I've gotten my hands on 1967 20hp FD 21R Johnson that runs strong once it's started but gets water in the gearcase oil. After reading the forums I decided this 35 year old outboard could use a new seal kit, and I'm the man to do the job. I bought a kit and Seloc manual from iboats and an old parts catalog from eBay and went to work. Now I have the gearcase apart and need some help!<br />1) How do I get the old seals out? They are in tighter than heck and I've already mangled the old prop shaft seal trying to get it out of the bearing head. The prop was rubbing on the bearing head and there's a "rim" of metal kinda fusing the seal into its seat. The drive shaft seal doesn't have that problem, but it doesn't want to come out either. What's the trick to getting the old seals out? Is there also a trick to getting the new seals in?<br />2) How do I get the shift rod bushing out so I can replace the o ring? Seloc's says "A special taperd punch is required to remove the bushing from the lower unit housing. Obtain the special punch, and then remove the bushing and the o-ring". What special punch, and how am I goung to punch out a brass bushing buried way in there?<br />3) There was no o-ring at the top of the drive shaft. Is it stuck up in the motor? I didn't get a likely replacement in the seal kit either, but that's another issue. <br />4) Someone in the past incorrectly installed the front bearing, failing to line up the slot in the bearing with the pin in the housing. The telltale mark from the pin that Seloc's says to look for is right there. There's still a wee bit of the pin sticking out; it's not completely driven into the housing. If I line the bearing up properly it catches what's left of the pin and holds its position. Is this OK? I hate the idea of drilling out the old pin and trying to find a replacement somewhere. How much pin is supposed to stick up? Seloc's doesn't say.<br />5) The seal kit I got is not like the picture in the catalog. I got four seals (two different sizes), four o-rings (all different sizes), two nylon washers, and two composit washers. I've emailed iboats to get this straightened out, but I'm confused on what exactly I'm suppoed to be replacing. Seloc's just says to "throw away all the old o-rings, gaskets, and seals and replace with new". Okay: prop seal and driveshaft seal; shift rod o-ring, driveshaft o-ring, gearcase head o-ring, and spaghetti seal. What else? What's with the washers?<br />I sure hope someone can steer me in the right direction. This "simple" job is becoming a major production. Sorry to be so windy!
<br />5) Shift rod pivot screw o-ring (little tiny one). The nylon washers are for the lube fill and vent screws, and should be replaced every time you remove those screws (ie, every gear oil change). I have no idea what the composite washers are for, but I suspect the extra seals are for older style gearcases that used different sized propshaft seals.