Johnson Gear

[windy84]

Hi Im New Hope This Is Correct
Ive Been Trying To Fix My 35hp Johnson Seahorse 1978 Which Has Been Jumping Gear,and Getting Progressivly Worse,first I Turned The Dog Around And It Was Fine For A While,then I Started Jumping Again After 2 Miles Say,i Used It Like This For A Bit And It Started Jumping Straight Away ,,ok At Tick Over ,so Replaced Forward And Dog Gears At A Cost ! But It Still Jumps Gear Straight Away???there Is No Play In Gear Rods Gear Change Is Ajusted Full,not That This Makes A Diffrence As It Seems It Is Either In Gear Or Out (have Tryed To Push Rod Connector With Screw Driver ) , I Can Put It In Gear When Not Running And Feel It Pop In To Gear Whilst Turning Prop With Hand And It Is Engaging,,only Things Are A Part Of Gear Case Had Broken Off Say The Size Of A Small Mach Box From The Open End,, Which Has Been Well Stuck Back And The Prop Seems A Bit Warped Could This Be The Problem??
Any Suggestions Would Be Much Appreciated

 

[tashasdaddy]

Re: Johnson Gear

you need to see if the prop or the prop shaft is bent. bent prop shaft could have that ill effect, vibration throwing it out of gear.

 

[windy84]

Re: Johnson Gear

Yes Prop Bush is Warped but shaft is true

 

[5150abf]

Re: Johnson Gear

First of all, kill the caps on every word, makes it very hard to read.

I would look on Ebay for a used lower, can be had for probabaly less than you paid for the gear and dog.

I have rebuilt several lowers both with new gear sets and mix and match parts and none of them have lasted very long, the tolerances in a lower are very tight and the forces involved are very very high so you probably won't ever be able to get it yourself.

I had mine to where reverse would click if you put lot of gas on it, I adjusted the knurled knob on the shift cable and it went away immediately but I am sure you have already tried that.

Do you have an OEM manual for this motor? (Not Seloc/Clymers or anything on CD)

If not get one.

 

[windy84]

Re: Johnson Gear

Havnt Had Much Luck With Ebay Did Buy A Lower Unit But It Had Drill Holes Going Right Through The Case !!
Trouble Is How Much Do You Spend On An Old Engine After Paying Out For The Gears Havnt Much Appetite Left(or Money)
But Have Located A New Prop Shall Give This A Go ?!

 

[wilde1j]

Re: Johnson Gear

When you replaced the fwd gear and clutch dog, did you use brand new parts? Did you follow all of the procedures in the shop manual (like shimming)? A new clutch dog and fwd gear should ALWAYS work, if correctly installed. I've done a bunch, and they were always like new when finished.

 

[windy84]

Re: Johnson Gear

ooo

 

[windy84]

Re: Johnson Gear

So The New Gears Are Not Engaging Fully Because I Avnt Used Shimms Made Unworkable By A Warped Prop
So I Need To Find Out How To Shimm It
My Guess Is It Needs Packing Between The Roller Bearing And Forward Gear To Shove It Forward An Extra 1mm ?
Trouble Is I Havnt A Good Ocm Manual And May Have Problems Getting One
Can Enyone Tell Me (in Simple Terms) How To Shimm The Forward Gear
Cheers Paul

 

[wilde1j]

Re: Johnson Gear

I don't have a manual for your motor, but try Ebay or Ken Cook. Ebay is the least cost for a proper shop manual.

 

[chocholek]

Re: Johnson Gear

I had a similar problem on a 1964 40hp Johnson outboard. I pulled the gears and dog out and flipped the dog. Put it all back together only to find it started jumping out of gear after about 25 minutes of driving in mid range. I didn't notice any severe wear that would cause the dog to disengage. Yet it still jumped in and out of gear. Feels like it was hitting those wooden alligators that love to swim just under the water line. Couldn't figure it out for the best of me. I called a Johnson shop and spoke with a technician and he too suggested to turn the dog around. After I explained that I had already done so he suggested a new / used lower end. Just before I hung up with him he gave me one more thing to check. He told me to remove a small cover on the right side of the exhaust housing and check that the shift linkage connector was tight. Sure enough it was only hand tight. I could see the shift rod move up and down about an 1/8th inch before it actually moved the lower linkage rod. I tightened it up and my problem was cured. I can run at WOT and doesn't jump out at all anymore.

I tried to upload a picture of the cover, but I can compress it to under 50 kb.

Anyway there are two screws that you need to remove to take off the cover. The cover is about 3/4" wide and 3" long. It is positioned vertically on the right side of the motor. There will be another cover behind this one with a gasket. There aren't any fluids, the gasket keeps out the exhaust. Once you remove this you will see the connector. You may even get little bit of adjustment from this connector.

Give this a try. I am very happy that it worked for me. Hopefully you will find a loose connection.