Gearcase rebuild 1994 johnson 25 hp

[kevin11mic]

I am in the process of replacing all the seals in my lower unit due to finding water in it. Im pretty sure it was the upper driveshaft seal under the waterpump that was leaking but doing a full rebuild due to the age. One question I have is how do you remove and replace the lower shift rod seal under the water intake. and also is there a certain way that the clutch dog is supposed to go. I noticed that one side of it has a grove and the other side dosent. thanks

 

[boobie]

Re: Gearcase rebuild 1994 johnson 25 hp

The gruve normally goes to the rev gear. You'll need a few special tools to replace the shift rod seal. Send F_R a PM and maybe he can help you out.

 

[kevin11mic]

Re: Gearcase rebuild 1994 johnson 25 hp

Thanks, the reverse gear is the one closest to the prop correct? And I think I'm going to skip the shift rod seal. It feels pretty tight still when I push the rod through.

 

[out 2 launch]

Re: Gearcase rebuild 1994 johnson 25 hp

Better double check that, I believe the clutch dog groove faces forward mating with the forward gear. As far as the shift rod seal, I use a puller for the bushing made out of threaded rod.

 

[boobie]

Re: Gearcase rebuild 1994 johnson 25 hp

Sorry, I "sit" corrected. The gruved end of the clutch dog faces the forward gear.