How to remove lower gear housing???????

[b22smith]

1980 Johnson 25 hp LONG SHAFT. I have the entire lower unit removed, but now I have to remove the extension housing (not the gear housing). I removed the four bolts, but the extension housing is still stuck on the long stud bolt. Any suggestions to break it loose without damaging anything? I whacked it good with soft mallet, soaked the seam in WD-40,... The corrosion has it locked tight unless I'm missing something that's not in the book. Help!!!

 

[wayne h]

Re: How to remove lower gear housing???????

good luck that is the worst setup ever. if u can move the housing back and forth on the stud keep spraying it up and letting it site but u might need to use heat. i have heated them up and cooled them off by sprayed them down with good penetrating oil doing with will suck the oil in.you might want a rubber mallet also to bang on it. i know its not easy but u will get it. it just takes time. when u get it off clean it up really good and use antiseize on it when putting it back together. i used a drill and bit to drill all the crap out of the hole before i reinstalled it thats the only thing that would break out all the crude that was in there.

 

[bubbakat]

Re: How to remove lower gear housing???????

Get you some pb blaster to soak them in. It works twice as good as WD 40.

 

[b22smith]

Re: How to remove lower gear housing???????

What is "pb blaster" and where do you get it? Thanks for the replies. You guys confirmed what I was planning.

 

[bubbakat]

Re: How to remove lower gear housing???????

PB blaster is a good crud cutter you can buy it allmost any parts store. Rust cutter in a can.<br /><br />

 

[b22smith]

Re: How to remove lower gear housing???????

Got me some PB Blaster at Advance Auto today. Soaked the housing good. I'll keep some pressure on it and see what happens this week. I don't want to use heat unless absolutely necessary. I read about drilling some holes in the housing to get some of the PB Blaster directly on the stud bolt shaft then fill the holes with epoxy later. Any thoughts on that???

 

[seahorse5]

Re: How to remove lower gear housing???????

Unless there is just a minute bit of corrosion, a penetrating oil will not loosen up 5" of salted up metal stud.<br /><br />Chances are you will have to use an oxy-acetelyn torch to heat up the aluminum and pry off the gearcase. You will probably find the hole full of salt after you get it apart. A salt-water repair shop is very familiar with your problem with a stuck gearcase extension stud. Be sure to use a heavy coating of marine grease on the stud when you install it.<br /><br />All this is assuming that you already removed the shift connector screw thru the side plate on the exhaust housing.

 

[b22smith]

Re: How to remove lower gear housing???????

Yeah, I have the entire lower unit removed. Just having a bear of a time with the long shaft extension housing. It took me a couple hours of working loose the entire unit from about 1-inch of the stud bolt, so I have been a little doubtful on the possibility of getting the extension housing loose from the corroded 5-inches. I should probably take it to a professional, since I've never done this. I like learning on my own, but I know when to call it quits. Hate to spend the money, but if they break it then they fix it.

 

[DHPMARINE]

Re: How to remove lower gear housing???????

b22smith, If they break it they fix it? Yes but at your expense.It's your corrosion not mine.Did you think I'd give you new parts free if they broke when I couldn't get it apart any better than you?<br /><br />Not attacking,just wondering.<br /><br />DHP

 

[seahorse5]

Re: How to remove lower gear housing???????

In severe corrosion situations, I've cut the stud off just above the gearcase to remove the l/u. The stud is easily replaced.<br /><br />The 5" extension can now be removed and sometimes by using heat and a hydraulic press, the rest of the stud can be removed. If not, just find another extension piece. Used parts like that are almost everywhere since they have been used for lots of years.

 

[b22smith]

Re: How to remove lower gear housing???????

Okay, okay, okay. So I foot the bill. Another question. Is the other end of the stud screwed into the lower gearcase unit (not the extension housing) or is it pressed in? Just curious cause if I end up cutting the stud like Seahorse says, then do you have to drill out that piece or press it out? Sorry, but I'm learning as I go and appreciate all the responses!