Re: Repairing my new 77 Johnson 115 - water tubes from the impeller housing destroyed
Ah yes, I can tell you what probably happened. It is impossible to see what you are doing when installing the gearcase back onto the exhaust housing. So, the manufacturer provided two short plastic water tube guides, which are inserted into the water pump top to guide the tubes in. When the gearcase is removed for service the plastic guides will be found shinnied up the tubes and must be retrieved and stuck into the pump for reassembly. The last guy didn't do that, so the tubes didn't enter the pump and were smashed when he forced it.
IF, if you can repair the tubes as you suggested, that is one option. Replacing the tubes is quite a chore. They are attached to the bottom of the powerhead adapter, which is between the exhaust housing and powerhead. The powerhead and lower unit must be removed, then the exhaust housing removed from the rubber mounts, then the adapter can be removed from the exhaust housing to replace the tubes.
Good luck & have fun......Oh, and find those guides and use them
