95 - 60hp Johnson, gearbox removal issues

[Fury]

I am replacing a waterpump on my brothers 60hp, but have encountered some problems.

The main one is I cannot disconnect the shift rod. I believe there are 2 differing sorts, one with a bent upper shaft, sitting in a connector under the powerhead, and the other is on the rhs with a pin arrangement.

This one is right under the powerhead. Do I need to remove all the accessory parts, ie carbies, hoses and electrical equipment to get to this? Any tips or tricks?

It looks difficult to get to, but it is the only thing left to do for disconnecton.

It seems the shape of the shaft is bent or hooked in some way and also looks like it is a difficult fit through the gromet in the base of the engine case housing.


This is a photo of the item...

Also snapped off the bolt under the trim tab, but I have searched other threads on that and have found ideas for it's removal
Thanks

 

[Okee Jimmy]

Re: 95 - 60hp Johnson, gearbox removal issues

Hello Fury, you do not have to remove any accessories to disconnect the shift rod. All that is necessary to disconnect it is to remove the hairpin clip on the starboard side of the motor (shift linkage) and push the linkage towards the port side. The shaft will slide in and disconnect the pin that is going through the shift rod in your picture.

Hope this helps, Jimmy

 

[Fury]

Re: 95 - 60hp Johnson, gearbox removal issues

Thanks Jimmy, I will have another look for this clip, it obviously must be there, although the manual states this as well - I cannot see it. The manual has a drawing of this clip, but the drawing and the shift lever seem to be different enough to seem like that it is another system

It seems like a solid shaft connected too the control lever - hense, my original description of perhaps 2 differing types of connectors...

Perhaps the pin has been removed previously or has been replaced with a split pin - but there seems to be no hairclip pin ( anywhere near on ) the shift linkage.

As I said, Ill have another good look. Thanks for confirming what I was looking for in the manual.

 

[Okee Jimmy]

Re: 95 - 60hp Johnson, gearbox removal issues

If the clip has already been removed, you should be able to see the hole in the shaft where it goes through. Try pushing in on the shaft that connects to the shift rod lever in your picture, it should slide in if the clip is out. If this doesn't work, please post the model #, and myself or someone else can look at an exploded view in a service manual to see if this model has a non-standard shift linkage.

 

[Fury]

Re: 95 - 60hp Johnson, gearbox removal issues

Thanks again,
Ill have another good look and also try pushing in from the starboard side. I won't be around there again till next week, but I will see if I can get a photo of the starboard side. I know there was a mix up with getting the correct waterpump, (It is between 93 and 95) - as the actual model number ( on tilt bracket) had corroded and is unreadable. The waterpump was tracked down via the serial number ( confirmed by numbers stamped on the block)

Once again, thanks for your help, it is appreciated.

 

[Fury]

Re: 95 - 60hp Johnson, gearbox removal issues

Thanks, the clip was NOT there, but the hole was - so obviously it hadn't been put back after the last time the gearbox was off.

Waterpump is back on, and reinstalled ( with a new shaft clip- that linkage shaft took some lining up to get back on under the powerhead...)

Now I have other issues, such as major flooding. Wont start too much fuel - so much it is comming out the exhaust
I see a new thread in my future ... how to recognize and adjust the choke.