1962 johnson 75 hp lower unit overhaul pictures plus cutaway view

[Kohrah]

Greetings fellow iboaters,

As many of you know I just purchased an older boat and engine. I knew buying it that I would have some work to do it before I splashed it. And this winters project is going to be overhauling the engine.

This will be my first overhaul of an outboard engine or any marine engine for that fact. I've scanned many different threads as well as the top secret file on the main page. (i've printed out numerous pages of info from many of the more knowledgeable guys here) I have a repair manual on order and it's currently in shipping hopefully it gets here soon.

Onto the problem at hand. Pulled the vent plug to check lower unit oil level and found nothing. hmm ok so pulled the drain plug with a bucket under the engine to catch whatever comes out. I was greeted with a mixture of approx 50% water and 50% oil. Ok so I know one or multiple seals are leaking. I have a seal kit on order and waiting for that as well from our good friends here at iboats.

Now onto my main question. I plan on thoroughly reading the manual before diving into this adventure as it's one of the best sources of info, but the first best source, in my opinion, is from other guys and gals who have actually ripped into these engines before. So my question is this, are there any tips, tricks, or any potential hang ups that i should know about, that you could pass onto this "yung'in"?

Also I will be posting pictures as I go along this adventure, as i'm sure it will be just that an adventure.

Thanks in advance for any help and encouragement.

 

[Daviet]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

I can't think of any tips to pass on, just make sure and read the section of the manual that you are getting ready to do a couple of times. Don't be afraid to come and ask questions if you don't understand something, I read all the time where someone caused more work or problems because they didn't understand something and guessed on something and was wrong.

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

I know from working on my cars that there's little tricks here and there to keep from busting a knuckle or causing more work, once the manual comes in i'm sure i'll be updating this thread with numerous questions

 

[62 ROYAL SCOTT]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

Hell-o I'am glad to read about your project. Hope everything goes smooth. Just take you time ,don't get in a hurry It sounds like you are starting in the right place These people know everthing and will be glad to help you. I too will be seeking help when i start my overhual. [ 62 ROYAL SCOTT 43.7 CUSTOM ] that's what i like about iboats . please POST PIC'S FROM THE START. THANKS

 

[Kohrah]

Thanks Scott, I plan on chronicling my experience (with plenty of pictures) both here and on the blog i've setup, if anyones interested ill gladly send them the link.

Sent from my DROIDX using Tapatalk

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

ok have another question here. just got my shop manual in and was beginning to read about how to remove the lower unit/gear case and how do I tell if the engine i'm dealing with is an electric shift or hydro-electric?

Started reading both and the removal differs

 

[62 ROYAL SCOTT]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

HEY,Is it v4s-14 or a v4a-14 so i know what iam looking at

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

v4al-14l is model number sorry for delay i'm currently at work on the overnights. figured now was a good time to get some reading done

Ok update here got some of the pictures off my phone. sorry for quality, a) it's a phone camera b) it was starting to get dark so trying to hold phone and a drop light to take pictures not always the best.



question about the lower unit. I've circled the area in red (not sure how well it will show up) but it looks and feels like plastic that I have no idea what it would be for. Or if it's for a coverup repair job.

 

[Kohrah]

Well ok as you can see in one pic I've drained the lower unit oil. Passed a rare earth magnet over it with some cellophane to protect it. No metal frags were picked up which is a bonus.

Sent from my DROIDX using Tapatalk

 

[F_R]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

ok have another question here. just got my shop manual in and was beginning to read about how to remove the lower unit/gear case and how do I tell if the engine i'm dealing with is an electric shift or hydro-electric?

Started reading both and the removal differs

Hydro-Electric had not been invented yet in 1962. A better question is if it is Electramatic shift, or manual shift. Answer is easy--does it have a shift lever on the side? If it does, it is manual shift. No lever, it is Electramatic. You need the proper control if Electramatic $$$.

That nose job may be serious. If it is a result of a wound that goes clear through, you have a problem. At any rate, the putty repair will bust off the first time you run over something, like a floating object.

Potential tips for the repair depend on the same question---Electramatic or manual?

 

[Kohrah]

Its an electric shift model as I found out tonight. I've begun pulling the lower unit apart. I've been putting each set of bolts in zip lock baggies and using permanent marker to write a short description of where I pulled them from. I've also been taking pictures of anything and everything as I've ripped into it.

I've managed to drop the unit out, remove the exhaust extension and water pump. The impeller looks decent but im replacing it anyways as I've got it opened.

As to the nose job im looking around for a parts motor that I can scavenge parts from including a new gear housing. As you said the putty repair could ne serious so while I have it apart im gonna replace it.

My list of stuff keeps growing as I rip into this engine more and more lol but I love old engines.

Pictures to come later as im not sure how to upload em directly from my phone

Sent from my DROIDX using Tapatalk

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions


The two access panels for feeding the wires for the electric shift.


Lower Unit removed and sitting on some concrete blocks for time being.


Close up of a part i'm sure i'll forget where it goes when i rebuild it again atleast this way I'll remember. Sitting on top of the extension housing.


Extension housing taken off and sitting on the ground/cardboard.

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions




Two views of the water pump housing with the extension housing removed.


A look inside the water pump with the impeller and the direction for the fins. I'm currently leaving the old impeller in the housing until I have the new one in my hand and ready to go in.


water pump and impeller taken off. Down to bearings and seals now. Time to go re-read the manual for a third time from this point on. Also had to stop at this point as Life got in the way and had to finish cleaning up the barn and also do some laundry for the week. Once I get a chance to get back to work on it I'll update some more. So far it's been fairly easy going and easy to understand.

 

[F_R]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

Be careful when you separate the upper and lower gear housings. If the lower is allowed to drop, it will yank the coil wires in two. They are not solderable or repairable. In fact, I have one that somebody did that to and the wire guard bent and I cannot get it out nor disassemble the rest till I do.

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

ahhh thanks F_R that's a good point to know. I'm reading here in the disassembly portion of the manual that it says to block it by the skeg which would keep that from happening. Good to know why.

 

[62 ROYAL SCOTT]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

hey so far so good.[old saying ] I think

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

question before i begin posting more pictures. I have a lead on a parts engine, mine is a 1962 electric shift model, the parts motor i'm looking at is a 1961 manual shift. Am I still able to use the gear housing from the '61 for my '62 engine? If I purchase the parts motor so far i'll be about 750 into the boat.

EDIT - MOARRRR pictures


HAHA drive shaft and thrust bearing removed.


hmmmm seems something is missing from this bearing......


Lower gear case loose from upper case.


fuzzy picture I know but the silver gob of crap is hiding a half arsed repair job on the electric shift cables


removed the silver gob of crap to reveal how badly sliced the cable actually was.

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions


oops dang it all guess i'll have to repack that bearing at the very least. I did find all the pieces so I can rebuild it. :facepalm:


HAHA success the lower gear case is separate.


forgot to take a shot of the silver crap that they used to try and seal around the wires but when I removed it found this chunk of metal. Any clues what it could be from? It's attached to something because the gears still spin without interference. but I dunno on this one.


another picture of the chunk of metal.

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul questions

Re: 1962 johnson 75 hp lower unit overhaul questions

in disassembling the lower gear case today I discovered that the piece of metal actually had a use as a plate/cover for the forward coil wiring so that it didn't get chewed up in the gears. I learned something today WOOHOO

Now onto the pictures of today's adventure....


Gearcase cover removed (sorry at work so technical terms are not at hand)


Reverse snap ring, you are the devil even with snap ring pliers


reverse coil removed


ohh look there's a washer/spacer ah dang it all picture time


reverse coil and snap ring removed time to pull the prop shaft and reverse gear.

NOTE at this point my picture taker extraordinaire (AKA my girlfriend) had to goto work so the amount of pictures from here on out tonight isn't as many and further between stops. I didn't want to keep cleaning my hands after every step to snap a picture unless there was a part I wasn't sure about.

 

[Kohrah]

Re: 1962 johnson 75 hp lower unit overhaul pictures included

Re: 1962 johnson 75 hp lower unit overhaul pictures included


Prop shaft removed with reverse gear still attached.


hmmm pitting on the prop shaft. Is this serious? should I look for a new shaft? the drive shaft is pitted same way too.


Pinion gear. book states to tip it towards rear of housing to remove.... I beg to differ or maybe was just me but it was a witch to remove kept hanging up on the forward gear.


Forward gear


Forward gear top view.

There is surface rust on some of the parts such as the pinion gear and forward gear. I figure taking a green scrubby to it and than a soak in parts cleaner before installing it in their new slightly used gear case housing. I have gotten it down to point that I can see the inside of the repair job on the gear case and I'm glad I am not using this gear case and ordered a new one.

Although I still need to remove the forward coil and bearing. Manual states to use a suitable puller...... that's real helpful... the dang thing doesn't want to budge, any tips, hints or tricks on how to remove that sucker?