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Author Topic:   OMC Lower End Removal
Cal posted 05-12-2001 12:52 AM ET (US)   Profile for Cal   Send Email to Cal  
Read the previous posts and tried to remove the lower end of my 92' Evinrude 150 last weekend. It came loose but couldn't find a way to unpin the lower unit shift rod from its linkage under the powerhead. I could barely see the top of the rod and pin but couldn't get a hand in there or think of a way to repin when done.

I appreciate any ideas as it came with the Outrage 20 I bought last fall and I have no idea of the water pump's or thermostat's age.


whalernut posted 05-12-2001 05:51 AM ET (US)     Profile for whalernut  Send Email to whalernut     
I would like to know the same things? I am going to attempt a Water Pump Kit myself in a week and need pointers on removing the Lower Unit! I thought the shaft just slid out of it`s spline? Regards-Jack Graner. P.S. The engine is a 85h.p. Johnson 1975.
Mark Gallagher posted 05-12-2001 06:38 AM ET (US)     Profile for Mark Gallagher  Send Email to Mark Gallagher     
I strongly advise getting a service manual, OMC or aftermarket. You'll get use from it many years into the future. On the V4 OMC you need rotate the propeller, shift the gearcase into reverse position. Next, pull the retaining pin, jesus clip, up by the powerhead, top of shift linkage and then push the shift lever towards the powerhead. This will disengage the shift rod and allow the lower unit to be removed.
DIVE 1 posted 05-12-2001 06:52 AM ET (US)     Profile for DIVE 1    
Cal & Whalernut,
Keep the lower unit in place until the shift rod is unbolted. Unhook the shift cable at the powerhead. Look in under the carbs on the left side of the engine while moving the shift linkage at the powerhead. when you can clearly see the head of the shift rod attachment bolt, you are ready to proceed. Use a 1/4" drive universal socket and a long 1/4" drive extension bar. Once the bolt is removed, proceed with unbolting the lower unit and remove it.
When you get the lower unit out, note the position of the shift rod. Move the shift rod up and down. There are 3 detents you will feel as you move the shift rod. Remember which detent the rod was in when it was removed. It will need to be in the same position for installation. DO NOT ROTATE THE SHIFT ROD - turning the shift rod clockwise or counter clockwise adjust the length of the shift rod. If you get the rod out of adjustment, you will need a heighth gage to reset it properly.
To reinstall the lower unit, set the shift rod in the same detent as when removed. When you are ready to reinstall the shift rod bolt, look in the left side under the carbs and line up the bolt holes by moving the shift linkage slightly up or down. Insert a piece of stiff wire or coat hanger through the holes to verify alignment. Remove wire and put a little grease in the universal socket that fits the shift rod bolt. Put the bolt in the socket and and install the shift rod bolt. A retrieval magnet also helps when the shift rod bolt continuously falls out of the universal socket.
Hope this helps.
whalernut posted 05-12-2001 07:16 AM ET (US)     Profile for whalernut  Send Email to whalernut     
Thanks guys! I think I will have a mechanic do it! I am all thumbz when it comes to mechanical projects and want it done correctly. In my case it is better for me to pay the Piper! Regards-Jack Graner.
Cal posted 05-13-2001 12:44 AM ET (US)     Profile for Cal  Send Email to Cal     
Jim, thanks for the clue to solve the problem. My new manual wrote about removing the shift pin or bolt but showed a picture of where the shift and throttle cables attach - so I disconnected the shift cable.

I looked at the left side several times, even put my glasses on, but all the plumbing an the V-6 kept me from seeing the shft rod. Now that I now it is there, I will find a way in.

Jack. Removing the lower unit isn't hard but each engine seems to have a unique way of disconnecting the shift rod, so Mark's method may work for you.

Now I need to find the thermostat.


Whalerdan posted 05-14-2001 07:50 AM ET (US)     Profile for Whalerdan  Send Email to Whalerdan     
I had the same problem. Had a buddy move the shifter back and forth to see where the rod connected. It was on the right side. Used a long screwdriver to get in there and remove it. Was worried about getting it back in but found that the bolt has a gide pin on the end of it. When we got the lower unit bolted back up my buddy moved the shifter until the holes lined up. Put the blot on the end of the long screwdriver with duct tape and stuck it back in. No worries.

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