Author Topic: Outboard lower unit rebuild  (Read 5615 times)

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Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #25 on: August 04, 2013, 03:16:30 PM »
Yes,

I found the root cause of the issue.  I think a combination of water through the shift grommet, which was never put back on correctly and the driveshaft bearing was completely destroyed.  So that was some of the metal fragments found in the lower end. 

The previous owner was not too descriptive on what it was or was not doing.  But I think it got hot and destroyed the bearing.  The rest of the bearings and o-rings look fine, but I am going to replace them all with some new lower end seal kit with some loctite and aviation gasket sealer. 

Throw some bright blue Mercury synthetic gear oil and I hope to water test it soon. 

VT
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline Hydro-Therapy

Re: Outboard lower unit rebuild
« Reply #26 on: August 07, 2013, 02:55:49 AM »


 VT before you put in the oil , you can do a pressure leak down test to make sure you are sealed up properly. This can save you some time and money and a milkshake to clean.

  H-T
Fish forever Work whenever !!!!!
"89" 19SR Keith 115 Merc. 15 4s kicker W/trollmaster Raymarine A70D

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #27 on: August 07, 2013, 07:52:54 AM »
H-T,

Yes, I plan on doing the pressure test for 45 minutes.  I should get most of the seals, and what not today and tomorrow.  I will double check the shims or drive shaft lashing too.

VT
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline allpauwork

Re: Outboard lower unit rebuild
« Reply #28 on: August 07, 2013, 10:14:13 PM »
That's great that you are tearing into it.  You know that old saying about "If you want it done right you have to do it yourself".

I once bought a used Evinrude/Johnson that a guy supposedly rebuilt.  The paint was nice and shiny.  Turns out the two bearings on the prop shaft were installed backwards and looked like they were pounded in place with a sledge hammer!

Good luck!

Offline Sea Bear

Re: Outboard lower unit rebuild
« Reply #29 on: August 07, 2013, 10:22:43 PM »
 :yeahthat: I got my motor from a shop that had rebuilt the carbs.  Wouldn't run, so I tore the carbs apart & found a part missing.  Go through that motor yourself, and you'll know its good! 
1981 Arima Sea Chaser 17'
Evinrude 70hp 2 stroke & Evinrude 9.5 Sportwin

www.skagitbroomworks.com

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #30 on: August 08, 2013, 12:49:57 PM »
Thanks guys.  It has been somewhat fun.  I really haven't messed with an engine since I sold the Porsche a few years back.  If there is a next time to take the lower end apart it will be pretty darn easy to do.  Especially after making up some custom bearing removing tools. 

I should get the rest of the parts this afternoon and if I get some time tonight I should have it all back together. 

VT
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #31 on: August 10, 2013, 11:19:29 AM »
So I have an issue with the drive shaft thrust washer and bearings.  I will try to get a photo, but the bearings and washer will not fit flush on the drive shaft.  They rest about an 1/8 of an inch above.  So I can't get the drive shaft bearing housing to fit flush.  Both the bottom thrust washer and bearing were destroyed.  Any thoughts on getting the washer down to fit flush?  I don't know if it is build up from the other washer being destroyed or?  Item number 35 is the lower thrust washer that was gone.  Item 34 was the bearing that was in pieces.



VT
« Last Edit: August 10, 2013, 11:24:34 AM by Vancouvertechie »
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline Jeff

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Re: Outboard lower unit rebuild
« Reply #32 on: August 10, 2013, 11:40:39 AM »
Excellent score on the Johnson VT!  Those compression numbers sound very good, they're probably about that when new.  I've got that same motor in a 40hp, I believe the carbs are the difference.  Mine is only putting out about 110 psi.   :doh: 

1989 Sea Sprinter
2005 Yamaha 60hp
2011 Suzuki DF6

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #33 on: August 12, 2013, 07:44:14 AM »
I got everything back together yesterday, pressure tested and ran the motor for about 15 minutes in the drive way.  I cycled through the gears for a bit and no issues.  I then drained the lower end and put in fresh oil.  Oil looked good with a few small pieces of metal which I expected.  I didn't give the housing a nice bath before I put it back together so I assumed there was some bits laying around that I could not reach. 

Nothing to speak of as far as noise, water, and what not.  I hope to water test it some time this week or over the weekend.  Then drain the oil again and check for anything unusual. 

VT
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Online amazing grace

Re: Outboard lower unit rebuild
« Reply #34 on: August 12, 2013, 07:55:21 AM »
Congratulations John, sounds like you might have her. I hope your water test is a huge success. I am excited for you. As I said, I think you will be smitten with that Johnson and how it performs. :party:
1989 22' C-Dory Angler

Offline Markshoreline

Re: Outboard lower unit rebuild
« Reply #35 on: August 12, 2013, 07:59:35 AM »
You've made silk purse from a sow's ear- Outstanding!

Can't wait to hear about it's on-the-water performance...

OK, with the $200 purchase price how much to the parts and tools make the total cost?  This has got to be one of the greatest bargains ever!
2002 Sea Ranger HT 21, Yamaha 150, Yamaha 9.9

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #36 on: August 12, 2013, 08:11:25 AM »
Parts:

Marinengine.com
Drive shaft bearing and thrust washers 41.10
Lower end seal kit, O-rings, seals, spring, and bearings 59.03
Harbor Freight puller 17.99
Harbor Freight digital caliper 12.99
Harbor Freight vacuum pump and fittings 10.00
Harbor Freight 8" needle nose pliers 8.99
Johnson lower end oil 32 oz.  13.99 x 2.

Total = 178.08 parts and tools  200.00 outboard

VT
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline Sea Bear

Re: Outboard lower unit rebuild
« Reply #37 on: August 12, 2013, 08:29:44 AM »
Great job vct.  Just in time for some salmon fishing!  Good luck on your test run! :clap:
1981 Arima Sea Chaser 17'
Evinrude 70hp 2 stroke & Evinrude 9.5 Sportwin

www.skagitbroomworks.com

Offline Jeff

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Re: Outboard lower unit rebuild
« Reply #38 on: August 12, 2013, 08:50:43 AM »
John, did the motor come with a tach?  If not, I have an OMC tach which plugs into a spot on most OMC controls.  I'd be happy to let you borrow it if necessary.
1989 Sea Sprinter
2005 Yamaha 60hp
2011 Suzuki DF6

Offline ak-angler

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Re: Outboard lower unit rebuild
« Reply #39 on: August 13, 2013, 12:09:23 AM »
Good job getting it fixed! Let us know how it works.
1985 Sea Ranger 17 Skiff Top with 2012 Suzuki DF90A

2007 Cape Cruiser Marinaut 26 with twin 2006 Honda BF90's

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #40 on: August 13, 2013, 12:58:24 PM »
Jeff,

Do you want to sell it or do you need it for something else?  I could use one.

VT
Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline Jeff

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Re: Outboard lower unit rebuild
« Reply #41 on: August 13, 2013, 05:01:40 PM »
John, I'd like to keep it, though I though you might use it for prop selection and general info.
1989 Sea Sprinter
2005 Yamaha 60hp
2011 Suzuki DF6

Offline wedocq

Re: Outboard lower unit rebuild
« Reply #42 on: August 13, 2013, 06:50:35 PM »
VT,
I am very impressed! I have had my FrankenZuki apart in a thousand pieces, and was pretty confident I could get it back together properly. Lower units scare me!  :hoboy:
-Shawn
2002 21' Arima Sea Ranger HT  Suzuki DF175 4-stroke.
WEDOCQ= WE DO SEKIU! It pays homage to my Uncle Jay who died of cancer.

Offline Vancouvertechie

Re: Outboard lower unit rebuild
« Reply #43 on: August 17, 2013, 04:19:09 PM »
Shawn,

Thanks!  Well I was able to get out today.  After spending the day with Mark on the water I was more determined to get my boat done.  I didn't go too fast around 15-20 mph.  I still need to works some kinks out, but so far so good.  I will drain the oil tomorrow and give it a good look. 

VT



Boats owned:

2003 15' SeaHunter 50HP Suzuki (FI4Strk)
1991 16' SeaChaser 50HP Johnson (Keith)
1995 19' SeaRanger 115 Yamaha (FI4Strk)

Offline Markshoreline

Re: Outboard lower unit rebuild
« Reply #44 on: August 17, 2013, 04:58:26 PM »
Way to go!  Sounds like you put that day off to good use.
2002 Sea Ranger HT 21, Yamaha 150, Yamaha 9.9

Online amazing grace

Re: Outboard lower unit rebuild
« Reply #45 on: August 17, 2013, 05:31:07 PM »
Sweet vt, It makes my heart sing to see that Johnson on the water doing it's thing.  :dance:
1989 22' C-Dory Angler

Offline ak-angler

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Re: Outboard lower unit rebuild
« Reply #46 on: August 17, 2013, 05:47:01 PM »
Congratulations!
1985 Sea Ranger 17 Skiff Top with 2012 Suzuki DF90A

2007 Cape Cruiser Marinaut 26 with twin 2006 Honda BF90's

Offline CanvasGuy

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Re: Outboard lower unit rebuild
« Reply #47 on: August 17, 2013, 06:26:36 PM »
Right On ...Good to see you workin it...GO VT... :yeahthat:
Gary Smart
-1980 Hardtop Glasply Sedan"VistaCruiser" 
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“Two possibilities exist: either we are alone in the Universe or we are not. Both are equally terrifying.” Arthur C. Clarke

Offline Jeff

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Re: Outboard lower unit rebuild
« Reply #48 on: August 17, 2013, 06:39:38 PM »
Excellent!
1989 Sea Sprinter
2005 Yamaha 60hp
2011 Suzuki DF6

Offline Sea Bear

Re: Outboard lower unit rebuild
« Reply #49 on: August 17, 2013, 11:36:10 PM »
Congrats VT, you're in business.  You got a screaming deal on that motor, and it should serve you well.  Glad to hear you could get the boat up on plane and travel at that speed.  I spend most of my time going 20 or less.  I just don't want to be in a hurry.  How did you get such a good deal on that motor?  I've been looking, and those 50's usually go for a grand or more...
1981 Arima Sea Chaser 17'
Evinrude 70hp 2 stroke & Evinrude 9.5 Sportwin

www.skagitbroomworks.com