Johnson j200plssc HELP SHIFT ROD Adjustment HELP

[jh47828]

Hi,
Yes i'm must be the dumb ***. I have been performing minor maintenance on my J200PLSSC t-stats, new VRO2/OMS pump, new oil pickup, and new water pump. I messed up and turned the shift rod and it took me about 5 times taking the motor on and off to finally get the shift rod the right height. Everything was good.

Then, I decided to change the oil/grease in the foot. When i did, the oil looked like coffee with very little cream in it. I let it sit for 2 days and it separated with about 1/2 in very dark and the rest coffee w/little cream. It never separated water in the bottom, but it is my understanding that the oil is made to mix somewhat with water.

SOOO, I thought i would drop the foot again - change the shift rod seals - and pressure test. I did and all tested good at 9 PSI. I didn't want to test to high with old seals. I decided it must have been the fill or drain washer and changed them and all tested good. I put lower unit in Neutral - measured 21 15/16 from top of lower unit and have had the motor on and off 5 more times trying to get back to where i was. The problem is there is a little play in neutral - about 3/8 in. or more.

MY QUESTION IS: When i threaded the shift rod, should i have started with the shift rod in a specific location? I have tried doing 5 turns- six turns - now eight turns. Eight seems to be better, but goes in gear hard on both forward and reverse. I know the rod is measured with the turn (HOLE) towards the front. Before I try seven turns, I thought I would get any suggestions.

Thanks,
Dumb ***

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

I just finished taking off the lower unit again and tried it at seven turns. It is still going into gear hard. At 5 and 6 turns i had clicking and grinding. At 7 and 8 turns going into gear hard. Has anyone done as many as 9 turns to get the gears right?

 

[clanton]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

What do you mean going into gear hard? How far does the shift rod move from neutral to farward gear?

 

[schematic]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

There is a specific measurement from center of shift rod hole to gear case flange while in neutral. Then you must adjust the linkages to find neutral position. Should read manual.....

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

There is a specific measurement from center of shift rod hole to gear case flange while in neutral. Then you must adjust the linkages to find neutral position. Should read manual.....

I have the manual and have read the shift rod section. That measurement is 21 15/16 while in neutral. The problem is there is about 3/8 to 1/2 in play in neutral.

It makes a hard knock -- testing in the yard -- may be louder because out of water. Before it was real smooth. i goes into gear -- forward, reverse and neutral. It is a hare knock going into forward and reverse. Something is not right.

I will take it off again tomorrow and measure from reverse to forward, but I would guess 1-1 1/2 in. It is easier to put it in reverse by hand than forward. No shaving when changed oil. It was very smooth before I started fixing everything!!!

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Chief Petty Officer,
I am checking the prop to determine that i'm in neutral by adjusting the shift rod on the lower unit. Is that what you are saying when you say " then you must adjust the linkages to find neutral position" or am I missing a step that I should be doing?

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Rear Admiral,
I will measure the neutral to forward and let you know tomorrow.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

What i mean by 3/8 to 1/2 in play in neutral is: I can pull up on the shift rod from reverse to neutral. Then i can pull up on the shift rod another 3/8 to 1/2 in before i go into forward. All of this time the prop will turn freely in neutral.

 

[metriccrescentwrench]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

When you say there is at least 3/8 inch of play, are you talking about play in the shift cable or play in the linkage itself (with the cable disconnected)? There should be virtually zero play in the linkage, and 3/8 inch of play in the cable sounds like a bit much also. For instance, I have a nearly new cable on my boat and there's only approximately 1/8 inch play in it.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

I am talking about the shift rod itself. When I have the lower unit off.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

According to the manual, I must place the lower foot in neutral and measure from the top of the lower unit case (metal) to the center of the hole. 21 15/16 in. There is about 3/8in play (bottom to top) that the shift rod will move while in neutral before it goes into forward.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

I put new o-rings in the shift rod and greased them. It may be keeping the shift rod in a position of neutral that it would not normally be in.
I have not adjusted or moved the cable dial on starboard side of motor where the remote shift cable goes to the motor.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

I have noticed the remote control shift arm at the drivers seat doesn't seem to feel right both for forward and reverse.

 

[schematic]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Did you at any time remove all the innards of the gear case? (forward gear, prop shaft, shift mechanism?)

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Did you at any time remove all the innards of the gear case? (forward gear, prop shaft, shift mechanism?)

I did remove the shift rod to change the o-rings but just unscrewed it -- changed the o-rings in the cover -- and screwed the shift rod back back in.

It is making a loud clunk noise going into gear, both going into forward and into reverse. I have measured it sooooo many times --- studied and verified i'm doing it correctly --- i'm starting to think maybe the clutch dog is worn or something. Just don't know why so smooth before and now so loud when going into gear.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Also, once it is in gear -- no noise at all. Sounds great.

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Also, at crank up, it goes through the fast idle then slow down to about 800-900 rpm. After slow down, that's when i put into gear. Do you think the rpms are to high?

 

[schematic]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

wouldn't hurt to drop it to 650 - 700 rpm

 

[jh47828]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

Everything back together at seven (7) turns and without the motor on i put into forward and turned the prop and it is engaged into forward. I put back into neutral. Then, I put into reverse and check the prop. When i turned the prop to see if it was engaged it turned about 2-3 inches (slippage) then went into reverse.

Should I take the LU off and turn down to six turns? Will this situation ware out my gears? Can the cables be adjusted to off set the amount I need to engage reverse without slippage?

 

[schematic]

Re: Johnson j200plssc HELP SHIFT ROD Adjustment HELP

When i turned the prop to see if it was engaged it turned about 2-3 inches (slippage) then went into reverse.

That is of no concern. Turning the prop is misleading if you don't know what to expect.



What I would be concerned with is the up and down play you say you have in the shift rod. Almost sounds like the detent is missing or the pivot pin. These of course would have had to had the unit totally disassembled in order to lose them....


Maybe post a little video on the up and down play to see if we are spinning our wheels....