about a 30-40 degree angle to reach in there. Maybe more, depending on the model...

 

[tx1961whaler]

Re: Johnson 10 hp 1961 OD22 disassembly

Would one of these work?

 

[Sea18Horse]

Re: Johnson 10 hp 1961 OD22 disassembly

HI thb. I have the exact same motor. Great deal you got there. Are you sure you really need to remove the power head? Have you tried dropping the LU and then hooking a garden hose up to the copper, water tube to flush out any debris? Lots of folks have aso had luck getting things unclogged that way. I've also heard of folks removing the thermostart and running salt out throught the engine with good resulsts too. Just a few suggestions. I only offer them b/c removing the power heads on these guys can be such a pain. I've heard of floks bending whrenches with a torch to gain easier access to some of the hard to reach nuts and bolts. Look at post #3.

http://forums.iboats.com/showthread.php?t=452432

Keep us posted and let us know what you find. Good luck.

I agree with KFA, slow down there big fella! You say you had the foot in the water. How much water? How deep? The water pump itself needs to be submerged completely. The water level needs to be up to the lower mounts or it will not pump. Are you sure you're not going through all this for nothing? Good luck anyway.

Cheers....................Todd

 

[Chinewalker]

Re: Johnson 10 hp 1961 OD22 disassembly

Would one of these work?

I don't think so - the wall with the ratcheting apparatus in it is to thick to fit in the space between the nut and the crankcase...

 

[F_R]

Re: Johnson 10 hp 1961 OD22 disassembly

Getting those powerhead nuts out gets MUCH easier if you have a bent 1/2-inch box-end wrench to reach in there. I have a long-handled cheapie one that I bent in a vice, using a propane torch and a hammer to effect the desired angle. You want the handle to be at about a 30-40 degree angle to reach in there. Maybe more, depending on the model...

Like this:

 

[samo_ott]

Re: Johnson 10 hp 1961 OD22 disassembly

I'd also slow down. You're taking too much off. You don't need to remove the rubber engine mounts to get the power head off. Nor the pull starter and I don't think the carb either. And I took a cheapo wrench and ground down the outside perimeter so that the wrench could fit in on my 18. The 10's are the same as I recall. I have the QD22 parts manual if you want it. PM your request and email address if so.

 

[thb]

Re: Johnson 10 hp 1961 OD22 disassembly

Thanks for all the inputs. I took a 1/2 open ended wrench and bent that end and also bent the box end of the same wrench. Ground down the open end to make it a little narrower as well. The open end worked for two of the three nuts and the box end worked for the other 3rd nut. Power head is now off. Found a piece of old rubber ( off an old impeller ) lodged inside the brass water tube.

I have a tendancy to take everything apart and then I can see any hidden issues which will rear up and bite me one day. The cost of a few more gaskets is well worth it to me. I want to know that all the water passages are free and not corroded up. I guess that's the mechanical engineer in me and 35 years in the aviation industry.

The ratcheting adjustable wrench is pretty cool but I also think it is too wide to fit into this space between crankcase and nut.

There was plenty of water in the bucket and well above the lower mount. I have used this same bucket ( actually a wet and dry vacuum canister ) for testing several other small outboards. I also keep the water running into it sothe level does not go down during splashing.

Now does anymore know where to get some replacement rubber bushings p/n 377582. ?????The OMC ones are outrageously expensive at $62 each. There must be an off the shelf rubber bushing out there which would work.

Tom in Steinhatchee

 

[levi_tsk]

Re: Johnson 10 hp 1961 OD22 disassembly

no that wrench wont work - i have that set and its pretty usless if your bolt or nut is in a tight spot

nope youll have to buy em either from them or off ebay

http://cgi.ebay.com/ebaymotors/JOHN...4595571QQptZBoatQ5fPartsQ5fAccessoriesQ5fGear

are they broken and dryrotted or something ?

 

[thb]

Re: Johnson 10 hp 1961 OD22 disassembly

The bushings were detatched from their bolt ends. Nuts also sheared off several bolt ends of the bushings. Just 50 years old age problem I guess. Gee they don't make them to last very long do they???

Tom in Steinhatchee

 

[tx1961whaler]

Re: Johnson 10 hp 1961 OD22 disassembly

I have made the motor mounts before using old car shock bushings, carriage bolts, and vulcanizing rubber cement. Don't know if they'd last for 50 years.....

 

[levi_tsk]

Re: Johnson 10 hp 1961 OD22 disassembly

tom ,
are they all messed up?
have you tried asking the guys on aomci.org?

 

[samo_ott]

Re: Johnson 10 hp 1961 OD22 disassembly

I rarely see them busted. You'd be better off buying a parts engine and taking them off. Parts engines are cheap and many many models and years used the same ones. And BTW, where the heck is Steinhatchee?

 

[kfa4303]

Re: Johnson 10 hp 1961 OD22 disassembly

I agree with samo. See if you can scavenge them off a donor motor some where.Samo, Seinhatchee is here in Florida. I live in Tallahassee and there are all kinds of other places with funny names that have lots of e's in them Glad you got your water tube unclogged. She should run like a champ once you get her put back together.

 

[thb]

Re: Johnson 10 hp 1961 OD22 disassembly

I went onto the e-bay website provided by levi_tsk and decided that 29 each is a lot easier to stomach so ordered me some. Will probably be 10 days before I have all the parts on hand to go back together. Still have to take off the head, the exhaust cover plate and clean out the passages. Also need to get out the paint stripper and remove the dark blue someone put on this motor. Will go back with J/E white. Two head bolts are not yielding yet so more impact work required. Wondering how to impact a 7/16 bolt head while putting some CCW torque on it???? I used to have an impact screwdriver 40 years ago but lost track of it. Any good ideas on where to find another one????

I think this salvaged motor will become something I keep as too much money spent already to ever make it pay for itself. I might try finding a donor motor as suggested as little things are still missing like carb adjustment knob and choke lever knob, carb intake, etc.

Really appreciate all the inputs and this is a great forum.

Tom in Steinhatchee ( Google map it and look for Hidden Rd - there are only two families out here )

 

[samo_ott]

Re: Johnson 10 hp 1961 OD22 disassembly

I use a propane torch to get the head bolts off and then turn em carefully. It doesn't take much to snap em (been there also) abd then you gotta drill em out. Which can be done.

Hey, I see Steinhatchee. Middle of nowhere! I'm driving down to Ormond Beach the end of next week to visit a buddy