Plastic stopper in gearcase Johnson 40 HP 2002

[Affertus]

So this is my first ( i think stupid for the way that i have made) problem:<br />This mornig i decided to change oil in gearcase (Johnson 40 HP 2002).<br /><br />I have removed the old oil (he was in good conditions) and then I have put the new one through three jars. The problem is that i think to have inserted the third jar with a small plastic stopper (soft plastic) that then it is remained caught in the gearcase. <br />I know i was a great stupid.<br />Now, what i can do ??<br />I have thought that the gearcase mechanism can destroy the small stopper and then i can remove it like detritus in next change oil. <br />Do you yhink that could damage the gearcase?<br />I need to tape apart the gearcase ???<br />Please help me !!!!!!!

 

[CATransplant]

Re: Plastic stopper in gearcase Johnson 40 HP 2002

Stefano,<br /><br />I think you must take apart the gearcase and remove the plastic stopper. It is soft, but, if it engages the gears, it could cause serious damage.<br /><br />I am sorry, but I do not believe it is safe to leave it inside the gearcase.

 

[G DANE]

Re: Plastic stopper in gearcase Johnson 40 HP 2002

I think you must be able to flush it out if you flush teh gearcase with I. Exa mineral spirit. Or flush it down at the drain hole so you can get it out with a plier or something.

 

[Affertus]

Re: Plastic stopper in gearcase Johnson 40 HP 2002

I never taked apart the gearcase.<br />It is hard to do ?? <br />I'm good with mechanics even if i have little experience with outboard ( i do the off season maintenance and i'have changed the water pump)

 

[umblecumbuz]

Re: Plastic stopper in gearcase Johnson 40 HP 2002

Stefano,<br /><br />My view differs from CA's. <br /><br />We're talking about a simple set of transfer gears here, running in an oil-bath, not a complicated multi-stage gearbox. My feeling is, just as you say, a piece of soft plastic in the gearcase will do no harm. It will either get chewed to small pieces or it will rest on the bottom forever.<br /><br />If it gets chewed up, you can flush out the oil and remove it.

 

[CATransplant]

Re: Plastic stopper in gearcase Johnson 40 HP 2002

Stillfishing,<br /><br />You could be right. However, there are a couple of areas where it could cause a real problem. First is the chance of it engaging the pinion and the other gears. Low tolerances there and, soft as the plastic may appear to be, wedging it into the gears will create very large forces, enough to break something. Another danger area is the clutch dogs. Again, wedging this soft plastic into position could prevent further shifting in or out of gear if it causes a serious enough misalignment.<br /><br />Gears aren't designed to cut things...even soft things, and the plastic is only so compressible. I dislike thinking about a chunk of soft plastic being wedged under the pinion for part of a revolution. Those shafts just aren't that sturdy. They're not designed for side forces.<br /><br />I sure wouldn't risk it.