1996 johnson 88hp spl - carb rebuild and lower unit replacement

[filth]

I have a 96 johnson 88hp that is leaking a small amount of fuel from the carbs when i pump the primer bubble on the fuel line. Also, the engine starts ok, and runs well while accelerating and top end, but constantly dies when shifting from neutral to drive in a slow or normal manner. I assume that problem is related to the carbs as they have not been serviced in the last 5 years. I am considering buying a shop manual and attempting this rebuild myself due to the high cost of outboard mechanics in the DFW area. Secondly, I have a 2 inch crack in the housing of the lower unit because a seal in it went bad causing it to fill up with water and then froze over the winter. I cannot afford a new lower unit but I am considering finding a good condition used one online and installing myself. The question is how difficult will either of these repairs be with a Clymer shop manual. Is it something that should be attempted or would it be more of a waste of time and money?

 

[MichaelP]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

I just rebuilt my carbs on a 1990 90hp Rude with no worries. It was my first attempt at a carb rebuild. No manual but got alot of good tips from this site. Look at the Top Secret Files on the top of this forum. Your about to hear the good folks here say to get a manual..An OMC service manual.

As for the lower unit..Just wondering if it could be welded...I'll bet someone here with more experience will chime in on that soon.
Good luck!

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

I have ordered a manual. As for the lower unit, I have been told that it would not be possible to weld it because it's aluminum, the crack is not straight enough, and the metal is badly bowed out from the ice that developed. It's junk. If anybody out there has a good condition used one please let me know. Ebay has one or two from unreliable or unknown sources, but they are coming from out of state and have been used in salt water, so it's buyer beware and I can't take the risk.

 

[SparkieBoat]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

watch craigslist/local sales paper...and check with some out board repair shops..you can get a new aftermarket foot for around $800..I would expect to pay from $200-400 for a gearcase in good condition..

 

[emdsapmgr]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

We aluminum weld replacement skegs on lower units all the time. If the lower is "junk," I'd be tempted to try and have the crack welded. Aluminum welding does not generate as much heat as metal welding-so it may not damage any internals or warp the case. You might find an expert who can run a bead down the crack. He may insist that the lower be stripped first, prior to welding. Once done, a pressure and vacuum check will tell you if it is leaking or not. Surely someone on this board has experience with this problem.

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

the case is already warped from the ice. Not only is the case cracked but there is. A sizeable gap between the crack and most of the side is bowed out.

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

Here is the latest. Boat mechanic in Houston says he can replace lower unit with his good condition used one and install new water pump, along with rebuild both carbs for 500. That's a bargain but its almost too good to be true. It would require 2 round trips to Houston (approximately 900 miles total combined mileage). Plus I would not have learned anything about working on my engine because I wouldn't be doing it myself. A deal that good is hard to pass up though, so what do you more experienced boaters and mechanics think I should do?

 

[SparkieBoat]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

900 miles..how much fuel cost is that?? rebuild the carbs yourself and find a good used foot near you..

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

Fuel cost would be about 200. Is foot another word for lower unit?

 

[SparkieBoat]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

foot=lower unit...yes..so then it will cost you $700 plus 2 days of driving..I can earn $100 a day easily so thats another $200 cause your time has to be worth something...bringing your total to $900...that is not much of a deal

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

I never thought about it from that angle. It makes sense now that you point it out. Thanks Sparkieboat.

 

[SparkieBoat]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

that what this forum is for..we all get emotional when making decisions..other people seem to be able to see our lives more clear than we can sometimes...God Bless...be patient and look around for a good used foot or get a new after market one...rebuild the carbs yourself...there are some great you tube videos on how to do it..

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

Ok so I just did a compression test. Readings are as follows: 110, 105, 110, 95. Are those numbers acceptable? Also, I have located a local foot so I will get a chance to learn and do the work myself.

 

[SparkieBoat]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

the 95 cylinder is borderline...you need to check the secret files on how to do a decarb...

 

[filth]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

Today I removed and carefully separated and labled all the parts for both carbs. I have read that the first step in dropping the lower unit is to remove the shifter rod bolt somewhere in the area of the lower carb. I cannot find such a bolt. This may be because I don't know exactly what i'm looking for or where to look. If anyone can advise me I would appreciate it. Remember I'm very new to working on an outboard and the motor i'm working on is a 96 johnson 88hp spl with power tilt and trim.

 

[SparkieBoat]

Re: 1996 johnson 88hp spl - carb rebuild and lower unit replacement

it is in the center of your engine on the carb side at the bottom...there is a rod coming up and a 3/8 hex head bolt holding it to the linkage