I have been lurking for some time trying to picking up some pointers from the experts the post here. After getting a service repair manual and seal kit I thought I was ready to do a simple lower unit gear O-ring and shaft seal replacement on a newly aquired 1967 V-4, 60hp Johnson, manual shift. I will not likely do that again, @#$%#!!, unless there is an easier way.<br /><br />After taking the prop off, removing 4 small pan machine screws from front gear housing and removing housing, I was able to replaced the outer O-ring seal. But it was not clear on how to remove the pressed in shaft seal. Is there a small puller or special tool for removing the seal? The Johnson OB Service Manual did not describe method. It looked to be in good shape, not brittle, no tears so just left it in place for now. Started to reassemble...thats when the real "fun" started.<br /><br />The round mounting plate that the 4 small machine screws engage "floats". When the 4 screws are engaged it pulls the plate firmly againts the internal 2" diameter circle clip. With the screws out, the plate falls back too far to engage with the short screws. After several trys, my son & I ended up snaking a piece of wire thru the bottom drain hole, along side the gears to push and hold the mounting plate againts the circle clip. After many tries, we finally got the screws to engage with all the parts in their correct positions.<br /><br />There has to be an easier way to assemble this?? If the wire trick didn't work, our last recourse was to take the OB off the transom and try to use gravity to our advantage when assembling or else get longer screws? I'm pretty sure I am going to have to replace the shaft seal as I see very small amounts of milky oil leaking out around the prop, so isn't there a tried-and-true way to do this?<br /><br />Thanks.
