79 Johnson 115 - Lower unit STUCK - Now What?

[rdenis]

Okay, I am about 99.9% certain my drive shaft is rusted into the crankshaft spline thus preventing my lower unit from coming out. I tried a block of wood and mallet, tried wedging/prying but I don't want to break something. She won't budge.

I'll let it sit overnight and hope gravity does its thing but I am not optimistic.

I really don't want to play tug of war with the powerhead at this point but I fear that is the next step unless someone else has a less drastic solution.

Rich

(Cussing my father in law for never once having the lower unit removed in 25 years. And cussing myself for not having removed it in the 5 years since we've had it.)

 

[tashasdaddy]

Re: 79 Johnson 115 - Lower unit STUCK - Now What?

hang motor up side down, power head is heavier than lower. lots of PB blaster thru the space between lower and mid section.

you did get all the bolts out? ( the one underneath the fin) and disconnect the shift rod?

 

[rdenis]

Re: 79 Johnson 115 - Lower unit STUCK - Now What?

Ahhuugh - I knew this was going to be a PITA. Any tips for disconnecting and lifting the motor off the transom? This motor has a built in lift hook.

Once its upside down, should I empty a can of PB Blaster in there and then wait for gravity to work?

 

[rdenis]

Re: 79 Johnson 115 - Lower unit STUCK - Now What?

So this all started because I had milk in my lower unit. Knowing it needed to be addressed sooner than later I thought, I've got some time now might as well. First step was to remove the lower unit for inspection and pressure/vac test to find source of leak. Well as shown by the title and my first post in this thread, she is stuck good. I tried all of the conventional wrestling moves but still no go and knew in the back of my mind I was going to have to get this motor upside down.

Yesterday was Day 2 of the saga - I started by ordering a lower unit seal kit and water pump kit from TCMarine since they were the only ones who could get me the parts by Wednesday. Not having the OEM manual and not being able to confirm the source of my leaky gearcase I needed to order nonetheless - so hopefully I've got the right parts coming.

Anyway onto the engine removal. Yep this is a serious PITA for a 30+ year old boat and motor that has never had anyting removed - I had visions of bolts snapping, plywood ripping, etc. My approach was nice and easy, don't force anything and work with the ol gal instead of wrestling if at all possible. 11pm last night finally got the motor control lines disconnected, power tilt trim cables disconnected, steering linkage removed (had to do that in conjunction with lifting the motor off the transom - despite the trim tube being gunked up a little gentle pursuasion freed it up). Went to bed after that as my brain was fried so I free hung the motor back on the transom overnight.

Woke up this morning and immediately went to work designing an engine stand that will alow me to flip the motor 180 degrees and then allow me to hoist it by the petard (aka lower unit). Off to build the stand and then will dump a can of PB Blaster in to do its work (along with gravity) to free up the drive shaft from the crank housing.

FEDEX tracking ETA is Wednesday 5pm PDT so that gives me a little over 24 hours for the PB Blaster to do its thing. Need to reassemble Thursday and then hit the water Friday. At least that is the current IF EVERYTHING GOES ACCORDING TO PLAN philosophy which thus far has proven wildly inaccurate.

I'll post up some pictures once I've got her all done in case it might be of assistance to others in the future.

Wish me luck.

 

[t3thomas]

Re: 79 Johnson 115 - Lower unit STUCK - Now What?

Not exactly sure of your motor, but if it has a spring clip which connects the shift linkage to the drive shaft, the clip has to be removed and then the shift linkage pushed inward to release the shaft? Just a guess of what might b holding it since all of the parts your talking about are stainless.

 

[rdenis]

Re: 79 Johnson 115 - Lower unit STUCK - Now What?

Its just an old fashioned pin bolt which secures the shift rod to the linkage just under the carbs. Nothing else holding the drive shaft in the spline at this point other than 30 years of neglect.

But I'll beat this puppy yet - gotta go get some heavy duty screws from Home Depot and then motor should be upside down within the hour.

 

[rdenis]

She's FREE

She's FREE

Getting her upside down and PB Blaster did the trick - now to find the leaks.


I also found some sand on the outside of the copper water tube, not much but....?