Lower unit removal problems.

[enstar]

I am trying to replace the impeller on my 1991 Johnson 150. I have the manual for the outboard, and followed the procedure to remove the lower unit. Well 5 hours later no luck, still stuck.. I have tried rubber mallets, screwdrivers, wood wedges, metal wedges, and a combination of all.. Used pb blaster to try loosen it, no luck.. So what are my options besides just giving up.. Everything is disconnected that should be... I am at my wits end...Any suggestions? Thanks in advance...

 

[Joe Reeves]

Re: Lower unit removal problems.

You say that everything has been disconnected. Did the lower unit drop down any at all? There are 6 bolts holding the lower unit counting the one under the trim tab... and then there's the shift rod.

If all of the above have been removed, I'd suspect that the driveshaft splines are rusted within the crankshaft splines due to someones failure to grease the driveshaft splines and/or install the upper driveshaft O Ring. If this is the case.... hellava job!

 

[enstar]

Re: Lower unit removal problems.

Everything disconnected. I can get it to drop maybe a 1/2 inch or so.. I am reluctant to take it to a shop since I believe all my attempts would be the same that a shop would do. I am just afraid of causing more damage.. I am about ready to hook a com-a-long up to the lower end and get some tension on it as I attempt to drive wedges around it.. I stuck longer bolts in so when it does go it won't fully drop out.. Any body think that's a good idea? Or any other suggestions???

 

[Joe Reeves]

Re: Lower unit removal problems.

If you have indeed disconnected the shift rod, I am puzzled to how the engine dropped the 1/2" mentioned... OR was it a battle right from the start such as a metal to metal fit, then a constant battle to get it to drop that 1/2" (rusted/frozen splines)?

If stuck, rusted, frozen splines, that is bad indeed! Many members have encountered that problem and have mentioned having the engine upside down, squirting powerful penetrating oil (power blaster?) on the driveshaft to have it flow down into the rusted spline area.

Hopefully some of those members will jump in here with a remedy they've come up with.

 

[enstar]

Re: Lower unit removal problems.

It was metal to metal from the start. So my 3-4 hours of trying different methods got it to drop about a 1/2 inch or so. About how long are the splines before they become disengaged? What a pain in the arse..

 

[Joe Reeves]

Re: Lower unit removal problems.

A rough measurement of the splines would be about 2" .

 

[enstar]

Re: Lower unit removal problems.

Well after many attempts, my efforts proved fruitless.. I guess I will attempt again in the fall when the boating season comes to an end so if I inflect to much damage at least I will have all winter to repair.. I appreciate your help Joe..