Advise on taking a gear case apart. 35HP Johnson

[GLORY]

I bought a 35HP 2 years ago and manage to rebuild the motor and respray the 'body'. It's looking good and the motor is going well, but the gearbox jumps out of fwd gear as soon as it takes a bit of load. Allthough I rebuild just about everything I somehow are reluctant to do the gear case, but with some help I shall try. So please don't hold back I need all the advise I can get and no I dont have a Manual. Had one when I did the motor, but there was not much in off the gear case.

 

[F_R]

Re: Advise on taking a gear case apart. 35HP Johnson

Care to tell us what year this 35 is?

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

It is a 1979 model. Model number 35R79A. Thru exhaust lower unit.

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

It is a 1979 model with thru exhaust. Model number 35R79A.

 

[tx1961whaler]

Re: Advise on taking a gear case apart. 35HP Johnson

If it sounds like you hit a log when it jumps out of gear, then it is likely the clutch dog and/or forward gear that is worn. It could also be the shift cable out of adjustment, but that can be checked by disconnecting the cable and manually shifting it. A spun prop is when the motor seems to rev up but not go forward at mid-power. But a spun prop is usually smooth, not a bang.

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

I only use the manual shift on the motor. If I hold it down(keep a force on it) in fwd gear then it sounds like it's hitting logs, because if I don't then it jumps into neutral. The motor was fine after the rebuild and has only started doing it lately. - after I pulled the kids on a tube. think I overloaded the gearbox, but then again it is a 79 model. Thanks for all the feedback.

 

[1946Zephyr]

Re: Advise on taking a gear case apart. 35HP Johnson

Has this lower unit been off before? I think this is the type of lower unit, where you turn the shift rod clockwise to adjust the shifting to pull harder into forward gear. I haven't worked on many of these, but that's the last I heard.

 

[Joshua Nichols]

Re: Advise on taking a gear case apart. 35HP Johnson

I had a old rude(Not near as fine looking as your smoker) that use to do the samething.. I could hold the lever and could make it go..

Took the lower case apart. There was a lever in there that moves the cluch dog to change the gears.. It was broke..
This was many moons ago.. I was only like 16 years old.. Still yet was pretty handy with a wrench and did it myself with no manual..
I looked at the parts in your lower and it looks to have the same part in it.. I would bet ya thats the problem... GOOD LUCK

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

Yes the lower unit has been off a few times. At the start of my problems I had a issue with the shiftrod, the connector was loose so it did not pull it fully into fwd gear. With that fixed it went ok for a few times then it started jumping out of gear. It would just be nice to get into the gear case to see what the problem is. Does anyone know how to get the bearing housing out? Do you have to turn it and pull or do you just pull as hard as necessary? Don't want to brake it.

 

[dew2]

Re: Advise on taking a gear case apart. 35HP Johnson

Once the bolts are removed it should pull right out (Bearing housing)

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

Thanks I'll go and try that

 

[jeremyswallace]

Re: Advise on taking a gear case apart. 35HP Johnson

do you have to have a special pulling tool to get it out

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

do you have to have a special pulling tool to get it out

This is the puller i made to pull the bearing housing from the casing. I had to use penetrating fluid, some heat and a few taps with the hammer to get it out.

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

OK finally I got the gear case apart. Wasn't that bad afterall. Thanks for the tips. I attached photos of the gears and clutch dog. To me they don't look to bad, but i'll leave it to you experts to decide. Allthough some of the edges are a bit round, I would think thats normal because thats the side that engage then you put it in gear. If the clutc dog is fully engage I cant see how it would slip out, unless the shift rod is not properly adjusted. Thats my theory anyway.
. Wait on you guys to tell me the next step.
Please note that the rev and fwd gears are labled wrong. (pictures)

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

Photo of the clutch dog in the disengaged position

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

Well because of the rounded sides on the clutch dog I think I should just go ahead and get a new one, while it's open. Found a few bits of a bearing casing ( that was replaced on the big rebuild, just below the waterpump) among the gears that might have prevent it from going into fully fwd gear.

Does anyone know where I could find a clutch dog, cheap?

 

[peter94]

Re: Advise on taking a gear case apart. 35HP Johnson

Hey I was just wondering if this ever fixed your problem? I was also wondering what others though of your clutch dog.

 

[dew2]

Re: Advise on taking a gear case apart. 35HP Johnson

OK finally I got the gear case apart. Wasn't that bad afterall. Thanks for the tips. I attached photos of the gears and clutch dog. To me they don't look to bad, but i'll leave it to you experts to decide. Allthough some of the edges are a bit round, I would think thats normal because thats the side that engage then you put it in gear. If the clutc dog is fully engage I cant see how it would slip out, unless the shift rod is not properly adjusted. Thats my theory anyway.
View attachment 92882View attachment 92883View attachment 92884View attachment 92885View attachment 92886. Wait on you guys to tell me the next step.
Please note that the rev and fwd gears are labled wrong. (pictures)

The clutchdog looks pretty bad,the gear is rounded,You can on that clutch dog turn it around and use the good ears,It looks as though you may be able to use the gear with the dog turned around BUT seeing its rounded it will ruin the good side of the dog in time.I'd replace the F gear and turn the dog end for end.E bay is a good place for a fairly low cost gear.

 

[wilde1j]

Re: Advise on taking a gear case apart. 35HP Johnson

The reason for failure isn't overload, it almost always either a) poorly adjusted shift mechanism or b) poor shifting technique, with 'b)' the winner over 90% of the time. Shifting should always be brisk, never gentle. When you have a worn clutch dog, the fwd gear is almost always shot as well. BTW, most people think the clutch dog and gears always "look pretty good", since they've never seen new and don't know what "good" looks like.

 

[GLORY]

Re: Advise on taking a gear case apart. 35HP Johnson

Hey guys, here are some pic?s of a brand new clutchdog. Hope this will help you decide whether you should change it or not. At last I am going to assemble the gear case, only changing the clutchdog. Will let you all know if it?s all working. Thanks for everybody?s input.