johnson 9.9 lower leg removal

[cat5cable]

help
i am trying to remove lower leg to change impellor but leg wont come off i have found the hidden gear shift rod connector and undone it but leg still wont come off, i now have a least a 1 inch gap between lower and upper leg should i just hit with hammer until it drops off. engine has no serial nums anywhere but guess its about a 1974 ish, engine is white and it does start but no water from wee hole.
many thanks
tim
uk

 

[ezeke]

Re: johnson 9.9 lower leg removal

You have to remove the screw on the shift rod connector. You may need to use a screwdriver to spread the opening to release the lower shift rod. Try to move the gearcase front to back and side to side while someone rotates the flywheel with the plugs out. The driveshaft may be stuck because it was not lubricated or because the o-ring was left off.

 

[cat5cable]

Re: johnson 9.9 lower leg removal

yes i have found and removed the shift rod same as picture you posted and will get a mate round tomorrow to try what you say.
many thanks
tim
its midnight here in uk it will have to wait till tomorrow.

 

[cat5cable]

Re: johnson 9.9 lower leg removal

hi tried removing spark plugs and turning flywheel i can see drive shaft turning inside leg i have about an inch gap and can see impeller but lower leg still wont drop off, should i remove prop and drain box oil.
thanks all
tim

 

[johnson1989]

Re: johnson 9.9 lower leg removal

Draining the Lower leg wont help. Either the Shift rod or Drive Shaft are holding you up. Hopefully its not rusted on. Look for a diagram here of your engine

http://epc.brp.com/default.aspx?brands=ej&lang=e

 

[cat5cable]

Re: johnson 9.9 lower leg removal

yahoo got lower leg off only took me a week, many thanks all for your help, impeller has been installed the wrong way maybe this is why no water from pee hole, the drive shaft stayed in engine and pulled out of gearbox end is this right??

thanks all
tim

 

[ezeke]

Re: johnson 9.9 lower leg removal

No. The driveshaft must be removed from the crank at the top, Otherwise there is no way to replace the waterpump. Turn the motor upside down and run some WD-40, Liquid Wrench or better, down the driveshaft and let it sit overnight.

You wil then have to try to grab the driveshaft with ViseGrips and using wood to protect the midsection, try to lever the driveshaft loose. The condition is caused by not using Moly Lube on the splines at the top and/or not replacing the o-ring to keep water away from the top.

All you did was pull the driveshaft, with the impeller pin in place, through the waterpump, destroying the waterpump.

 

[cat5cable]

Re: johnson 9.9 lower leg removal

had engine upside down with wd40 for a few days but drive shaft just wont move its jammed solid. is there anyway i can put this back together leaving drive shaft in engine, also i cant find an impellor pin anywhere. Looks like someone has done all this previous to me and just thrown it back together.
thanks
tim

 

[DaveInGA]

Re: johnson 9.9 lower leg removal

Tim,

Try soaking with a better penetrating oil than WD-40, such as Liquid Wrench (liquid) or PB Blaster (spray) or an equivalent, then get a bit of leather to wrap around the part so you can get a better grip. Sometimes tapping such a part with a "not overly large" ball pen hammer at the end will get such an item to break loose.

If you can get PB Blaster in the UK, that's what I would use. Works very well in "stuck" steel/aluminum applications.

Regards,

Dave

 

[ezeke]

Re: johnson 9.9 lower leg removal

Put a block of wood on the bottom of the shift rod and give it a few sharp taps. Then try pulling it up again with the vise grips. If you have a rubber mallet, strike the driveshaft while you are lifting.

 

[cat5cable]

Re: johnson 9.9 lower leg removal

many thanks all i am getting there slowly, bought new impellor and pin today also some other type of penatrating oil, when i get home from work i will set about removing the shaft, fingers crossed.

ta

tim

 

[cat5cable]

Re: johnson 9.9 lower leg removal

Engine has been upsidedown for a while 2 days with loads of penatrating fluid but it will not budge, so a freind said i will have to drop the upper casing off how is this done local guy at outboard shop thought engine was a 1975 9.9 also could this be made into a 15hp easily.
thanks
all
tim

 

[F_R]

Re: johnson 9.9 lower leg removal

You might as well pull the powerhead. Even if you were to get the drive shaft out, the splines in the crankshaft have to be cleaned up and the recess for the o-ring de-rusted so a new o-ring will slide in and seal. The splines will eventually completely rust out of the crankshaft if not fixed now. You may have to destroy the driveshaft. Rig up some sort of clamp arrangement so you can yank on it with a slide hammer.

Buy a service manual if you don't feel comfortable removing the powerhead. All this is caused by the last guy not replacing the o-ring on the top end of the driveshaft. But he saved 10 cents, U.S.

 

[cat5cable]

Re: johnson 9.9 lower leg removal

hi all tried in vein to remove powerhead but i have 3 crosshead screws that need drilling as heads nearly rusted off, yes i rigged a slide hammer on the shaft but it has made a real mess of the shaft but it still wont budge clymer shop manual on order, think i may have to take it to the outboard shop.
Many thanks for all your help, i will keep you informed.
ps: its personal now this little engine aint gonna beat me but it has so far.

timmy