CONTINUOUSWAVE

Oldslowandugly

A few years ago I added a brand new tilt gauge and sender to my 48SPL. Within a year the sending unit was corroded to uselessness. The gauge works fine when tested. Test your gauge by disconnecting it at the motor and follow the directions for whatever brand motor you have. If [the gauge] passes the...

Oldslowandugly

No, it went on for several days. I could not report it at the time since I was blocked. Once I made it in I focused on updating the gearcase thread.

Oldslowandugly

The firewall only intervenes when it see repeated log-ins and connections from the same user or same ip-address. The firewall has been a TREMENDOUS asset as it has allowed me to block malicious attacks from the nations of China and Russia. Prior to the purchase of the firewall, the website was ofte...

Oldslowandugly

Phil T wrote:There is a some unusual behavior with the website's host's firewall.

The take-away: it's not you. Take a breath, breathe easily. Do not throw your computer at the plate glass window. At least not today.

Thanks Phil. Good to know!

Oldslowandugly

Thanks Jim. While this repair concentrated on the 1993 to 2005 Evinrude 40, 48, and 50-HP engines, the procedures are common to earlier and different displacement motors as well. I was afraid to take this job on because of the special tools and measurements required. I have the factory service manua...

Oldslowandugly

Torque fasteners specifications for Evinrude 40, 48, 50-HP engines All units in inch-pounds unless noted otherwise Water pump screws: 60 to 84 Oil level and fill drain plugs: 60 to 84 Gearcase retaining screws 3/8": 18 to 20 foot-lbs Gearcase retaining screws 7/16": 28 to 30 foot-lbs Prop...

Oldslowandugly

At this point the used fresh water gear case is finished. SOME FINAL REMARKS ON THE PROJECT The gear case came apart fairly easy with simple tools. A common automotive steering wheel puller can extract the propeller shaft bearing carrier if it is not badly corroded and stuck in the case. I used the ...

Oldslowandugly

Next the propshaft sacrificial zinc anode goes on. If your anode looks like the one on the right side- replace with a new one like on the left side. Fig56a.jpg The anode slips down the propshaft and two small stainless bolts secure the anode to the propshaft bearing carrier. Torque to specs. Fig57a....

Oldslowandugly

Once you are sure the impeller will turn with the driveshaft you can insert the stainless housing bolts into the holes that have been coated with anti-seize. Tighten the bolds with torque wrench and to the specified torque. [Moderator's note: here is a good place to insert the actual torque value.] ...

Oldslowandugly

Now that the case has passed the seal tests I can finish installing the rest of the parts. I replaced all fasteners with marine grade stainless steel fasteners. I also use anti-seize on all threads. NEW PROJECT: WATER PUMP SERVICE The water pump service used a a new impeller and new seals. The pump ...

Oldslowandugly

Have you pressure-tested the gear case seals after your latest final assembly? Yes, I pressure and vacuum tested the case after giving the sealer three days to cure. ....what is the recommended maximum pressure in PSI to use in the test? The manual suggests 3 to 6-PSI initially and then check if th...

Oldslowandugly

Ok Jim. When it happens I get a page that informs me I have been blocked due to my ISP. I can't remember what it was but it was one of the commercial firewalls available. Even if I try to get in from a Google search as a guest it remembers me and blocks me. If it happens again I will jot down the in...

Oldslowandugly

I keep the Board Index as a bookmark on my PC and that page has always opened immediately for me until lately. As for pictures with my latest postings, I have always taken them directly from the Canon camera program on my PC. They load to the site fine, but later when I return they are missing. If I...

Oldslowandugly

While waiting for the Ultra Black to cure I turned my attention to the parts gearcase. The front of the cavitation plate suffered a big bend and cracked on both sides. I wanted to try the aluminum brazing technique I see in videos. I took my grinder and cleaned off the area along the crack and found...

Oldslowandugly

I am having a very hard time logging in. If I can get in, topics don't load, pictures get dropped, the page locks up, sometimes I get kicked off and told I am blocked. Then I wait a few hours and all is well. Anyone else getting this or is it just me?

Oldslowandugly

Update: either the new double-lipped seal is not worthy or perhaps I failed at installing it. Either way, when tested it leaked air terribly. I removed it and purchased two new single-lipped seals. I installed them back-to-back as per the factory manual. When tested they held air nicely.

Oldslowandugly

fig45a.jpg The Ultra Black must be allowed to cure for 24-hours. I will give the Ultra Black a longer during time because of the large carrier flange surface I coated. Do not pressurize the case for a test and blow out uncured sealer. That would ruin all your work and require rebuilding it all over...

Oldslowandugly

With the carrier seals in place and working I can finally place the carrier into the gearcase and seal it up. I removed the propshaft again to clean inside. I had to wirebrush the remains of the cured Ultra Black from the inside of the case. It comes off very easily by using a wire brush on a long s...

Oldslowandugly

I now have the old-style seals. I found that the bearing in the carrier is the same as the pinion bearing. So the same bearing tool can be used to install the inner carrier seal. fig39_.jpg The smaller part of the tool fits the carrier roller bearing and guides the seal straight in. The OEM double t...

Oldslowandugly

Good to know. I had all my fire extinguishers replaced several years back during a big recall. I carry two 5-BC and one 10-BC.

Oldslowandugly

I was able to extract the seal without damaging the bearing. Fig37_.jpg It looks like [the propeller shaft seal is composed of] a very thin steel ring surrounded by a hard rubber molding. and there are two lips with springs behind them. Fig38_.jpg I guess the gear case manufacturer expects the thick...

Oldslowandugly

The Ultra Black has cured and I tested for leaks on the gearcase. Another problem has emerged. The original double seals on the propshaft were superseded by a single double lipped seal. The instructions that came with the new type seal explicitly warned to NOT use sealer when installing. That did no...

Oldslowandugly

Figure 36 shows all the parts salvaged from the "junk" gear case.They all appear to be reusable. Nothing is broken except for the gear case housing I cut open, and even that can be repaired if really needed.

: Fig. 36. The junk gear case and parts from it.; Fig36_.jpg (70.84 KiB) Viewed 8456 times

Oldslowandugly

On February 16, 2022, I removed the rest of the parts from the junk gear case. Using a telescoping magnet-on-a-stick helps in reaching in and grabbing the reverse gear, thrust bearing, and washer. Before the propshaft can be removed, the shifter pivot screw must be removed from the side of the gearc...

Oldslowandugly

While waiting for the Ultra Black to cure I turned my attention to the frozen gear case. To pull out the bearing carried I tried every trick I knew--they all failed. I used my Dremel-tool cutting disc to cut open the gear case housing at the bearing carrier. I used the OMC carrier puller tool to put...

Oldslowandugly

Figure 29 shows the bearing carrier when fully seated into the gear case. The outboard end of the bearing carrier will be located about 1/8-inch into the gear case housing. The clamp will press it in very easily. You will know when it hits bottom and is fully seated.

: Fig. 29. The bearing carrier is fully seated in the gearcase.; Fig.29_.jpg (44.79 KiB) Viewed 8458 times

Oldslowandugly

Break is over: back to work. The bearing carrier has a large O-ring that must compress to allow the carrier to seat all the way. This is important because the position of the carrier establishes the position of the reverse gear in relation to the pinion gear as well as clearance at the prop shaft be...

Oldslowandugly

I am looking out the window as it snows. Single digits tonight. Years ago we used to fish all Winter at the power plant outflows. We even snuck small boats in to get way back near the warm water discharges. I guess that annoyed the powers that be. Now they schedule maintenance and shut them down jus...

Oldslowandugly

Thanks for the encouragement. Don't worry. There is plenty of Winter left to finish this project.

Oldslowandugly

I like Winter. No bugs, less noise, and I catch up on indoor projects. I am rebuilding my two gearcases but getting frustrated. Someone smarter than me once said you need to know when to walk away. So I did. I am also building a TV room with a surround sound system. There is always something interes...

Oldslowandugly

I thought of using grease, but sealant is supposed to be used on the O-ring area. Sealant and grease don't play well together. I cleaned off all the sealer--AGAIN--and tried a dry fit. [The propeller bearing carrier] went into [the gear case housing] all the way with some difficulty. There is a slig...

Oldslowandugly

I can't get the propeller bearing carrier into the gearcase when the O-ring is installed. Otherwise it fits inside fine. Further study is indicated.

Oldslowandugly

Oddly, when GEICO first took over the insurance for BOATUS, an agent advised me that I could carry the same boat/trailer towing coverage on my policy as my BOATUS membership offered. I was able to save several hundred dollars. Since then the premium increases have negated that.

Oldslowandugly

I have been with BOATUS for many years and used their insurance. They used to reduce your premium if no claims were made. I have never made a claim. Then GEICO took over and all of a sudden my agreed value was reduced, and my premiums went up. The 2022 year is the highest it has ever been. I am very...

Oldslowandugly

Jim has given some great advice. Something else to consider: small children don't stay small for very long!

Oldslowandugly

I had the prop shaft bearing carrier dry-fitted and ready to go. I applied sealer to the O-ring and flange. But when I went to insert it into the gearcase it would not go in the last half inch. Do not be tempted to bang it in! It may need a slight tap, but not a forceful blow. I had to remove it, cl...

Oldslowandugly

A fellow at my marina has an 18 Ventura. I would love to own abs 18 VENTURA. He takes his wife and three kids out in the 18 VENTURA, and all are seated comfortably. The bow seats and stern bench seat are what makes it so versatile. He knew what he wanted but an 18 VENTURA. To find one took him quite...

Oldslowandugly

For the outer seal would the lubricant is water. The pressure of the fluid seawater would press the seal lip against the shaft. I read that the open side of the seal faces the seawater for this reason, however, I am no expert at seal operation. The factory service manual instructs for the installati...

Oldslowandugly

[I combined another thread on the topic of gear case rebuilding into this thread on the same topic--jimh] [The original thread containing these posts already had over 40 illustrations and remains available as Rebuilding Gear Case of 48SPL-Part 1 . Threads with so many images are difficult to load fo...

Oldslowandugly

ASIDE: Nice process. How did you build it? I wanted to send the bare gearcase out for hot tanking. No one near me does that anymore. Only for ferrous metals. I have a dry blast cabinet but I don't use it for aluminum.

Oldslowandugly

[Moderator's note: I moved this very important first step in disassembly to be located much earlier in the narrative, instead of at the end of the narrative.]

Oldslowandugly

I put the forward gear, thrust bearing, and spacer into the gearcase. The OMC roller bearing grease holds the parts in place while you work. Next, the driveshaft bearing carrier goes on the driveshaft and the whole assembly is placed into the gear case. Wrap some masking tape around the driveshaft s...

Oldslowandugly

I put the new seals into the propeller shaft and drive shaft bearing carriers. I did not have, nor could I locate, the proper seal installation tools. I found that a brass lavatory sink tailpiece fit the propshaft seal perfectly. A 13/16-inch deep-socket fit the driveshaft seals perfectly. IMG_0281_...

Oldslowandugly

Before starting the rebuilding, I did thread chasing and final clean-up. An amazing amount of dirt gets into the nooks and crannies while working. IMG_0279.JPG I can advise a simple addition to any workbench. I bolted two short sections of two-by-four to the underside of the workbench. Now the gearc...

Oldslowandugly

I found the console mounted switch that came with my trim/tilt kit. The part # 0172899 is absolutely available. But I don't see the long cable from the console to the motor. [The switch] may just plug into the existing harness at the control box. https://www.crowleymarine.com/parts/14062.cfm Visit t...

Oldslowandugly

IMG_0278.JPG Show above is the tool used to measure the upper bearing carrier to pinion gear distance. OMC wants to see .030" clearance. This tool is calibrated the exact distance minus the .030". I assembled the roller bearing, spacers, shims, upper bearing carrier, and properly torqued ...

Oldslowandugly

It is listed at Crowley under rigging accessories at https://www.crowleymarine.com/johnson-evinrude/parts/39617.cfm The whole kit is for rigging from the console to the motor I believe. It is similar to what came with the power trim-tilt kit that I back-fitted to my 48SPL. If you look the switch its...

Oldslowandugly

Here is the prop shaft with the grooves rough sanded by machine and then sanded down smooth by hand.

: Fig. 17. Rough sanded by machine.; IMG_0270.JPG (163.3 KiB) Viewed 11898 times

: Fig. 18. Smooth finish by hand.; IMG_0271.JPG (149.66 KiB) Viewed 11898 times

Oldslowandugly

I accomplished a lot today. I sanded the Marine Tex off of the shafts with the sanding disc, then finished with the sandpaper strips.' IMG_0274.JPG The inside prop shaft seal groove was worse than the outer groove. The inner groove was deep, wide and well defined, while the outer was shallow and inc...

Oldslowandugly

I hope you can clean the switch and get it working. Fresh control cables are always a good idea. Crowley marine lists a top-mount remote control as an accessory replacement going back to 1978 up to 2010. It is part # 5006182. https://www.crowleymarine.com/parts/105996.cfm I believe the OMC "sna...

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