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Author Topic:   Need help with gear case removal
BillS posted 09-08-2000 10:16 AM ET (US)   Profile for BillS   Send Email to BillS  
I have a 1973 Johnson 40HP with a leaky seal in the gear case, and since I don't have a trailer I thought that I would just take off the gear case and have a dealer replace the seals. So I followed the instructions in the service manual (disconnect the shift connecting rod and remove seven bolts). When I pull on the gear case it moves about an inch and then hangs up on something but I can't see what. Any help would be greatly appreciated.
reeltime2 posted 09-08-2000 01:53 PM ET (US)     Profile for reeltime2  Send Email to reeltime2     
Did you get the bolt from under the (im not sure what its called the little tab that you can adjust to make sure the boat tracks straight)there is a bolt to remove the tab and usualy one under the tab.
BillS posted 09-08-2000 02:09 PM ET (US)     Profile for BillS  Send Email to BillS     
The gear case is separating from the exhaust housing by about an inch, the only things that I can see going up the housing are the drive shaft and the connecting rod for the shifter. I can see that the shifter is disconnected thru the access hole on the side of the housing. I am thinking that it is stuck where the drive shaft connects to the motor, and that should just slide apart.
I am really tempted to try a bigger hammer but then I'll have to take the whole motor to the shop.
Arch Autenreith posted 09-08-2000 02:27 PM ET (US)     Profile for Arch Autenreith  Send Email to Arch Autenreith     
Funny, Bill.
I have the same saying for what you may do: "If it sticks, force it. If it breaks, it needed replacing anyhow."
Lil Whaler Lover posted 09-08-2000 03:30 PM ET (US)     Profile for Lil Whaler Lover  Send Email to Lil Whaler Lover     

Go to and post your question or search for it in there postings. In spite of the humor in previous postings, parts for the old 40 can be hard to come by and expensive, so do not break it if at all possible. Dave

ffk posted 09-13-2000 09:52 AM ET (US)     Profile for ffk  Send Email to ffk     
Just found about this site. Certainly great info and activity. Regarding your gearcase, I have a factory shop manual that you can use if you care to. I am restoring twin 1972 65hp electric shift models for my 72 Outrage, and may be able to help if you need anything.
BillS posted 09-15-2000 10:12 AM ET (US)     Profile for BillS  Send Email to BillS     
I have the service manual for my motor but unfortunately it doesn't cover what to do when things go wrong. I am making some progress; I've gotten the gear case off by pulling the driveshaft out of the gear
case. Now all I have to do is get the drive shaft to disconnect from the power head. At least now I can see what I what I am working on. I'll try some penetrating oil and vibration this weekend.

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