Replace lower unit shift rod O-ring Johnson 60

[h_lankford]

Please advise. Am replacing water pump on LU of 1986 Johnson 3 cyl 60 hp. Decided to replace shift rod O-ring on the shift rod cover, too. The O-ring resides in a circumferential groove cut midway in the inside of the shift rod bushing. <br /><br />Manual says unbolt shift rod cover (done) and remove O-ring. For installation of new O-ring, manual is equally short on details. Just talks about being careful to slide and turn the lubricated shift rod down into the new O-ring. But I haven't gotten that far yet.<br /><br />So to replace the old O-ring, do I ?<br />Remove the old O-ring with a suitable hooked wire or other jury-rigged device?<br /><br />And for installation of the new O-ring, do I slide it up or down the inside of the bushing with a 5/16" wooden or plastic dowel (or butt end of a 5/16 drill bit) until it pops into the groove? Seems straightforward, but I don't want to mess up.<br /><br />Thanks for any tips. Harvey

 

[Goodoleboy]

Re: Replace lower unit shift rod O-ring Johnson 60

You can buy a set of o ring picks at an auto parts place, 5 bucks or so. Handy litle devils to for lots of things.<br /><br />Like picking hickory nuts and walnuts and setch.<br /><br />Once you get the old o ring out, just put the new back into the same grove, by any means nessary. <br /><br />Just dont scuff it up. little dab of vasilene will help. Then put a little of the same on the shift rod and waw-la your done.<br /><br />It helps if you stick your tounge out the side of your mouth and sorta hold on with your teeth. Funny how much that helps.....And if things get really tuff.... then switch sides.... real fast....... Grin!<br /><br />good luck!

 

[rodbolt]

Re: Replace lower unit shift rod O-ring Johnson 60

try not to use a steel pick. if you do dont scratch up the shift cover housing groove. its a pain but not hard. work the new oring into the groove carefully I use a 1/4 punch and a tapered punch with blunt ends. and the tooth position and amount of grinding is directly related to ease of installation

 

[h_lankford]

Re: Replace lower unit shift rod O-ring Johnson 60

Well, I did it. Thought I would pass on some advice.<br /><br />The original O-ring was probably the source of my leak. The inner hole was the correct size for the rod, but the outer size-circumference was too small compared to the replacment one that I was able to get in. I apparently the smaller one was installed at the factory, which explains why I have had milky lower unit oil every season ever since brand new. <br /><br />But getting the old one out was a bear. I tried using a 14 and a 12 gauge copper wire to avoid nicking the aluminum shift rod cover. Even put the copper wire in the freezer to harden it up so it would not bend as easily. Never could get it to pull the o-ring out. Would get it part way, then bend. Gave up after waaaay too many attempts. Instead, used a coat hanger, the cheap thin white ones from cleaners, bent it 90 degrees, cut if off with just a nubbin maybe only 3/16". and hooked that o-ring right outta there, no problem.