'66 Johnson 80 popped out of forward

[riktweed]

Our '66 80hp Johnson popped out of forward yesterday while cruising at about 3/4 throttle, at first just for a second so we thought maybe we had hit bottom, and then later it popped out and would not re-engage. We still had reverse.

There were no odd sounds, only that suddenly the motor was in neutral and would not go into forward. This motor is electric shift.

Has anyone else had this happen, or any ideas on what would cause this? I thought perhaps it was the electric shift actually putting the transmission in neutral or rather failing to hold it in forward?

Thanks for any input!

 

[Joe Reeves]

Re: '66 Johnson 80 popped out of forward

NOTE... That unit demands what is called Premium Blend gearcase lube, also known as Type C. If you're using the standard HiVis lube or anything else, therein lies your problem. Also, I'm assuming that there is no water in the lower unit.

Check to see if you have 12 volts at the engine harness shift wire where it connects to the shift wire leading to the lower unit. The forward wire should have a green color to it, reverse is blue.

If 12 volts is present at that location, disconnect the wire and check the resistance of the forward gear shifting coil via that green wire. It should be approximately eight (8) ohms.

If the above checks out as they should be, either the forward gear shifting spring is slipping on the shifting hub OR the spring has broken.

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

Thank you - we will start with checking the gearbox fluid and then the electrical circuit.

Your advice is greatly appreciated.

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

After getting another message regarding the need to use Type C fluid I checked what we had used to refill the case recently and it is not the right stuff. In fact, it says on the label, "Do not use in OMC electric shift gear cases."

We will drain and refill with type C for sure this time. Hopefully no damage and normal operation will return.

 

[Joe Reeves]

Re: '66 Johnson 80 popped out of forward

And from hereforth on, we shall always read the label huh? (grin)

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

And from hereforth on, we shall always read the label huh? (grin)

OK, that was called for!

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

We changed out the gear case fluid with fresh type C (no water present), then checked the voltage at the green and blue shift wires. We had between 9.5 and 11.5 volts going into reverse and then forward, respectively.

Still no forward engagement, however. The prop spins while idling in neutral, and when forward throttle is increased it spins faster but you can stop it easily. Reverse is solid.

We are not sure we want to attempt this gear case repair ourselves and thought someone might recommend a shop to which we could send the gear case for repair/rebuild.

Any recommendations would be appreciated. Thanks!

 

[Joe Reeves]

Re: '66 Johnson 80 popped out of forward

That voltage is low! Before going into the lower unit, run jumper wires directly from a good known fully charged battery to those shift wires (at the powerhead) leading to the lower unit.

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

We swapped the leads and determined that voltage wasn't the issue. We are planning to attempt replacing the forward spring ourselves and will check the coil while we are at it. We have the shop manual and it looks like we will need a puller and long snap ring pliers, but since the bearings are OK that should do it for special tools. Feel free to chime in if you have done this job and learned anything we should know.

Found the spring new for $150, used for under $50 on ebay.

 

[F_R]

Re: '66 Johnson 80 popped out of forward

You must use an accurate torque wrench to tighten those two stud nuts. A special tool is required if you have to replace the forward coil. You MUST be careful when separating the upper and lower gearcases. If you let the lower drop off, it WILL rip both coil wires in two, and they are not repairable without replacing the coils. You MUST use the high strength Locktite on the setscrews holding the clutch spring. May have to heat it to 300 degrees in an oven to get the old ones out.

Um....you are in Sarasota? Salt water, huh? Good luck getting that gearcase apart. A hacksaw is the usual tool. I'm in Sarasota too and have used the hacksaw method more times than I care to remember.

 

[jere1972]

Re: '66 Johnson 80 popped out of forward

FYI If looking for a great OMC MECH to help you with that gear case, contact Gary Fisher @ Gary's Marine (New Port Richy Florida) Garysmarine.com .....He should have everything in stock for those older engines one of the few OMC shops in the country that does! and as honest and Experienced as they come!

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

Thank you sir - the corrosion factor is not too bad. It is a fresh water boat that we have had in saltwater for only a short time. We still expect resistance having rebuilt the impeller assembly and replaced the heads earlier. We appreciate the tool insight and caution on the wire situation.

We are also getting estimates on the work and may go with a pro if not too painful. See you on the bay if all goes well.

You must use an accurate torque wrench to tighten those two stud nuts. A special tool is required if you have to replace the forward coil. You MUST be careful when separating the upper and lower gearcases. If you let the lower drop off, it WILL rip both coil wires in two, and they are not repairable without replacing the coils. You MUST use the high strength Locktite on the setscrews holding the clutch spring. May have to heat it to 300 degrees in an oven to get the old ones out.

Um....you are in Sarasota? Salt water, huh? Good luck getting that gearcase apart. A hacksaw is the usual tool. I'm in Sarasota too and have used the hacksaw method more times than I care to remember.

 

[riktweed]

Re: '66 Johnson 80 popped out of forward

FYI If looking for a great OMC MECH to help you with that gear case, contact Gary Fisher @ Gary's Marine (New Port Richy Florida) Garysmarine.com .....He should have everything in stock for those older engines one of the few OMC shops in the country that does! and as honest and Experienced as they come!

Thanks! We will contact Gary and see what he thinks before we dive in.