1998 25hp Evinrude lower unit removal

[blasutton]

Am I missing something, I removed the 4 bolts and the nut in front of the motor and also disconnected the linkage thru the plastic intakes. For some reason the front of the lower unit will not release from the motor. I have sprayed penetrate oil on the threads of the stud and have screw drivers wedged in to try to put tension on the stud to maybe break it loose. Do you think the stud is frozen in the upper housing?

I removed the philups screw on the bottom of the lower unit and can't get that back in (oil screw with magnet), feels like its hitting a bearing. I plan to replace the shaft seals (they were leaking) and the bearings while I have it apart. Boat/motor was my father-in-laws and I plan to buy a manual. Any suggestions/help would be appreciated.

 

[HighTrim]

Re: 1998 25hp Evinrude lower unit removal

The drain plug screw should not be hitting anything. Are the threads stripped?

Is the gearcase dropping about a half an inch or not budging at all?

 

[blasutton]

Re: 1998 25hp Evinrude lower unit removal

It only drops in the back probably about an 1/8 of an inch. I have screw drivers on each side about half way to the front in the crack. I have twisted the lower unit side to side in hopes of maybe breaking it loose if it is frozen but to no avail. I have been letting it sit with penetrate 2-3 hours spraying occasionally.

I have never removed the small screw before only the two larger fill and drain screws. THis screw is in front of the bottom larger drain screw.

 

[blasutton]

Re: 1998 25hp Evinrude lower unit removal

Attached a picture of where I am so far. As you can see the front won't drop.

 

[Cofe]

Re: 1998 25hp Evinrude lower unit removal

You will have to remove the plastic cone shaped keeper on the upper shift shaft, it has a vertical slit in it that you can spread with a fingernail or small screwdriver then remove the upper half brass nut. See pic

 

[Cofe]

Re: 1998 25hp Evinrude lower unit removal

That front stud goes through a steel sleeve and likes to corrode. Spray penetrant and pry gently on the stud with the nut barely on. Sometimes this takes time. See pic again

You will need to get an OMC manual. Ebay usually has them.
Do not attempt to disassemble the gear box with out it, you could damage parts.
Yes that one screw you removed is for the gear set.

 

[blasutton]

Re: 1998 25hp Evinrude lower unit removal

Thanks Cofe, I am gradually moving the screw drivers and making some headway. Found some knocker-Loose and have been putting that on and prying slightly with the screw drivers. I did take the plastic cone off since I posted the picture but am working on the male brass portion for when I hopefully make the disconnect. I tryed prying per your picture earlier but I made no headway due to the rubber shocks giving way. Thanks for your help and any more thoughts that come this way!

 

[Daniel Zammit]

Johnson BJ4RESR 4HP

Johnson BJ4RESR 4HP

Can anyone send me a manual of this model number plsss...

Johnson BJ4RESR 4HP

 

[HighTrim]

Re: 1998 25hp Evinrude lower unit removal

You can get it online.