1983 johnson lower case removal-need help

[lutherhenninger]

1983 -7.5 hp - with 5 inch extension. Model j8rcta

I want to replace the water pump.

Removed all bolts and got case down 3/4 inch.
Flywheel still turns the prop.
The shift lever goes forward and reverse and turns shaft but is not engaged in gearcase.

What must I do next ? What did I over look. Tryed tapping the case to no avail. need help.

 

[Vic.S]

Re: 1983 johnson lower case removal-need help

Pretty much the same as my '84 6hp.

The shift rod should not pull from the gearcase... it is retained by a clip. It should however pull easily from the gear at the top.

I found that it was essential to take the 5" extension off with the gear case because the drive shaft will not pull through the bush in the extension until it is cleaned up.
then take the extension off to access the pump.

Attempting to pull the drive shaft through the bush in the extension will eventually pull it from the gearcase .... its not retained ... but as it comes the pump impeller key wrecks the pump housing.

Fit the extension to the leg first when rebuilding so that you can ensure that the water tube goes into the pump properly.

Recurring problem I have is corrosion around the grommet at the top of the water tube closing it over the top of the tube and cutting off the water flow.
Power head off as well to access that!

Not my picture but this is the grommet

 

[lutherhenninger]

Re: 1983 johnson lower case removal-need help

Still no luck pulling the gearcase down with the extension bolted on. Opening is about 7/8 inch. Don't know how much force to apply. See no way getting to top of shift linkage other than removing power head. Any suggestions appreciated.

 

[Vic.S]

Re: 1983 johnson lower case removal-need help

Surprised that the shift rod wont pull from the gear at the top. Also surprised it has pulled from the cam at the bottom unless the clip has come off. If that has come off I'm sure it will pull all the way out.

It seems unlikely to me that it is the shift rod causing the problem, more likely to be the driveshaft rusted into the crankshaft!

 

[lutherhenninger]

Re: 1983 johnson lower case removal-need help

Vic
We will try again. Possibly loading it up with wd 40 may help loosen the rust.

How much leverage do you think I could apply with out breaking anything?

I see drive shaft is splined and the shift shaft is cut like an L on both ends. The parts catalog does not show any pins or bolts where its connected to the motor or shift control.
Luther