Evinrude 35 hp Shifting Problem

[plutz]

I have the same problem as Redeemed does in another post. A 35hp 1980 Evinrude which pops out of gear underway. I have determined through this forum and a mechanics verdict, that the clutch dog and possible the forward gear needs to be replaced. I have no metal chips in the oil. I decided to do the work myself. I am using the Clymer Shop Manual. The shift rod connector has been unbolted through the water intake ports. The 5 bolts have been removed, BUT the lower unit will not seperate. The back will seperate about 1/8 of an inch but the front will not budge. Am I missing anything? How much pressure needs to be applied to seperate the unit? The last thing I want to do is cause more damage. Any help here would be appreciated.

Thanks

Paul

 

[F_R]

Re: Evinrude 35 hp Shifting Problem

The stud on the front (forward) end can be a real sonofagun to get out, especially if it has been ran in salt water. My motor still has burn and pry marks from when took it apart with heat and wedging.

 

[joe31764]

Re: Evinrude 35 hp Shifting Problem

bump

I have the same problem 82 johnson 35 hp. I can not get the lower unit off. It will come down about 2 inches and stop. How do I remove the shift linkage at the top?

Thanks

Joe

 

[joe31764]

Re: Evinrude 35 hp Shifting Problem

Try this, I found it in search, and it worked on my boat just 10 minutes ago.

Joe


If you have removed the 4 bolts and the one nut, and you have disconnected the shift rod in the little space between the water screens, there is absolutely nothing else to remove. The lower unit is probably stuck on that stud in front where the nut screws on. The stud builds up with salt and makes it difficult to drop the gearcase. You may need to apply heat to the area around the stud and wedge two strong screwdrives on either side of the gearcase between the gearcase and the exhaust housing (as far forward as possible) and use the screwedrivers to pry the gearcse down away from the housing. You can also put the nut back on the stud and screw the nut down so the top of the nut is even with the top of the stud and try wacking it with a hammer as you apply heat. This stud can get very stuck. Try penetrating oil around the stud. If you get the gearcase off and the stud is damaged you can replace it-it's cheapThe only other thing that can get stuck is the drive shaft can get stuck inside the crank shaft up under the powerhead but this usually happens with larger motors-then you have major problems

 

[plutz]

Re: Evinrude 35 hp Shifting Problem

Thanks folks,

I am trying to do a little a day so I don't rush and really damage something. I finally got the lower unit off. Soaked the bolt with lots of W-40. Carefully using chisels as wedges I slowly tried to drop it. Got the front, at the stud to drop just a wee bit. Took drastic measures and decided to slip a hack saw blade in the space and cut the stud off. I figure I could replace that easier then tossing a wrench through a window. After a few minutes of this, the unit decided to give up and drop off.

Will dig into the guts this weekend. No hurry as the parts did not arrive yet. Ran into another problem. I'll need to replace the impeller housing as it is cracked near a couple of holes. Any suggestions on how to remove from the shifting rod?

Thanks for all your help and I look forward to possible helping someone in the future.

Paul

 

[plutz]

Re: Evinrude 35 hp Shifting Problem

Folks, I need more help. Tried to pull the gear housing out using a gear puller. Attached it to the top 2 threaded holes and tightened onto the shaft end but it would not budge. Is this the way to pull the gear casing? Need to know for tomorrow before I try again and make matters worse.

Thanks

Paul