Need Help W/ Prop Shaft Removal

[200GT]

I have a 1991 Johnson 200GT. The prop shaft is slightly bent. It has been this way for some time. The seals are not leaking & but I would like to replace the shaft before they do. I have the lower unit off but I am not sure how to remove the shaft. Do I need a special tool to get the bearing carrier out?

 

[tashasdaddy]

Re: Need Help W/ Prop Shaft Removal

you need an OEM manual, and special tools.

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

I have a manual & it does list a tool part number but I was wondering if there was something I could get at a local parts store to do the job.

 

[HighTrim]

Re: Need Help W/ Prop Shaft Removal

You will need things such as a honking big pair of snap ring pliers and a harmonic balancer puller, plus others. I hope you have an original OEM manual to follow for this removal, not a Clymers or Seloc.

 

[jay_merrill]

Re: Need Help W/ Prop Shaft Removal

I have been fooling with the older, split casing lower units/motors for the most part and haven't yet had to do anything to my 72 65hp LU, so I can't advise you much on this. I can tell you however, that my OMC puller kit includes the parts needed to disassemble a one piece casing. You can order one through your local OMC dealer. They are more expensive than automotive pullers that you can adapt for use with outboards but, if you are going to work on your own motors to any significant degree, they make life a lot easier because they come with a selection of properly sized bolts (both diameter/thread & length) for various motors.

 

[flabum]

Re: Need Help W/ Prop Shaft Removal

There should be two threaded bolt holes in the bearing carrier that you can use two long bolts and a harmonic balancer puller to extract the carrier (don't forget to remove the two bolts holding it in). after that, the reverse gear and bearing should fall right out. You will then need the OMC spline tool that fits the driveshaft and a 7/8" wrench to remove the pinion gear and drive shaft. All the pinon bearings will fall out at this point DON"T LOSE ANY OF THEM! Then you need to push the shift shaft all the way down and unscrew it and remove it. Then pull the propshaft and fwd gear assembly out. Consult your manual for details. You do not need to re-shim it.

The only OMC tools you will need is the spline tool and seal installers.

During assembly, you will need two guide pins for the bearing carrier installation.... you can fashion these from 1/4" 28 pitch threaded rod.

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

Thanks for the information. I got the bearing carrier lose with an axle puller combined with a couple of long "hook" bolts I still have a bushing on the prop shaft that won't budge. Until I get this off I can't slide the carrier out. I think I way have to heat it in order to get it off. The biggest wheel puller I could find was not deep enough. I thought I could pull it off using the axle puller but it is just bending the hook bolts. Any thoughts..

 

[flabum]

Re: Need Help W/ Prop Shaft Removal

can you post a picture of this bushing?

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

give me just a minute.....

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

Here are a couple of pictures. It is what the prop rest agianst.
do you have direst email. can't post pic file to large

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

Ok here is a pic. got file compressed

 

[flabum]

Re: Need Help W/ Prop Shaft Removal

That is the prop thrust washer. Try a crowbar uder it, it should pop right off

 

[wilde1j]

Re: Need Help W/ Prop Shaft Removal

I made a puller using an old trailering draw bar, some 1/2" allthread and some cutting and tapping. Getting bearing carriers out from salt water motors can be very challenging, to say the least. BTW, you don't need to replace the prop shaft. Just get it straightened by a good machine shop. Way less $'s. If you're interested, send me a PM with your email address and I'll send you a picture of my homemade, really strong puller.

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

Got the thrust washer off and the bearing carrier out. I went to auto zone & borrowed a axle puller and a cv boot tool. Git my money back when I returned them. I Used the cv boot tool to remove the thrust washer. popped right off. I used the axle puller wit some long Hook bolts to get the carrier out. This saved a good amount of money compared to buying the oem puller.

 

[flabum]

Re: Need Help W/ Prop Shaft Removal

You will still need the OMC tool for the driveshaft to get the pinion gear off.

 

[wilde1j]

Re: Need Help W/ Prop Shaft Removal

As long as you have the LU apart, change the prop shaft and drive shaft seals, and the shift rod seal also. Inexpensive and will save you money down the road.

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

I have the pinion lock nut off but cannot get the pinion gear off. The manual says to remove the pinion gear & drive shaft in order to remove prop shaft. I I have the upper bearings & shims off of the drive shaft. Do I just need to apply more force. I read one post that suggested leaving the lock nut on and hitting it with the prop shaft to losen. I already removed the locknut and don't want to damage the threads.

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

I got the pinion nut back on the drive shaft. backed it of a couple of turns & then hit it with the prop shaft. Pinion gear popped right off. Thanks for the suggestion. Nnow I am trying to decided if I should buy a new prop shaft or try to get the old one straightened. It is out about 1/16". I think it is bent on the prop end because all bearings, gears & seals appear to be fine. I will go ahead and replace all seals since I have it apart. Any thoughts. Thanks for the input.

 

[HighTrim]

Re: Need Help W/ Prop Shaft Removal

It will definately be cheaper to get it fixed than to replace if you can find somewhere in your area that can do it.

 

[200GT]

Re: Need Help W/ Prop Shaft Removal

Can anyone tell me what the oem # for the seal kit is. I assume I can buy a kit for the entire lower unit instead of buying each seal seperate. The oem on the prop shaft is #395209.

I thought it was a 1991 but it may be a 1990 johnson 200 gt (V6)