clutch dog

[diggerdan17]

i need to replace my clutch dog on 35 h.p. 1980 johnson....and i know i should have one but i do not have a manual yet.i have removed the lower unit and taken the waterpump and drive shaft out. next i drained the oil and remove the shift linkage....then i removed the 2 5/16 head bolts inside where the prop attaches to....then i removed the large phillips head screw beside the lower oil drain plug.now i can not seem to slide the propshaft assembly out of the lower unit.what is the next step?i am assuming i need a slide hammer of sorts but do not want to go reefing on this assembly if i have not taken it apart properly.i put an old prop on the prop shaft and put the nut on and used that as an impromptu slide hammer but it only moves a quarter inch then stops.am i missing a step?

 

[OBJ]

Re: clutch dog

Just pull on the prop shaft Dan...it'll come out. The detent balls are holding it in. When it pops lose, recover the detent balls (2) and the spring right away.....they seem to get lost real easy if ya' don't. After that, just pull the shift yoke out. The forward gear will need tilted a little to get past the pinion gear. Then pull the pinion and thrust bearing out.<br /><br />Piece of cake.

 

[diggerdan17]

Re: clutch dog

so i got everything out and upon inspection i noticed that all the gears and the clutchdog were in near perfect condition.the only bit of wear i saw was a tiny bit of rounded corners on the clutch dog ...and when i say tiny i mean tiny.i am almost certain that this is not my problem.the problem i have is that it momentarily jumps out of gear or feels like i am hitting a log.i adjusted my shift cable and it fully pulls my gear shift into the forward position and keeps it there.i unhooked my shift cable and it would not stay in gear any better with cable off.i am now wondering if there is another adjustment to the shift rod i can make to make sure the clutchdog is fully being pushed towards the forward gear.when i unscrewed the lower part of the shiftrod to get the prop shaft assembly outi didn,t notice if it was screwed in all the way.when i put it back together i screwed it in all the way...maybey this was loose before and this is where i was getting slack ?i can,t see the coupler that attaches the upper shift rod to the lower rod being able to be adjusted...it has to be screwed together tight to prevent vibration from causing it to become looser.one more thing...when i put the big snap ring in i am having trouble getting the 2 5/16 head bolts int the plate that sits right behind the snap ring to thread into the holes on the plate.i have used flaslight and screwdriver as a line up bar and i have those holes perfectly aligned ...yet i can,t seem to get the bolts to start threading in...any ideas?

 

[diggerdan17]

Re: clutch dog

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[OBJ]

Re: clutch dog

Dan...can you post a picture of the gear lobes and clutch dog lobes. Your description of hitting a log is characteristic of bad lobes.

 

[diggerdan17]

Re: clutch dog

i am still in the dark ages and do not have a digital camera . i am assuming by lobes that you mean the pieces on the inner gear that mesh with the same pieces on the clutch dog.i had my lower unit down to my mechanic friend and as i said in above post the amount of wear on the lobes is so minamal...i mean there is no syncro when they are forced together so i would expect a bit of rounded corners on the lobe ...and i mean little. i am going to try and adjust my linkage and if this still produces the hitting log effect then i will take the dog out and buy a new one..and maybe a new forward gear...i,m still having trouble getting those 2 bolts into the plate behind the snap ring.what is the forward gear...is it the first gear that comes out when disassembling the lower unit?

 

[OBJ]

Re: clutch dog

Forward gear is the gear furthest from the prop.<br /><br />You can make yourself a rod to align the holes in the plate with the holes in the bearing carrier. Just take a 1/4" rod and thread it for 1/4-28 threads.<br /><br />There is an adjustment plate in back of the shift lever. Couple screws hold it in place. Take a look. Possible the lever slipped on the screws putting the throw outta' kilter.

 

[dwest]

Re: clutch dog

Dan,<br /><br />I just completed a seal kit install on my 1977 35 hp Evinrude. Had a similar problem. Make sure the "O" ring is lubed and don't be afraid to push on the hub a little bit. Your bolts won't reach unless the hub is pushed in far enough. You may try a longer bolt with some washers to get it pulled together a little closer. <br /><br />I had some hitting of the log noise and was fortunate enough that it was only a minor linkage adjustment.<br /><br />Dave

 

[diggerdan17]

Re: clutch dog

okay i got the screws to line up finally!when i put it all back together i had forward and neutral....no reverse!it turns out that you can adjust the linkage by removing the water intake screens and unhooking the shiftrod coupler and then screw or unscrew the small piece of linkage that goes into the lower unit...after i adjusted this i had reverse and foward gears and i tank tested and all was well.now all i have to do is hook on to her tommorow and take her to the lake to try it under load.i,m fairly certain that this was my problem as i did bugger around with the linkage under the water intake screen when i replaced the impellar 2 weeks ago.i,m sure if i had bought a manual it would tell me these things.....i,m going to buy a manual now as i,m sure you guys have better things to do than solve my petty problems...but thanks all the same...you guys are the greatest.i,ll post the results tommorow night when i get home

 

[diggerdan17]

Re: clutch dog

well ..i,m back from the lake with mixed results.first of all i put in forward using remote shifter and went to wot...still had the bumping log effect...back to shore and remove water intake screen and adjusted linkage.back on the water i put in forward and went to wot...problem fixed i ran for 15 minutes and not one bump in the log effect.only problem is i adjusted the linkage to far and now when i put it in reverse it stays in neutral.so i very slowly increased the length of linkage adjustment so it would just barely go into reverse and back out on the water i went....now i have bumping the log effect....so i adjusted linkage back to where it will run without jumping out of gear and i will not have reverse...i am at my wits end.

 

[G DANE]

Re: clutch dog

Chances are you problem lies in remote control and/or cables. Clutch dog position should not be set by adjusting shift shaft position, this just have to be right from the start. I think your shift movement is too small. Clutch dog should move untill the ball lock in prop shaft holds in in one of the three positions. If it wants to jump out of gear because of worn lobes, cables wont be able to stop it. The stay-in-gear function lies in the lowerunit. Try to set shift shaft length properly, and adjust lever position so neutral is right up, by the screw in lever. Run it without remote, and I am sure you will have no problem. Trace down what is worn or binding in cables or remote, and you will be fine again.

 

[diggerdan17]

Re: clutch dog

sounds good g dane...i will try what you suggested .

 

[diggerdan17]

Re: clutch dog

i noticed from looking at the parts breakdown on brp site that i do not have a prop spacer and as a result when i put the prop on the nut will tighten down until it hits the end of the threads on the prop shaft and the prop can move back and forth on the prop shaft a half inch.....do you think this would cause the clutch dog to slip back a bit and cause my popping out of gear problem?i have gone ahead and remove lower unit yet again(i,m getting good at it )and taken out the gear set.i think i will go ahead and order a new dog and maybe a forward gear as well.i will take the old gear and dog with me to the dealer and see what the mechanic thinks of the minmal wear(or at least i think its minimal.also i read somewhere that i may be able to get a machine shop to true up the lobes on gear and dog...is this a wise move to try?

 

[diggerdan17]

Re: clutch dog

one more thing.i also noticed when i took gears out first time that the shift yolk that has the hook on it to attach to the shift lever...well the hook on shift yolk was kinda bent open...so i hammered back to a 90 degree angle and put it back together and water tested the boat.tonight when i took gears apart again i noticed that this hook on the yolk was bent open again...i wonder why that is?could i have accidentally bent it by using too much force when putting engine in gear?

 

[OBJ]

Re: clutch dog

Dan...drop me an email at outboardjim@comcast.net. Think I can help with some info.

 

[diggerdan17]

Re: clutch dog

okay....i finally got the parts i ordered..installed new clutch dog last night and went for a spin on the lake this evening..very happy to report that the problem is now fixed.....to anyone that may search for clutch dog info in the future,let me just say ,even if the corners on the lobes are rounded just a bit...the dog is NFG!<br />on a bitter note...i was on the water for 15 to 20 minutes...went up to get my pickup truck and noticed a nice pile of glass on my front seat.they cleaned me out....stereo,sage flyrod and reel,fishing vest with spare spools and 300 worth in flies and gear,cel phone c,ds, sat radio,lunchkit ,waders and the change in my ashtray...and ripped my dash apart.i didn,t expect my clutch dog to cost me 1200 bucks!

 

[OBJ]

Re: clutch dog

Glad to hear about the engine running well Dan... <br /><br />More sorry to hear about ya' gettin' ripped off. Man that draws major vacuum.....