Johnson 35 1977 model dead in the water!

[gm280]

Re: Johnson 35 1977 model dead in the water!

Racerone, why did you have to say "simple job after that!"..... I have to laugh, it had to go wonky at some stage! It just wouldn't be my life if it came off that easy. Got the plate off no worries. Removed the lower screw, and the shaft was loose. Undone the four bolts holding the gearbox on. Then I noticed this nut........... It appears to be a stud from the gearbox, and it is bent. Since the attached photo, I have gingerly straighted it, and the nut still screws on ok, but it will not release! I have had it soaking in Inox, and even scraped old salt from around the thread. Can't get it to let go. Am I correct in thinking this bolt is holding the gearbox on? The rear of the gearbox is free, and the seal around the gearbox is broken, but at that front stud it just will not let go. It can probably move another 1mm, I am just scared I am going to make a right mess of it. If worse comes to worse, will hitting this stud to make it a little straigher do any damage that I can't undo? I cannot imagine how it got bent in the first place, but it seems that it must have been a while ago as salt has built up behind it. I know the studs are available if I wreck the thread, but I am more worried about damaging the gearbox where it screws in. It looks like it is well set into the cast, and am hoping it will move enough to let go. I am using a very big wooden mallet, and a steel punch to hit it. Sound reasonable?? Feel like an idiot, but just want to be careful. View attachment 221951

I hope there isn't corrosion up at the end of the drive shaft holding everything from coming apart. It should come apart fairly easy if the drive shaft comes out of the splines at the power head. Some times it gets water in there and corrodes and makes if very hard to remove.

 

[jbjennings]

Re: Johnson 35 1977 model dead in the water!

I don't recall there even being a bolt there????? Wish I could help.

 

[racerone]

Re: Johnson 35 1977 model dead in the water!

Long stud at the front----Gets jammed with the white aluminum oxide that develops in there.

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

Got the leg off with some heat and a bit of gentle persuasion. I have to replace that stud, but so be it. Now the next little drama occurs. The impeller cover has melted! So has the extension. Sourcing local parts now. It just keeps getting better and better! I just pray that the stud comes out easily. Will attach some pics of the state of the housing. Thanks all.View attachment 221998View attachment 221999

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

Trying to put up the pics from my last post. For some reason they don't want to come up.

 

[gm280]

Re: Johnson 35 1977 model dead in the water!

You shouldn't have too much trouble finding those parts. I would replace the entire water pump assembly being how the cover is toast. Make sure the inlet is completely clean and open as well, and verify the tube going to the power head doesn't have anything stuck in it either and the fit is still good at the power head or all your work will be for nothing. O/B's can be finicky animals some times. Good luck and keep us posted...

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

This is like Star Wars without the fanfare! The saga continues.... The dreaded stud has broken off in the housing, just below where the thread starts. Looks like it was only hanging on by tiny bit of metal, seems it has been nearly snapped off before. Now this would normally worry me, but not now. After all the dramas I consider this to be the least of my worries. Have tee'd up the local marine shop to take a look on Tuesday. I doubt the remaining piece of stud would ever come out, so I am prepared to braise a good stud in, minus the bit size of what is still in the housing. As long as it does the job of holding the housings together what they hey! Not like this part would "normally" be taken out during a routine service. I am determined to see the old girl working again, one way or another.

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

I ran water from the hose up the water pipe and it poured out of the block, in the right spots. I don't know where the rest of the impeller is but it isn't in the system that I can see. The impeller was a shocker, just stumps left on it. Now I just have sort out this broken stud. Hopefully my bad luck has had its run. Thanks for the advice. I am enjoying playing with the outboard, despite the cost of parts!

 

[jasper60103]

Re: Johnson 35 1977 model dead in the water!

I ran water from the hose up the water pipe and it poured out of the block, in the right spots. I don't know where the rest of the impeller is but it isn't in the system that I can see. The impeller was a shocker, just stumps left on it. Now I just have sort out this broken stud. Hopefully my bad luck has had its run. Thanks for the advice. I am enjoying playing with the outboard, despite the cost of parts!

Hopefully, the power head checks out with the new head gasket. Else, there are a few rebuild threads you can reference on similar motors. Good luck.

 

[EZSteury]

Re: Johnson 35 1977 model dead in the water!

I found several frozen bolts when I did the rebuild on My OB and some of them broke off where I couldn't reach so I drilled them out carefully and then used a tap the same size to clean the threads, You need patience and work slow for this but if I can do it anyone can do it. Then You know for sure what You have specially if You plan to rebuild this OB and keep it.

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

All the parts arrived. Put the head back on, and got the wiring tidied up. The coils I got were not the right size to bolt between the two bolt holes, but one bolt at the moment is enough for testing. Made sure all was ok, and turned the key. She fired up straight away! You could have knocked me over with a feather. I had my little girl running around distracting me, and I was sure something had gone wrong. Purred like a kitten for the short burst I gave it. Now I just have to get this broken stud sorted out and I can get the gearbox back on. Thanks to you guys for all the advice thus far. Hopefully the good luck will continue! Cheers All.

 

[jasper60103]

Re: Johnson 35 1977 model dead in the water!

Glad to hear to its coming together.
Now you can change your handle to "NoMoreSufferingHusband".

 

[jbjennings]

Re: Johnson 35 1977 model dead in the water!

Always fun to hear 'em fire up after a repair! Hope it goes well and you have a nice "test run" on the lake.

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

Well, that was the top end. I am doing battle now with the fierce gearbox refit! Got a new locating stud in. All new impeller housing and parts in. I have the gearbox in but not up all the way, about 1cm out! I know the drive shaft is located ok, as is the water pipe. Have not connected the gearbox linkage yet, but it is free where it is with the control in FWD. Can't seem to get the locating stud/sleeve to line up in the upper housing. I have a bit of thread coming through the housing from the stud, and the nut will lock onto it. Not sure whether to try and do up the nut, pulling the locating sleeve into place or what. Advice now would be great please. I am on my own, and struggling a bit. Now I am at the end of the tale, it doesn't want me to finish!

 

[jasper60103]

Re: Johnson 35 1977 model dead in the water!

All I can say is make sure you have plenty of light and inspect things closely.
Having someone to lend a hand would be great.
Once everything is properly aligned you shouldn't encounter much resistance.
Good luck.

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

Nice early start on it today. After more attempts, and a few prayers.... It dawned on me that the housing extension tube "may" have to be in the outboard housing first, instead of on the leg. I took this off, and with a gentle tap with a rubber hammer it popped into place. Slide the shaft in, and with a bit of wiggling up she went! A tried and proven method, I should have known! Got it all together without a hitch. Had a few issues with the gear rod linkage, but eventually realised my mistake of not fully removing the screw. It is all back together, and ready for the bucket test.
I want to ask one question, that will put my mind at ease. When I put this in the water, and start it up, should water be flowing from the exhaust and telltale right away?? If anything has gone wrong I want to catch it right away. Thanks so much to all for your invaluable assistance with this. All the advice given was graciously received, and taken on board. Nearly over. Soon I can say it started and pumped water till the cows came home. Fingers Crossed!

 

[jbjennings]

Re: Johnson 35 1977 model dead in the water!

Make certain you get the water level above the water pump housing if in a barrel. The pump is not self priming and needs to be underwater. As long as your impeller is getting water (lubrication for the impeller), the powerhead can idle for a short time without overheating. It should start spitting water out the tattletail in about 5 seconds or so. I don't think you'll have any problem as long as the water tube is in the pump outlet grommet.

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

The eagle has landed! Put her in the tank, made sure the pump was under water (thanks to a few bricks under the rubbish bin!). Started her and kept my fingers, toes and eyes crossed! Water was spitting out the exhaust, but only dribbling out of the telltale. Gave it a few revs just above idle and it picked up a little. Checked the tube going to the telltale and as soon as I wiggled it, water started coming out as it should. There must be some junk in the tube that I have to clean out. All in all I was very happy. Thanks guys for all your wisdom and support. I only hope I can help someone else out as you have helped me. Cheers

 

[sufferinghusband]

Re: Johnson 35 1977 model dead in the water!

The telltale had some junk clogged in it. Cleared it away and all is well. Thanks again one and all.