Gearcase Head Assembly - 1978 25 hp Evinrude

[jecartag]

I recently bought a 1978 Evinrude 25 hp. Have had it on the water many times and it runs great. However, I was getting water in the lower unit, so I decided to change seals. When removing prop, I found small amount of fishing line, which makes me want to change the prop shaft seal as well. According to my manual, the seal is sandwiched between a bushing and the gearcase head assembly. How do I go about removing this seal and replacing it? Any help is appreciated!

 

[14ftgrumman]

Re: Gearcase Head Assembly - 1978 25 hp Evinrude

Should be like my 72 25HP. I got a lower unit seal kit from the local CarQuest store, had everything in it.

Basically, you remove everything that is in the way and replace the seals. Sounds easy, but you will need to have a vise, some drift pins (I used some old screw drivers) to drive out the flat washer and the seal behind it. I wound up using a dremel grinder to get the seal out.

My friend who is a marine mechanic said that the head assy can't be resealde, but mine doesn't leak-yet.

They show up on eBay, but buying a used one is iffy, at best. You could wind up with one that leaks worse than the one you replaced.

 

[jecartag]

Re: Gearcase Head Assembly - 1978 25 hp Evinrude

So basically I'm supposed to get the seal out of the head assembly without pulling the bushing? Dremel...good idea... How would I then get the new seal in? Would I just bend in and wiggle it back in place? Thanks for the reply

 

[14ftgrumman]

Re: Gearcase Head Assembly - 1978 25 hp Evinrude

Push it in , using the vise as a press. Then tap verry carefully until it is fully seated against the brass bushing. Or put the washer against the seal and usin g the vise again, push it in the rest of the way. If I remember correctly, there is no room for the head assembly if the seal isn't in all the way.

I wonder if we are on the same page.

The large flat washer/spacer on the prop end, and behind that is the seal I replaced.

I don't remember if there is a seal farther in, but if there is, I didn't change it out.