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Author Topic:   Johnson 1984 25-HP Gearcase Re-seal

Jholmes105 posted 10-03-2014 06:08 PM ET (US)
I own a 1984 STANDARD 13 in 100-percent original condition. Its outboard engine is another story! [The Johnson 1984 25-HP outboard engine is a] very low hour unit. It has a new impeller, new plugs, freshly cleaned carburetors, and new lower unit oil. The lower unit lubricant all came out on first start up after changing. I guess it will need a lower unit seal. How difficult is it to [seal a gear case]? It will be done by me, a guy who loves a challenge but on the same hand is willing to hand over a job that is best done by somebody who has done it before. I have a very reputable outboard guy who quoted $160 and $40 for parts. What do [readers] think? Thanks.
By the way this little 13 is for my son in the coming years! Once I get a few pics uploaded I will share a link.
Jeffrey
jimh posted 10-03-2014 07:53 PM ET (US)
The hardest step in installation of a new gear case seal may be removing the rear main nut that seals the unit. These are often corroded in place and hard to remove. They also may require a specialized tool. Sometimes the best tool in your toolbox is your checkbook.
contender posted 10-03-2014 08:29 PM ET (US)
kinda have to agree with jim on this one, the two bolts could be corroded and will snap, You could try to unscrew them. Might be worth spending the bucks to have it done. I have done this once, I created my own tool and welded it to do this, the engine was a 140 OMC, after removing the two bolts the gears came out with no problem using the puller I made.

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Author	Topic: Johnson 1984 25-HP Gearcase Re-seal
Jholmes105	posted 10-03-2014 06:08 PM ET (US) I own a 1984 STANDARD 13 in 100-percent original condition. Its outboard engine is another story! [The Johnson 1984 25-HP outboard engine is a] very low hour unit. It has a new impeller, new plugs, freshly cleaned carburetors, and new lower unit oil. The lower unit lubricant all came out on first start up after changing. I guess it will need a lower unit seal. How difficult is it to [seal a gear case]? It will be done by me, a guy who loves a challenge but on the same hand is willing to hand over a job that is best done by somebody who has done it before. I have a very reputable outboard guy who quoted $160 and $40 for parts. What do [readers] think? Thanks. By the way this little 13 is for my son in the coming years! Once I get a few pics uploaded I will share a link. Jeffrey
jimh	posted 10-03-2014 07:53 PM ET (US) The hardest step in installation of a new gear case seal may be removing the rear main nut that seals the unit. These are often corroded in place and hard to remove. They also may require a specialized tool. Sometimes the best tool in your toolbox is your checkbook.
contender	posted 10-03-2014 08:29 PM ET (US) kinda have to agree with jim on this one, the two bolts could be corroded and will snap, You could try to unscrew them. Might be worth spending the bucks to have it done. I have done this once, I created my own tool and welded it to do this, the engine was a 140 OMC, after removing the two bolts the gears came out with no problem using the puller I made.