I have to offer up big thanks for all of your videos Stu. I followed your carburetor videos to help my brother in law address the performance problems in his Johnson 50 outboard. The improvement was nothing short of astounding! Now my brother in law thinks I'm a genius. Thanks again.
Absolutely thankful for the video! I didn’t have all the tools or a press but a good vice is key! Most of the bearings went in with a properly sized socket and extensions and I converted mm to inches and it worked great! Also the prop shaft tool for the detent balls install I got really lucky with a zip tie holding them in and when I put the shaft in one side the ball was gonna be exposed and one was going to be set into the dog clutch ear so I held a flat head firmly on the side that was open and smacked the shaft and it all went in perfect! And for the second gear going in if you put a thin feeler gauge under the gear but over the shift selector the gear goes right in with the bushing still installed! Thank you so much for all your videos!
Thanks for putting these videos together mate, very helpful. You don't need the special tool either, to get those bearings in I ground a small divot into the end of a (broken) flat blade screwdriver and used a bit of grease to hold the ball on there. To get it installed put one ball and the spring through the shaft with a bit of grease to hold them in place, then insert the shaft aligning the ball that in there with one of the dogs such that the dog holds the ball in place and the hole on other side lines up between the other two dogs. I then used the screwdriver to push the other ball in and compress the spring and gave the end of the shaft a tap with a dead blow to send it all home. It was as fidly as all hell and took probably a dozen or more goes to get it in, but it's in there now.
well done. my clutch dog had only two teeth so I would have needed 3 hands or a helper to use your method. Here's a video of the DIY tool I made: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
This series has some of your best detailed descriptions and closeups in recent memory. Let us know if that tool has a name. Please title this video series "1 of 4" etc. so we can find them easily in the future.
Stu, I'm sure that you gave all the info but I would probably have to "do-undo" the assembly 10 times before getting it right. Make that 15 times. Thank you very much for your generous info sharing.
What part inside of the lower unit is made of aluminum? My motor bucked under throttle and upon inspection there were two chunks of aluminum I was able to extract without tearing the whole thing down. Trying to get a game plan for the repair I need to tackle.
Hi Dangar Stu, thank you for all these insights to your life on the Island, Aussie dry humor and for sound real world instructions. This channel is and will be an outstanding resource to boaters. I hope to get the DM T’s I ordered soon here in the UK. Very pleased to support your efforts even in a small way. Could or have you ever covered oils? Engine not baby oil! Why and how the grades work, lower case gear oil. As I think there is some room for your good honest reasoning on the subject. Oils especially oem branded ones are a big cost factor in regularly maintaining our outboards. Can you expand and help cut the facts from brand marketing hype. Cheers Will.
Hey Will. I have been wanting to a video on oils for a while. The rep for the company we buy our oil from is very knowledgable so I would like to get him involved. Thanks for buying a t-shirt! :)
Oh man! I'd love to work in a marine engineering dept. if that's what they play with all the time! What a neat little mechanism! :) Greetings from Canada.
You can actually I just did it 20 min ago install the spring and ball bearings into the shaft and install the dog onto the shaft and drop the shift bracket into the bottom of the foot and wiggle the driveshaft in the foot and get it seated onto the dog without the tool. Probably not the right way but if you need it together now like I do you can do it that way.
I think Crowley Marine had one for sale but I'm too cheap. I made a tool out of cheap scraps in this video. My clutch dog has 2 teeth instead of three but same concept might work: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
You are my resident expert....across the ocean in Canada "eh". Lol. Working on a 1990 Force 90hp. About to tackle this job myself to deal with what I'm guessing is a bent prop shaft causing water pumps to be mangled. There is a bearing of some sort behind the prop itself that none of the units you're showing have...any advice? Other than dont buy a boat with a force motor? Too far into this to stop now. After all of this work I sure hope this boat treats us well. REALLY glad I came across your channel. Thank you for helping those of us who can't afford to pay mechanic's! You are appreciated!!!!
Great video Stu! There's a lot going on inside the gear housing. I'll make sure to secure a prop shaft bearing tool before my rebuild. Looks impossible to install the spring and 2 ball bearings without it.
If you were just doing a 1 off rebuild would a length of PVC pipe cut to suit the dog clutch 'fingers' handle the stress and do the job? If so, it would be a cheap disposable tol to make.
hey there thank you for all the videos. I'm a bit confused. earlier the the video you say for the groove in the clutch dog to face forward but then when demonstrating you showed the groove facing toward the prop.
Great video, Stu! Do you have any videos on older OMC motors, early 60's V4's? I have a 62' Gale 60hp that is having a hard time shifting after replacing water pump and gear seals.
Awesome video stu. I have a Yamaha outboard 3 hp 2 stroke. I was doing a service on the lower unit (impeller change) and noticed the drive shaft was badly rusted in the middle between the spline and the impeller. I scrubbed the rust off back to the metal but the shaft is badly pitted with corrosion. Is it difficult to change the drive shaft?
Your videos are incredible!!! I am currently rebuilding a 20 hp johnson .(j20crcca) 1988 . I fallowed this video exactly . I’m to the point now where I’ve got the water pump on and everything up to the bearing carrier. I stopped after the snap ring . The lower unit is separate from the motor still. It does not seem to be shifting correctly . The shift rod is pretty hard to move and I can spin the prop shaft at any time. The shift cradle seems to be moving the dog clutch. What should I be looking at? I’ve never done an outboard before thank you
Hey Stu, seen all your videos, thought I'd leave a com(pli)ment. Awesome work, keep it up! PS. Would be great to hear about your path / how you got into marine engineering some time. Cheers, Alex
Thanks mate. All the working outboards came about from living on an island and needing to keep my own boats running to get back and forth to the mainland.
That prop shaft tool really saves the day. It would probably be a nightmare trying to install the shaft without it! I’m enjoying the rebuild Stu. How’s your boat kit coming?
Hey Jack, that tool certainly made life much easier. Haven't done much on the boat recently but will definitely get back to it when this gearbox is finished.
If it is all the same gear going back together there is no need to. If it is a new gearset then yes, it needs to be shimmed to get the correct gear lash.
@@DangarMarine oh I see! Let's say I put In another pinion gear and another forward gear (from another spare part motor), all other is same. Do I have to shim then?
OMG I literally did this last week, But I didn't have that tool for the Ball bearings! I've heard of people using tape and unravelling it to keep the ball bearings in till the last moment or even grease!
Please do! I would like to make one myself. Keep up the great work. Any advice on where to find manuals for a 90s force? May the force be wirh me...for years to come. So far its a play area for the kids....at least they are having fun with the boat. Not so much fun for me so far. 1st boat...its a learning experience. You've made it a much easier so far. Thank you
Any chance you want to come to Alaska and do that on a 40hp Evinrude? Great videos, thanks for taking the time to make them. What is the red jeep looking vehicle parked in front of the LTD?
Thanks Ryan, would love to visit Alaska one day. ;) That's a Series 1 Land Rover. I've put a bit of footage of it at the end of the video I'm just about to upload.
Great videos and knowledge . A question on installing the dog clutch.the section where you demonstrate the use of the tool to install the dog clutch on the shaft. it appears that the dog clutch is facing the wrong way in the demonstration?. Am i correct
I have a 1990 Jonson pro series tracker 60 HP 3 cylinder and I'm trying to find out if there is a different between the one I have and just a regular 1990 Johnson 60 HP so if I need to order parts . There is no video on this that I can find any where. It would be a good video for you to do because just explaining the difference and what part will work on both will help my and other people. I live by lake tawakoni in West Tawakoni Texas in the United States I like watching your videos. I have learned stuff about boat. I'm a First time boat owner
I found this video, but it must be part of a series. Nowhere is the gearcase idenified. Is it a 25 - 35 HP? No idea from the title or text. I am looking to assemble two Johnson 9.9/15HP gearcases.
Hi thank you very much for the great video. I need advice about my 2015 Evinrude 60 hp e-tec I have a little bit bend on my propeller shaft (hit a stump in the water with low speed ) I watch a video the guy straightening up without taking off the shaft out from the lower unite. do you think it's a good idea thank you.
Gday mate. Love your work. I dont suppose you know the factory specs on adjusting a 94 johnson 15hp shift shaft at the coupling next to the water pump do you. Cant find that info anywhere
I have a 2000 Evinrude 225 Hp outboard. Does it make a difference which direction the gear housing for the drive shaft faces? I noticed a oil hole in the case and one in the housing but they don't line up....Thanks.
Why does the dog clutch need to be locked to the prop shaft? Isn't it supposed to move along it to engage into gear? I'm mostly asking because I broke the spring when trying to engage gears after installing everything. I tried moving the shifting rod and it just seemed stuck. Did I do something wrong when putting the string and balls back together? Great suggestion on the tool, by the way.
Hi Jorge. It isn't so much locked as being a detent that gives it a distinctive click and it switches between F-N-R. It can take a bit of force to move it between the notches so you might find that you have done it right but just can't push it with your hand.
@@DangarMarine does the balls need to be in a specific place inside dog clutch? there are some smooth areas inside the clutch, what are these areas for?
the tool u use to slide over the propshaft to hold the bearings and spring,whats the name of that tool? ive looked for s that tool in sweden but cant find any,would be great if u could help regards Henrik
How many degrees should the propeller shaft rotate back and forth when in either forward or reverse. My son in law's is popping out of forward but apparently ok in reverse.
Do you have a video of installing the shaft on 1974 model Johnson 9.9. The clutch dog looks different on those models. Just wondering of it mattered which way the ball and springs lined up when installing the shaft into the clutch dog. Is it supposed to line up with the ears on the clutch dog?
I forgot to measure it but I'm going to do a video on making one. The inner diameter is really just a smidge bigger than the propshaft itself and the outer doesn't matter too much as there is plenty of room for the tool to fit in.
OK regarding the tool #328081 here is the question. Does the orientation of the dog clutch and the prop shaft matter regarding the splines? The tool has 3 notches that align with the dog clutch. Is this necessary because the splines must be set correctly on the prop shaft, or does the orientation of the two matter. I notice that the inside of the dog clutch has a 360 degree groove machined into it where the bearings seat, however there are 3 areas inside the dog clutch that don't have splines. Two of those are about the same size and one is larger. Thank you for your time.
When I shift into forward and try to manually turn the propeller it won't move both ways but when I force it to the right it moves then it stops both ways and u can't force it.
Stu great videos man thanks!! I do have a question or two though. Could you do a video on poppet valves (water pressure relief valves)? Also on my boat the serial number for my motor say it's a 1983 mercury and it does have the round poppet valve but the block/power head has the provision for the "lop sided" figure eight style poppet valve with the adapter on top of the power head behind the fly wheel. The "extra" opening appears to have a small freeze plug in it. Should I stay with the one that's one it or try to find the lop sided cover and put that back on? On plane at wide open throttle it does start to over heat some but I keep an eye on it and drop down in speed/RPM and it will cool off. I am replacing the water pump and impeller on the 27th of this month. Sorry for the long post. Thanks for any response.
I'll definitely do a video on this when I can get my hands on an outboard that has one. Given your problem is overheating at high RPM rather than low RPM it doesn't sound so much like a poppet valve problem though. I'm not really familiar with the Mercury configuration you are describing so can't really advise on whether to change, but I would definitely be looking at impeller and thermostat to solve your problem. I would also do a good engine flush.
Thanks for the reply Stu!!!!! I replaced the water pump and impeller today, the tell tale was peeing way better than before even on the muffs. Cant wait for the video if you get to do one. I apply what you do to my motor and it has HELPED a whole lot. I will be taking it out int morning and run it after it warms up to operating temp and see how it does. I think you're right about the poppet valve part will be getting new thermostats for it next week. Again thanks and keep up the great videos, enjoy them a lot!!!!!!!!!!
Nice Stu, I take it your reference material is throw away with the grease all over it. Haha Anyway waiting on parts for my project. I sent at couple of pictures to your FB page from a antique VW car show yesterday. Check it out I think you would enjoy it. Cheers🍻
Danger marine, I have a 79 merc 80 hp. I’ve cleaned the carbs, replaced the fuel tank fuel line. Was running fine, but then started running on only 3 cylinders, replaced the spark plug, and sometimes it’s hard to start, other times it starts right up, but after about a minute is starts to die, then idles again, and every now and then it looses some rpms at idle, do you know what is wrong with it?
Hmmm, that sounds like a strange one. You'd really have to go back to basics and check compression, reed valves, spark, timing fuel etc. It could be one of many, many things unfortunately.
Hmmm, that sounds like a strange one. You'd really have to go back to basics and check compression, reed valves, spark, timing fuel etc. It could be one of many, many things unfortunately.
Stu,on that Johnson 30 hp you have the dog clutch with the grooves facing the forward gear. The dilema on my johnson 35 hp(circa 1977), Is that the manual has those same grooves face the prop side,or reverse gear. Is the manual wrong,or am I missing something?
Not sure unfortunately. This is the only engine like this I had ever worked on and I can't remember the specifics of it. If you have the service manual for your exact outboard I would go with that unless it seems obviously wrong for some reason.
@@DangarMarine Thank you very much Stu! I will follow the service manual,reread it and make it isnt incorrect. Your videos on that johnson 30 are a huge help in my rebuild even though mine is 23 years older than the subject motor which is nearly mechanically identical to mine.
Hello. Is their a special technique to getting pinion gear in 1987 johnson 110. Having difficulty getting it in place. Also does dog clutch need to be certain direction. It looks to be symmetrical
I've never worked on one but I imagine it would a similar technique to this motor. Some dog clutches are symmetrical some aren't. It is is truly symmetrical than either way is fine.
Thanks. U have great videos... I finally got it together. Unit needed to be in forward gear and horizontal in order to have enough clearance to get by dog clutch. Keep the videos going!!
Is there a way to do it without the special tool to get the ball bearings in with the spring, also does anyone know if it would be okay to install a used lower drive shaft the holes where the ball bearings go with the spring, I bought a used one they are more rounded off where the ball bearings go compared to my motor it has low hours and the edges are very sharp , would that be a problem or should I just install it. I was thinking it should be okay just a little more play in the ball bearings hopefully it doesn't cause to pop out of gear
you need to say what year model the gear case is from because they had different way to install said shafts... I made a tool for them 80+ year models on a drill press...
you need to show why it's a pain in the ass to make it work.. and it's all about the 3 dog over the 2 dogs... I used a piece of PVC and made it work... never had one come back from a problem...
Thing about this installation is on the Ford and reverse gear they're supposed to be a thrust washer on the inside of the gear on both of them and you don't say nothing about it when you're putting it together do those washers vary from different units because I didn't see you say anything about those thrust washers and I need to make sure because I'm having trouble getting it the shift from forward to reverse
I have to offer up big thanks for all of your videos Stu. I followed your carburetor videos to help my brother in law address the performance problems in his Johnson 50 outboard. The improvement was nothing short of astounding! Now my brother in law thinks I'm a genius. Thanks again.
You're welcome mate, glad to hear they helped you guys. :)
I have spent my whole life working in the marine industry. The detail and order of operation makes you invaluable.
Thank you
Cheers
Shad Hendry
I love the attention to detail in the description, very necessary for us part time mechanics, you make it much easier, thanks
And Stu,Thank you for making these videos.They and you have been a livesaver and tremendous help with rebuilding my Johnson outboard motor!
How can I get a hold of this guy thanks
Absolutely thankful for the video! I didn’t have all the tools or a press but a good vice is key! Most of the bearings went in with a properly sized socket and extensions and I converted mm to inches and it worked great! Also the prop shaft tool for the detent balls install I got really lucky with a zip tie holding them in and when I put the shaft in one side the ball was gonna be exposed and one was going to be set into the dog clutch ear so I held a flat head firmly on the side that was open and smacked the shaft and it all went in perfect! And for the second gear going in if you put a thin feeler gauge under the gear but over the shift selector the gear goes right in with the bushing still installed! Thank you so much for all your videos!
Thanks for your help. A mate of mine is coming over next week and will bring them for me, cheers
Thanks for putting these videos together mate, very helpful.
You don't need the special tool either, to get those bearings in I ground a small divot into the end of a (broken) flat blade screwdriver and used a bit of grease to hold the ball on there.
To get it installed put one ball and the spring through the shaft with a bit of grease to hold them in place, then insert the shaft aligning the ball that in there with one of the dogs such that the dog holds the ball in place and the hole on other side lines up between the other two dogs. I then used the screwdriver to push the other ball in and compress the spring and gave the end of the shaft a tap with a dead blow to send it all home.
It was as fidly as all hell and took probably a dozen or more goes to get it in, but it's in there now.
well done. my clutch dog had only two teeth so I would have needed 3 hands or a helper to use your method. Here's a video of the DIY tool I made: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
This series has some of your best detailed descriptions and closeups in recent memory. Let us know if that tool has a name. Please title this video series "1 of 4" etc. so we can find them easily in the future.
+1 on numbering the videos.
Hey Bruce, they are all together here in order in this playlist th-cam.com/users/playlist?playnext=1&list=PLJD0gZGZdCueRlSHBwr5pGNPWpY1VQlHQ&index=1
You are an awesome teacher. Thank you so much for doing these videos.
You're welcome mate. :)
You have the best repair and how to videos on TH-cam. Thank you!
Thanks Thomas! Glad you like them. :)
Stu, I'm sure that you gave all the info but I would probably have to "do-undo" the assembly 10 times before getting it right. Make that 15 times. Thank you very much for your generous info sharing.
I know what you are saying Daniel, until you've done a few I think everyone would be like that.
Prop shaft Installation;
1 ) Prop shaft
2 ) Beer
3 )Geer Oil
4 ) Pinion Gear
5 ) Washers
6 ) Forward Gear
7 ) Reverse Gear
8 ) Unimportant, Parts
Thanks Mate; for the videos Cheers !!***.
You've gone the process down pat! ;)
What a difference in the leg!!! Like a new one!!
What part inside of the lower unit is made of aluminum? My motor bucked under throttle and upon inspection there were two chunks of aluminum I was able to extract without tearing the whole thing down. Trying to get a game plan for the repair I need to tackle.
Hi Dangar Stu, thank you for all these insights to your life on the Island, Aussie dry humor and for sound real world instructions. This channel is and will be an outstanding resource to boaters. I hope to get the DM T’s I ordered soon here in the UK. Very pleased to support your efforts even in a small way.
Could or have you ever covered oils? Engine not baby oil! Why and how the grades work, lower case gear oil. As I think there is some room for your good honest reasoning on the subject. Oils especially oem branded ones are a big cost factor in regularly maintaining our outboards. Can you expand and help cut the facts from brand marketing hype.
Cheers Will.
Hey Will. I have been wanting to a video on oils for a while. The rep for the company we buy our oil from is very knowledgable so I would like to get him involved. Thanks for buying a t-shirt! :)
You run very good tutorials. Very much appriciated!!
Thanks Bob!
Oh man! I'd love to work in a marine engineering dept. if that's what they play with all the time! What a neat little mechanism! :) Greetings from Canada.
It is pretty cool. :)
Excellent video. Very clear instructions!
You can actually I just did it 20 min ago install the spring and ball bearings into the shaft and install the dog onto the shaft and drop the shift bracket into the bottom of the foot and wiggle the driveshaft in the foot and get it seated onto the dog without the tool. Probably not the right way but if you need it together now like I do you can do it that way.
For the "special tool" to retain the spring and bearings, can this be purchased? Any instruction on making one? Love these videos by the way.
I think Crowley Marine had one for sale but I'm too cheap. I made a tool out of cheap scraps in this video. My clutch dog has 2 teeth instead of three but same concept might work: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
i guess it's quite randomly asking but does anyone know of a good website to stream newly released tv shows online ?
@Stefan Davion Try Flixzone. You can find it on google =)
@Kylen Junior Yea, been using FlixZone for since march myself :D
@Kylen Junior thanks, I went there and it seems like a nice service =) Appreciate it !
You are my resident expert....across the ocean in Canada "eh". Lol. Working on a 1990 Force 90hp. About to tackle this job myself to deal with what I'm guessing is a bent prop shaft causing water pumps to be mangled. There is a bearing of some sort behind the prop itself that none of the units you're showing have...any advice? Other than dont buy a boat with a force motor? Too far into this to stop now. After all of this work I sure hope this boat treats us well. REALLY glad I came across your channel. Thank you for helping those of us who can't afford to pay mechanic's! You are appreciated!!!!
Great video Stu! There's a lot going on inside the gear housing. I'll make sure to secure a prop shaft bearing tool before my rebuild. Looks impossible to install the spring and 2 ball bearings without it.
It is quite a complex arrangement. I certainly wouldn't attempt it without at least having a homemade tool for the job.
If you were just doing a 1 off rebuild would a length of PVC pipe cut to suit the dog clutch 'fingers' handle the stress and do the job? If so, it would be a cheap disposable tol to make.
@@ronpowell2373 PVC pipe might work. I built a tool and made a video here: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
Hi Stu, Everyone is thinking it so I'm going to say it .... " when are you going to get back on the boat build ?"..... There,said it 👍🍺
Soon!
Like always Mate you are the Man.
Good Day.
Amazing. I actually made the tool and it works!
Nice one! :)
Really like your videos. Very helpful
Love this video man
Excellent video
Thank you for your amazing expertise.
hey there
thank you for all the videos. I'm a bit confused. earlier the the video you say for the groove in the clutch dog to face forward but then when demonstrating you showed the groove facing toward the prop.
Great video, Stu! Do you have any videos on older OMC motors, early 60's V4's? I have a 62' Gale 60hp that is having a hard time shifting after replacing water pump and gear seals.
Thanks Joey, unfortunately not yet.
love the vids,keep them coming greeting from Holland
Thanks mate! :)
Did Snoop Dogg call yet? Im sure he is looking for his car :D
He's been a great customer, always pays his bills on time. ;)
Awesome video stu. I have a Yamaha outboard 3 hp 2 stroke. I was doing a service on the lower unit (impeller change) and noticed the drive shaft was badly rusted in the middle between the spline and the impeller. I scrubbed the rust off back to the metal but the shaft is badly pitted with corrosion. Is it difficult to change the drive shaft?
Thank you kawan
Your videos are incredible!!! I am currently rebuilding a 20 hp johnson .(j20crcca) 1988 . I fallowed this video exactly . I’m to the point now where I’ve got the water pump on and everything up to the bearing carrier. I stopped after the snap ring . The lower unit is separate from the motor still. It does not seem to be shifting correctly . The shift rod is pretty hard to move and I can spin the prop shaft at any time. The shift cradle seems to be moving the dog clutch. What should I be looking at? I’ve never done an outboard before thank you
Have you left the idea of making a vid showing how to fabricate the special sleeve tool?
G'day mate! Another good one
Thank you!
Hey Stu, seen all your videos, thought I'd leave a com(pli)ment. Awesome work, keep it up! PS. Would be great to hear about your path / how you got into marine engineering some time. Cheers, Alex
Thanks mate. All the working outboards came about from living on an island and needing to keep my own boats running to get back and forth to the mainland.
That prop shaft tool really saves the day. It would probably be a nightmare trying to install the shaft without it! I’m enjoying the rebuild Stu. How’s your boat kit coming?
Hey Jack, that tool certainly made life much easier. Haven't done much on the boat recently but will definitely get back to it when this gearbox is finished.
Hello! Thank you for the great videos.
I just wondering, where can i buy the tool for the prop shaft?
great video!
This playlist is great! Do you have any additional information on the special tool for retaining the spring and bearings?
I have that tool Reid...found it on e bay bu cross referencing my manual with marinemotors.com and looking it up on ebay.under OMC PART#328081
good comments on how people made one with a shower rod. I made a tool cheaply and did a video of it: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
great job! Awesome man
Pink 76 LTD! Pimp'n ain't easy but it's necessary!!!
I hear you brother, someone has to do it. ;)
Hi Stu! Thanks for these great videos. I was wondering if you should not shim the lower unit when putting it together?
If it is all the same gear going back together there is no need to. If it is a new gearset then yes, it needs to be shimmed to get the correct gear lash.
@@DangarMarine oh I see! Let's say I put In another pinion gear and another forward gear (from another spare part motor), all other is same. Do I have to shim then?
OMG I literally did this last week, But I didn't have that tool for the Ball bearings! I've heard of people using tape and unravelling it to keep the ball bearings in till the last moment or even grease!
I would certainly be tough without the tool. I think I'll do a vid on making one soon.
Please do! I would like to make one myself. Keep up the great work. Any advice on where to find manuals for a 90s force? May the force be wirh me...for years to come. So far its a play area for the kids....at least they are having fun with the boat. Not so much fun for me so far. 1st boat...its a learning experience. You've made it a much easier so far. Thank you
@@The_M-An-M here's how I made a tool but my clutch dog had 2 teeth. th-cam.com/video/0p80wlBqBkY/w-d-xo.html
Well done.
Any chance you want to come to Alaska and do that on a 40hp Evinrude? Great videos, thanks for taking the time to make them. What is the red jeep looking vehicle parked in front of the LTD?
Thanks Ryan, would love to visit Alaska one day. ;) That's a Series 1 Land Rover. I've put a bit of footage of it at the end of the video I'm just about to upload.
Great videos and knowledge . A question on installing the dog clutch.the section where you demonstrate the use of the tool to install the dog clutch on the shaft. it appears that the dog clutch is facing the wrong way in the demonstration?. Am i correct
I have a 1990 Jonson pro series tracker 60 HP 3 cylinder and I'm trying to find out if there is a different between the one I have and just a regular 1990 Johnson 60 HP so if I need to order parts . There is no video on this that I can find any where. It would be a good video for you to do because just explaining the difference and what part will work on both will help my and other people. I live by lake tawakoni in West Tawakoni Texas in the United States I like watching your videos. I have learned stuff about boat. I'm a First time boat owner
I found this video, but it must be part of a series. Nowhere is the gearcase idenified. Is it a 25 - 35 HP? No idea from the title or text. I am looking to assemble two Johnson 9.9/15HP gearcases.
HA this just showed up on my you tube front page and it is the same as my lower..(saving for future use)
Hi thank you very much for the great video. I need advice about my 2015 Evinrude 60 hp e-tec I have a little bit bend on my propeller shaft (hit a stump in the water with low speed ) I watch a video the guy straightening up without taking off the shaft out from the lower unite. do you think it's a good idea thank you.
Gday mate. Love your work. I dont suppose you know the factory specs on adjusting a 94 johnson 15hp shift shaft at the coupling next to the water pump do you. Cant find that info anywhere
I have a 2000 Evinrude 225 Hp outboard. Does it make a difference which direction the gear housing for the drive shaft faces? I noticed a oil hole in the case and one in the housing but they don't line up....Thanks.
looking at 3:14. Cradle and lever seem to be one part. Has that changed since 1985 where blowup shows two separate pieces?
Nice front license plate "SLEEZY", lol
Why does the dog clutch need to be locked to the prop shaft? Isn't it supposed to move along it to engage into gear? I'm mostly asking because I broke the spring when trying to engage gears after installing everything. I tried moving the shifting rod and it just seemed stuck. Did I do something wrong when putting the string and balls back together? Great suggestion on the tool, by the way.
Hi Jorge. It isn't so much locked as being a detent that gives it a distinctive click and it switches between F-N-R. It can take a bit of force to move it between the notches so you might find that you have done it right but just can't push it with your hand.
@@DangarMarine does the balls need to be in a specific place inside dog clutch? there are some smooth areas inside the clutch, what are these areas for?
the tool u use to slide over the propshaft to hold the bearings and spring,whats the name of that tool? ive looked for s that tool in sweden but cant find any,would be great if u could help regards Henrik
Hi man,back home,how was the trip to croatia,did you like it here?shame we couldnt meet eachother
Croatia was great. Yes it was a shame not to meet up but I know it tough to organise these things.
I know this 3 years old but can you possably do a 35 hp 1986 brown band merc lower unit rebuild just like this video I know its a Lil different
How many degrees should the propeller shaft rotate back and forth when in either forward or reverse. My son in law's is popping out of forward but apparently ok in reverse.
I have to change my shaft propeller on a 175 Jonhson.Where do i buy the plan for the job?
Aussie cars are neat. The pink '76 LTD looks like an American Chrysler Cordoba. Nice plate on it too!
I just checked out the Cordoba and you're right, it does look quite similar. :)
Hi, thanks for the video. Any chance to know the part nr of the prop shaft installer tool? Appriciate it.
Hi mate, having trouble sourcing those discs u used to sand and polish the green machine. Can u let me know where u purchased them please. Cheers
Hi Ray. I just get them from Bunnings www.bunnings.com.au/josco-100mm-120-grit-extra-fine-abrasive-flap-disc_p6320415
Classy car!!!
Do you have a video of installing the shaft on 1974 model Johnson 9.9. The clutch dog looks different on those models. Just wondering of it mattered which way the ball and springs lined up when installing the shaft into the clutch dog. Is it supposed to line up with the ears on the clutch dog?
Unfortunately not, I've never done one.
What is the inner and outer diameter of the tool that installed the spring and bearing? I have a machine shop next to me. Thanks
I forgot to measure it but I'm going to do a video on making one. The inner diameter is really just a smidge bigger than the propshaft itself and the outer doesn't matter too much as there is plenty of room for the tool to fit in.
OK regarding the tool #328081 here is the question. Does the orientation of the dog clutch and the prop shaft matter regarding the splines? The tool has 3 notches that align with the dog clutch. Is this necessary because the splines must be set correctly on the prop shaft, or does the orientation of the two matter. I notice that the inside of the dog clutch has a 360 degree groove machined into it where the bearings seat, however there are 3 areas inside the dog clutch that don't have splines. Two of those are about the same size and one is larger.
Thank you for your time.
Do you have a video on this for a 40 evinrude. I'm having some major problems getting mine fixed
If at all possible could you make a video on how to change the low end seals on a mercury 4 stroke 15 hp from yr 2000 mine will not come apart
what is the name of the spring ball prop shaf for dog gear
well done m8
Hi mate great videos, question. what is the tool called that holds the 2 ball bearings and spring in? Is it home made or can I buy one? Cheers
I made a tool cheaply in this video. My clutch dog has 2 teeth instead of three but same concept might work: th-cam.com/video/0p80wlBqBkY/w-d-xo.html
When I shift into forward and try to manually turn the propeller it won't move both ways but when I force it to the right it moves then it stops both ways and u can't force it.
I wish you worked on mercs
My plan is to a similar series videos for a common outboard from each brand.
Stu great videos man thanks!! I do have a question or two though. Could you do a video on poppet valves (water pressure relief valves)? Also on my boat the serial number for my motor say it's a 1983 mercury and it does have the round poppet valve but the block/power head has the provision for the "lop sided" figure eight style poppet valve with the adapter on top of the power head behind the fly wheel. The "extra" opening appears to have a small freeze plug in it. Should I stay with the one that's one it or try to find the lop sided cover and put that back on? On plane at wide open throttle it does start to over heat some but I keep an eye on it and drop down in speed/RPM and it will cool off. I am replacing the water pump and impeller on the 27th of this month. Sorry for the long post. Thanks for any response.
I'll definitely do a video on this when I can get my hands on an outboard that has one. Given your problem is overheating at high RPM rather than low RPM it doesn't sound so much like a poppet valve problem though. I'm not really familiar with the Mercury configuration you are describing so can't really advise on whether to change, but I would definitely be looking at impeller and thermostat to solve your problem. I would also do a good engine flush.
Thanks for the reply Stu!!!!! I replaced the water pump and impeller today, the tell tale was peeing way better than before even on the muffs. Cant wait for the video if you get to do one. I apply what you do to my motor and it has HELPED a whole lot. I will be taking it out int morning and run it after it warms up to operating temp and see how it does. I think you're right about the poppet valve part will be getting new thermostats for it next week. Again thanks and keep up the great videos, enjoy them a lot!!!!!!!!!!
Do you every need to test the contact pattern between either gear and the pinion and adjust it with shims if it isn't good enough?
Generally with outboards the pinion fear is shimmed to a set length rather than inking and checking contact pattern.
You don’t have to worry about backlash and shimming on outboards?
Nice Stu, I take it your reference material is throw away with the grease all over it. Haha Anyway waiting on parts for my project. I sent at couple of pictures to your FB page from a antique VW car show yesterday. Check it out I think you would enjoy it. Cheers🍻
These were just print outs but plenty of my real books are covered in oil and grease too. I figure it just gives them character. ;)
Danger marine, I have a 79 merc 80 hp. I’ve cleaned the carbs, replaced the fuel tank fuel line. Was running fine, but then started running on only 3 cylinders, replaced the spark plug, and sometimes it’s hard to start, other times it starts right up, but after about a minute is starts to die, then idles again, and every now and then it looses some rpms at idle, do you know what is wrong with it?
Hmmm, that sounds like a strange one. You'd really have to go back to basics and check compression, reed valves, spark, timing fuel etc. It could be one of many, many things unfortunately.
Hmmm, that sounds like a strange one. You'd really have to go back to basics and check compression, reed valves, spark, timing fuel etc. It could be one of many, many things unfortunately.
Stu,on that Johnson 30 hp you have the dog clutch with the grooves facing the forward gear. The dilema on my johnson 35 hp(circa 1977),
Is that the manual has those same grooves face the prop side,or reverse gear. Is the manual wrong,or am I missing something?
Not sure unfortunately. This is the only engine like this I had ever worked on and I can't remember the specifics of it. If you have the service manual for your exact outboard I would go with that unless it seems obviously wrong for some reason.
@@DangarMarine Thank you very much Stu! I will follow the service manual,reread it and make it isnt incorrect. Your videos on that johnson 30 are a huge help in my rebuild even though mine is 23 years older than the subject motor which is nearly mechanically identical to mine.
Hello. Is their a special technique to getting pinion gear in 1987 johnson 110. Having difficulty getting it in place. Also does dog clutch need to be certain direction. It looks to be symmetrical
I've never worked on one but I imagine it would a similar technique to this motor. Some dog clutches are symmetrical some aren't. It is is truly symmetrical than either way is fine.
Thanks. U have great videos... I finally got it together. Unit needed to be in forward gear and horizontal in order to have enough clearance to get by dog clutch. Keep the videos going!!
What is the name of that red cylinder tool for the bearings and spring on the drive shaft ?
Not sure what it is call, it probably just had some Johnson part number to be honest.
Is there a way to do it without the special tool to get the ball bearings in with the spring, also does anyone know if it would be okay to install a used lower drive shaft the holes where the ball bearings go with the spring, I bought a used one they are more rounded off where the ball bearings go compared to my motor it has low hours and the edges are very sharp , would that be a problem or should I just install it. I was thinking it should be okay just a little more play in the ball bearings hopefully it doesn't cause to pop out of gear
what is link to buy the special tool sleeve?
what year johnson is this looks way different than mine
I can't get the reverse past that blinking shift pin after bunch of tries.
Is there a easy way to change the dog clutch in a 01 johnson 175hp
What's happening with the boat build stu?
I was thinking the same thing. Hope he has not given up on it.
James Smith yeh me too. I am looking forward to seeing it finished
I have been a bit slack with it recently but will definitely pick it up again soon!
Dangar Marine hope to see some more progress. Blame it on this cold weather. We have been in the minus up her in the hunter valley
you need to say what year model the gear case is from because they had different way to install said shafts... I made a tool for them 80+ year models on a drill press...
This was a 1996 30HP.
you need to show why it's a pain in the ass to make it work.. and it's all about the 3 dog over the 2 dogs... I used a piece of PVC and made it work... never had one come back from a problem...
I am trying to change a 2001 Johnson 8 horsepower prop but pin not spline Drive
hi.
can you help me to point how to change clutch dog at evinrude 40 hp 1997, 2stroke?
Is there anyway to put shaft back in without the tool?
It would certainly be very difficult.
So what is the red tool called? Manufacturer?
Excelente!!🇧🇷
Thing about this installation is on the Ford and reverse gear they're supposed to be a thrust washer on the inside of the gear on both of them and you don't say nothing about it when you're putting it together do those washers vary from different units because I didn't see you say anything about those thrust washers and I need to make sure because I'm having trouble getting it the shift from forward to reverse
Great detailed video, Stu! Did this LU have that annoying bearing carrier ring/nut like on Yamahas?
Hey Jim, I think this one had a big snap ring from memory. I'll be putting it back in soon!
The LTD is purple !
No, the dress is white and gold! ;)
Okay, so rumours of its pinkness may have been exaggerated. ;)
do i have to have dent spring in a 1975 25 HP evinrude
Not sure, sorry.