Johnson 55esl69A water tube removal problem

[Stevewatr]

46Hi,
I am in need of replaceing one of the copper water tubes, and am having trouble. Please refer to the exploded view below, and I'll try to explain. The tops of the tubes are held in place by somthing I cannot see, so I assume the exhaust cover, #46 needs to be removed. I removed the 2 small covers, 44 & 45, snapping a few screws :blue:, This exposed 6 bolts, #48, that are good sized, and I removed all of them. I then found 2 small bolts inserted from the top through #76. I tried removing them, and they both snapped off easily Since they thread into #46, and snapped off, they are no longer an issue. I then assumed the cover cannot come off untill the lower support is disconnected. It is like a shock absorbing deal, #56. I removed 4 small screws that held on 2 covers, #57, this exposes a nut on a stud on each side, and 2 bolts on each side. It appears that removing the 2 bolts on each side will disconnect the cover, so I tried removing those, the first 3 came out, the 4th one snapped:facepalm: So the broken shank of the bolt is not going to allow the cover to move down, but just for giggles, I wanted to see if the cover would seperate from #76. It was tight, but using a sharp putty knife as wedge, I was able to get some seperation. The strange thing is the front will not seperate at all. It is like there is another screw still holding it, but no such screw/bolt is shown in the parts, and there isn;t really room for one anyways because the tube for the driveshaft, #83 is right near the front edge. Can anybody that has done this job please help?

Thanks,
Steve W.

 

[Joe Reeves]

Re: Johnson 55esl69A water tube removal problem

That graphic is too small to show any detail, however.............

When removing steel bolts from an aluminum housing, it's best to have a hand held propane torch in one hand to heat up the surrounding aluminum (expands) to help free the bolt(s).

The water tubes have a flange on top of them that sits within a rubber grommet. Remove the powerhead and lower unit, then you can remove the water tube(s) from the top side.

 

[F_R]

Re: Johnson 55esl69A water tube removal problem

Yeah, can't see the detail. But I can tell you that the water tubes are attached to the bottom of the powerhead adapter. To get the powerhead adapter off, you must remove the midsection from the rubber motor mounts. Two large bolts at the top and the mounts behind the covers at the lower end of the steering swivel.

 

[Stevewatr]

Re: Johnson 55esl69A water tube removal problem

That graphic is too small to show any detail, however.............

When removing steel bolts from an aluminum housing, it's best to have a hand held propane torch in one hand to heat up the surrounding aluminum (expands) to help free the bolt(s).

The water tubes have a flange on top of them that sits within a rubber grommet. Remove the powerhead and lower unit, then you can remove the water tube(s) from the top side.

Is removing the powerhead the only way? I thought the plange that holds the tubes in bolts up from the bottom?

Oh, and thank you for the speedy reply, I'd love to get this in the water just to test run before the season is over.

I used my mapp gas torch on some of the fasteners that felt siezed, but those two small bolts fooled me!

I tried enlarging the pic, but the sire keeps shrinking it, here is a link to it online:

Johnson Exhaust Cover Group Parts for 1969 55hp 55ESL69A Outboard Motor

 

[Joe Reeves]

Re: Johnson 55esl69A water tube removal problem

Is removing the powerhead the only way? I thought the flange that holds the tubes in bolts up from the bottom?

I used my mapp gas torch on some of the fasteners that felt siezed, but those two small bolts fooled me!

Yes, it's mandatory that the powerhead be removed... no way around that. You'll also need to remove the lower unit as there's no way you would be able to insert new tubes thru that adapter plate down into the water pump area.

On many models, the water tubes are indeed bolted up to the bottom of the adapter plate... but not yours, and that's good as it saves you some work.

I didn't need the graphic anyway as I have all the books.

Any torch hotter than a propane torch... use caution as most of them can melt aluminum.

 

[F_R]

Re: Johnson 55esl69A water tube removal problem

You sure about that Joe? My factory manual says they are bolted up to the adapter. Which of us has the correct data?

 

[Joe Reeves]

Re: Johnson 55esl69A water tube removal problem

F_R.... I was just going by the OMC 1969 55hp parts manual (section in question below). In checking further, I find you are correct (My apologies Steve). As you can see, the retaining flange is missing from the parts diagram which led me to believe that the tube could be removed from the top. The earlier and later OMC part books do indeed show the retaining housing attaches to the bottom portion of the adapter plate as per F_R's graphic. I couldn't remember exactly and therefore checked the book only to find later the book was in error.

 

[F_R]

Re: Johnson 55esl69A water tube removal problem

Yep, I just now checked my parts book and sure enough it does not show that second flange. I can see where the confusion could happen.

 

[Stevewatr]

Re: Johnson 55esl69A water tube removal problem

Thanks guys, did you get a chance to see the video? If I understand you correctly, I should be able to remove the exhaust cover to access those flange bolts (#88) without pulling the power head, but if that is the case, what do you think is not allowing the cover to drop down from the bottom of the adapter plate? Is it really just te one bolt I snapped off that appears to attach the cover to the lower mount on that side?

Steve W.

 

[F_R]

Re: Johnson 55esl69A water tube removal problem

So you are trying to drop the exhaust housing away from the powerhead adapter without removing the powerhead first? Why??? You already have the powerhead unbolted. It isn't that much work to go ahead and disconnect the few small items and lift it off.

As for doing it the way you are attempting, I have no idea if that is possible or not. I dunno, maybe it is and maybe it isn't possible. I've never tried it. You may have discovered the "new way".

 

[Stevewatr]

Re: Johnson 55esl69A water tube removal problem

So you are trying to drop the exhaust housing away from the powerhead adapter without removing the powerhead first? Why??? You already have the powerhead unbolted. It isn't that much work to go ahead and disconnect the few small items and lift it off.

As for doing it the way you are attempting, I have no idea if that is possible or not. I dunno, maybe it is and maybe it isn't possible. I've never tried it. You may have discovered the "new way".

Uhh, okay, I did not realize until you just said it that the 6 large bolts I removed that go through the exhaust houseing, and adapter plate are what hold the power head on, but what I still do not understand is if I remove the powerhead, I'll have access to the top of the adapter plate, but the retaining flang that holds the tubes is on the underside of the plate, and as we just all agreed on, te bolts thread up into it. So at the risk of sounding stupid, I do not understand how removing the power head helps me if this damn exhaust cover still blocks access to the underside of the adapter plate where those screws are. Maybe I can make a video explaining myself better?

Thanks,
Steve.

 

[Stevewatr]

Re: Johnson 55esl69A water tube removal problem

I thought I saw somthing in the parts breakdown, but I am not sure. Maybe bolts under the power head that thread down into the housing from the to of the adapter plate??

 

[Joe Reeves]

Re: Johnson 55esl69A water tube removal problem

The powerhead needs to come off. There are a few bolts that go down thru the adapter plate and thread into the top portion of the long exhaust housing.

 

[F_R]

Re: Johnson 55esl69A water tube removal problem

The book sez----
1. First it says to remove the Lower unit gearcase and powerhead.
2. Then it says to remove the parts and bolts from the rubber mounts, and remove the exhaust housing and adapter from the swivel bracket assembly
3. Then it says, and I quote: "d. Remove four screws and lift adapter, inner exhaust tube, and water tubes assembly from exhaust housing."

Pretty much what I said up at the beginning. Only way I know how to do it unless somebody shows differently.

 

[Stevewatr]

Re: Johnson 55esl69A water tube removal problem

The book sez----
1. First it says to remove the Lower unit gearcase and powerhead.
2. Then it says to remove the parts and bolts from the rubber mounts, and remove the exhaust housing and adapter from the swivel bracket assembly
3. Then it says, and I quote: "d. Remove four screws and lift adapter, inner exhaust tube, and water tubes assembly from exhaust housing."

Pretty much what I said up at the beginning. Only way I know how to do it unless somebody shows differently.

Excellant!, well not really because there is no short cut. But thank you, and Joe very much for your help. Completely removing the housing will be better for removing the bolts I snapped! I'll try to get to it today, and report back.

Regards,
Steve W.

 

[Stevewatr]

Re: Johnson 55esl69A water tube removal problem

Got the powerhead out, got to the cooling tubes. Reason one was too short was because it was bent horribly.:

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