1959 Evinrude Lark rebuild has water intrusion in lower unit

[Allenstark]

After rebuilding the entire electrical and fuel system the motor runs and sounds good. There was obviously some water in the lower unit so I replaced the impeller and seal and pushed the oil back in. When I started the motor for a water test I didn't have any water coming out the exhaust and the motor was getting hot. I had replaced the thermostat and seal but could hear what sounded like a hissing from the thermostat. The impeller appeared to be in backwards and I had thought it would straighten itself out. When I went back in reverse the impeller I found water again in the oil.

The control arm shifter seems loose where it goes into the bottom part. The manual shows what looks like a bushing , o-ring, and washer. Does anyone know how these assemble or how to keep oil from coming up along the shifter rod?
THanks

 

[HighTrim]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

Im a bit confused by your post. Which is not hard to do at 2am, lol

What do you mean by pushed the oil back in? When you reserviced the water pump, did you redrain the oil, and then notice the water intrusion?

 

[Allenstark]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

By pushed in I mean new 90w oil refilled into lower. I think I need to push a bushing out, replace that, the o-ring, and the washer along the control rod. Not sure if you just take a screw driver and drive it the opposite way out but if some has done it please let me know. Also it appears I need to double seal where the drive shaft is just under the impeller. The old one was twice as thick as the replacement part. Notice I have what appears to be a hairline crack and I'm wondering if JB weld will suffice in pic 2.
Happy st. Patty's day!

 

[HighTrim]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

Ok the seal for the shift rod consists of an o ring and a gasket. The o ring is part number 0301877

Evinrude Johnson OMC 0301877 - O-ring @ MarineEngine.com

...and the gasket is part number 0304764

Evinrude Johnson OMC 0304764 - Gasket @ MarineEngine.com

There is a bushing which holds these in the casting. The bushing needs to be driven out with a special tool. You can purchase this tool from F_R on this forum, or you can try to fabricate one from rod yourself. Others have driven the bushing out with a correct sized spade drill bit, but have only used the tool myself.

Here is the oil seal beneath the water pump for the drive shaft.

Evinrude Johnson OMC 0313284 - Oil Seal @ MarineEngine.com

The pics below should help with the shift rod seal

 

[Allenstark]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit



Ah! So that is what a repair manual looks like. Very kool, thanks. The cracks do not go all the way down the surface wall but I have no idea what types of pressure are occurring in the water pump area. What do you think about the the JB weld band aid to address the hairline crack?
I added a picture of what the 1959 14ft mckenzie and 35hp Evinrude looked like when I started the project.

 

[nwcove]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

am i seeing 3 cracks? ...one at the 6 oclock, one at the 4 oclock, and one at the 1 oclock positions?

 

[HighTrim]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

I myself would try it. There is not a ton of pressure there. I wonder if it sat outside laying on its side with water in it over the winter and cracked? '

What is the model number of your motor? I have the same one, as a long shaft.

 

[Allenstark]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

There are three cracks in that one area and now I see a fourth. The engine is the short model 35516.

 

[Allenstark]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

So I drilled out the weep hole and replaced the brass bushing with rubber o-ring that seals the shift control lever. I did what probably a poor mans oil pressure test by trying to force oil up thru what I think are the only two places for oil to raise up. That is the shaft which the new impeller sits on and the control lever. All new seals, bushings, gaskets and the prop seems to shift from fwd to rev fine. The motor runs what sounds to my ear as good. The cooling water is circulating out the tube and I'm about to have cool one.
Then I see oil in the bucket, quite a bit of oil but its not clear to me where it's coming from. It's in the weep hole and what appears to the exhaust area. I've taken a picture looking up into the exhaust chamber and think I see holes around the two water inlet grommets. Is this why I have water and oil mixed and should this area be sealed off from the bottom? I still don't know how the oil is getting up into the upper part of the lower unit. Ideas much appreciated.

 

[nwcove]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

90% of the time, its just unburnt fuel/oil mixing with water in the midsection. it will drip from the drain holes, and anywhere else it can find .

 

[Allenstark]

Re: 1959 Evinrude Lark rebuild has water intrusion in lower unit

Do you know if those are broken areas of metal where the two rubber water grommets are located?
I'm not sure if that area above the shifter connector should be solid. Last night I performed an upside down oil leak test and things seem tight in the lower unit.
Thanks