1989 Johnson 88 SPL won't go into gear

[Eterzian]

After sitting for one year and in the garage, My engine won't go into gear- F or R. Not the cable- checked that. The gear arm in the upper engine compartment is immobile. I greased it and it still is stuck. I don't want to force it for fear that I will break the cotter pin or the lever itself. I have owned the boat for 8 years and never changed the gear oil in the lower unit. That is bad I know. Boat was working fine when I put it in garage, and I have never had any problems like this before. I am trying to flush the gear oil but those darn plugs are stuck. I'll get them eventually with an impact wrench. Will new gear oil potentially solve this problem or is it more complicated than that?? Thanks in advance.

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

Sitting for one year, the shift mechanism should not be frozen. So you can move the control lever (at the console)? When moving the control lever, the first thing that moves is the shift arm, then the throttle linkage begins to move.

Moving the control lever, when the motor is not running, you need someone to rotate the prop by hand. Otherwise the clutch dogs may not align, putting the shifter in a bind.

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

Sitting for one year, the shift mechanism should not be frozen. So you can move the control lever (at the console)? When moving the control lever, the first thing that moves is the shift arm, then the throttle linkage begins to move.

Moving the control lever, when the motor is not running, you need someone to rotate the prop by hand. Otherwise the clutch dogs may not align, putting the shifter in a bind.

Thanks DargelJohn! Yes it is the shift arm that will not move. When the control lever is hooked up the shift arm will not move, and when I disconnected the the control lever and tried to move the shift arm by hand it is stuck. The prop spins, but doesn't engage or seem to affect the shift arm at all. So that's why I was wondering if a gear may be stuck in the lower unit which would cause the shift arm to be stuck in the upper unit. Once again I am an amatuer but have some experience working with engines and tools and with this particular engine...

 

[guy74]

Re: 1989 Johnson 88 SPL won't go into gear

Welcome to Iboats!
First thing that come to mind from what you have told us is that this engine has not been maintained very well. When you try to move the linkage at the motor by hand, does it move at all or does it feel solid. If it wiggles a bit, that would indicate the the binding is somewhere other than the pivot under the carbs. Next, if the LU oil hasn't been changed in 8 years, it may very well be water instead oil, and everything inside could be rusted in place. I guess you need to get the plugs out and find out what is in there.

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

Yeah, @guy74- the engine "linkage" or what I was referring to aas the "shift arm" in the motor wiggles a tiny bit, but for the most part is solid stuck. It wiggles only because it is not totally tight inside its housing, but it is definitely locked in place. Wow it would be really bad if everything inside was rusted and frozen... Still haven't been able to get the plugs out so I'm waiting on that. Trying to obtain an impact wrench.

 

[guy74]

Re: 1989 Johnson 88 SPL won't go into gear

If the shift arm wiggles, it isn't corroded in place. On the back of that shaft is an arm that runs the linkage to the LU. It sounds like the problem is in the gearcase. I guess we will know more when you get the plugs out.

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

If the shift arm wiggles, it isn't corroded in place. On the back of that shaft is an arm that runs the linkage to the LU. It sounds like the problem is in the gearcase. I guess we will know more when you get the plugs out.

OK- got the plugs out with an impact wrench. Gear oil was dirty BUT plenty of it and virtually no water in it- at least as far as I could tell. But shift arm still won't move more than a wiggle. Now I am peplexed. I fully expected that the issue would be a dried out lower unit. Any ideas anyone?

 

[dahoopd]

Re: 1989 Johnson 88 SPL won't go into gear

Hello,

Not trying to highjack a thread but I have been searching for days and finally stumbled upon this thread that is exactly the same problem I have. My grandfather gave me an 89 sunbird with the 88spl on it. The boat mechanically was taken care of for the most part but my grandfather has gotten to a ripe old age and doesn't want to mess with it anymore. He gave me the boat for the same reason. It wont go into gear. I have removed the cables and they move fine. The shift rod wiggles a bit but will not go into gear. Anyway, I have subscribed to the thread in hopes that Eterzian and I find help. Thanks again. I posted a pic of what the boat looked like I got from my grandfather and what it looks like after I wet sanded and buffed.

(I hope you don't mind Eterzian)

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

Next thing I would do is pull the lower unit off and see if you can get the shift rod to move up/down while turning the prop shaft or verticle drive shaft.

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

That's quite a transformation dahoopd. Lots of elbow grease.

 

[crappie14]

Re: 1989 Johnson 88 SPL won't go into gear

I had a similar problem with lower unit purchased (take-off) for a 1990 SPL. Luckily since the lower unit wasn't installed yet and I did check it before installing. The shift lever on top of the lower unit had a rubber boot over it, under the rubber boot was white I would describe as white corrosion, much like you would expect to see around your battery cables. I removed the housing the shift lever goes thru, and I could pull up and easily get it into forward or reverse, whatever it up, could easily put back in neutral by pushing down. I counted the turns and removed the shift rod out of the lower unit. Freed up and best I can remember purchased and installed new seal and gaskets, put it back together and reassembled the rod by once again counting turns. I had the manual and verified the shift height and it is still working today.

Don't really know why but the stainless rod was basically welded to the housing from the corrosion. Hope this helps.

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

Sounds like the sacrificial anodes were not doing their job... Disimilar metals will cause corrosion.

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

Crappie14- this sounds like what I am probably dealing with. I have never removed a lower unit before- 1. Is it a huge job?? and 2. Where can I see a schematic or parts diagram in case any of these internal parts are unsalvageable?? I love working on engines, I just want to know what I'm getting into before I do it...

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

Hey dahoopd-
Wow your boat looks amazing!!! Only if the engine would work now huh?? So frustrating... Anyway- looks as though I just need to pull the lower unit as "crappie14" said and go from there. I'm a bit scared b/c I've never done it before, but I figure if I really can't get it back together I can just pull in a professional to do the work. I will continue to post on this thread my progress and we'll see how it goes! Thanks to everyone who has responded- this is forum is a great help and a great idea!!

 

[dahoopd]

Re: 1989 Johnson 88 SPL won't go into gear

Thank you for the kind words, its a work in progress. Its my first boat aside from jon boats. I dont want to take away from Eterzian's thread, just having the same exact issue.

May I ask what and where the Anodes are? I have a wire that looks to be a small ground wire that has corroded and fell off the back of the motor. Would that keep the motor from shifting?

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

Hey dahoopd-
Wow your boat looks amazing!!! Only if the engine would work now huh?? So frustrating... Anyway- looks as though I just need to pull the lower unit as "crappie14" said and go from there. I'm a bit scared b/c I've never done it before, but I figure if I really can't get it back together I can just pull in a professional to do the work. I will continue to post on this thread my progress and we'll see how it goes! Thanks to everyone who has responded- this is forum is a great help and a great idea!!

To remove lower unit...

Basic Steps:
-Disconnect the top of the shift rod from the linkage.
-Tilt the motor way up.
-Remove the Prop
-Remove the adjustable Trim Tab (mark across the Tab/Lwr unit surfaces so you can line it upon reinstallation).
-Remove the bolts that hold on the lower unit (there's a bolt up inside where the trim tab goes).
-Slide the lower out. Careful not to twist or bind the drive shaft/shift rod.
-When sliding the lower unit back in place, pay close attention to the exhaust housing segment seating and make sure the water tube aligns with the water pump. May have to wiggle it a little so the drive shaft splines go into the engine. It helps to have a second person during this part.
- Bolt up the lower unit, Reinstall the Trim Tab, prop, lower the engine and reconnect the top of shift rod.
- Crank up the engine, on the water muffs, and check for normal water flow.

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

dahoopd, Item #74 is an anode. There is also an anode on the stern bracket. In order to function properly, anodes need to be clean, metal to metal contact with the housing. You can acess #74 anode bolt under the trim tab plate.

The wire is a ground between the outboard and the swivel bracket. In order to replace that wire, I believe the powerhead has to be pulled.

http://www.boats.net/parts/search/BRP/JOHNSON/1996/J88TSLEDR/GEARCASE/parts.html

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

Wow- thanks DargelJohn for all the info- I think I'll start today! I think the hardest part will be the fact that the fundamental issue is that the shift rod is immobile so getting that disconnected will be more difficult than if it was mobile. And im assuming that I'll have to remove the carbs first to get to the linkage bracket- which I've never done before but does not look difficult. That parts diagram link you posted was great! It should come in handy.

 

[Eterzian]

Re: 1989 Johnson 88 SPL won't go into gear

Thank you for the kind words, its a work in progress. Its my first boat aside from jon boats. I dont want to take away from Eterzian's thread, just having the same exact issue.

May I ask what and where the Anodes are? I have a wire that looks to be a small ground wire that has corroded and fell off the back of the motor. Would that keep the motor from shifting?

About that corroded wire- I am a novice here as you know but I would guess that the wire is definitely not why the shift rod will not physically move...

 

[DargelJohn]

Re: 1989 Johnson 88 SPL won't go into gear

Wow- thanks DargelJohn for all the info- I think I'll start today! I think the hardest part will be the fact that the fundamental issue is that the shift rod is immobile so getting that disconnected will be more difficult than if it was mobile. And im assuming that I'll have to remove the carbs first to get to the linkage bracket- which I've never done before but does not look difficult. That parts diagram link you posted was great! It should come in handy.

No need to pull the carbs...My current motor is a '96 88SPL and I've done this job before. Take your time...

Disconnect the shift cable (Green arrow), pull the clip out (Yellow arrow), then push in and twist the shift arm (Red arrow).

On reinstallation, I use a straightened clothes hanger, with a small hook bent in the end, to help line up the top of the shift rod.