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    Johnson 150 Rebuild/Remanufacture Guidance

    OK, I received my used temperature sensor and understand what you mean by just stuffing it in. It has a rubber plug/seal that holds the sensor against the bottom of the counterbore once you put the cylinder head cover in place. Thanks!
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    Johnson 150 Rebuild/Remanufacture Guidance

    The old one had a broken wire and it was difficult to remove. I ended up braking the center stem off of the sensor disk and found an EZ Out that was a force fit in the shallow hole. It then twisted out with a T Handle. I believe corrosion held it in place. It isn't a force fit when you press...
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    Johnson 150 Rebuild/Remanufacture Guidance

    I was not aware of this evinrudeparts.ca site, but was pleasantly surprised that although they did not have a new temp switch they provided me a few dealer names and phone numbers that showed availability. Albeit, a used option. I picked up a used bench tested temp sensor. The manual advises...
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    Johnson 150 Rebuild/Remanufacture Guidance

    James R, Thanks for reaching out. I already had my cylinders bored .020" oversized and am starting to put the engine back together. However, I am trying to buy a few parts I need. I may give Pro Outboard a call to see if they have a temperature switch for the cylinder head. Thanks
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    Johnson 150 Rebuild/Remanufacture Guidance

    Yes, I was trying to understand whether there were other replacement/compatible part numbers. I can't seem to find the two above p/n's as new items. evinrudeparts.ca does say "Price: Call Us". I will try that.
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    Johnson 150 Rebuild/Remanufacture Guidance

    I am in need of a temperature switch for one of my cylinder heads. I broke the wire off the original one. The original OMC p/n was 378176. I understand that p/n was replaced by p/n 0386686. Is there a source for these or a suitable replacement? Thanks for all of the guidance!
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    Johnson 150 Rebuild/Remanufacture Guidance

    I just found the seal in my WSM gasket kit. It is metal, but has a green finish on the outside diameter. So are you saying no gasket sealant? I wish I would have found the WSM bearing number first. I already ordered from outboardmotorparts. Hopefully they are the same quality.
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    Johnson 150 Rebuild/Remanufacture Guidance

    Thanks for the quick response Faztbullet. I will return the new one with the cage corrosion and buy the bearing from outboardparts.com (the only source I identified for the bearing). I'll also replace the seal. Do I use gasket sealer on the new seal and install similar to the method used on...
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    Johnson 150 Rebuild/Remanufacture Guidance

    My OEM Service Manual states, "If the upper crankcase head bearing is damaged, crankcase head and bearing assembly must be replaced". Given this guidance, I ordered a new head assembly, since I am replacing all crank bearings, but it came to me with corrosion on the bearing cage. Investigation...
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    Intermittent Alarm

    You can test the fuel restriction alarm by simply putting a kink in your fuel line. This will give you a continuous alarm until you release the kink.
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    Johnson 150 Rebuild/Remanufacture Guidance

    Question, my wrist pin replacement bearings are caged, not the original individual needle bearings. Do I use the thrust washers with the caged wrist pin bearings?
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    Johnson 150 Rebuild/Remanufacture Guidance

    I ordered OMC Gasket Sealant online, but received Loctite Aviation Gasket Sealant p/n 1525607. Is this an acceptable/recommended equivalent?
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    Johnson 150 Rebuild/Remanufacture Guidance

    OK, I'll break the outside edges with a medium India stone. Is that acceptable, or do you have a better process?
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    Johnson 150 Rebuild/Remanufacture Guidance

    Faztbullet, Thanks for suggesting Jay's Block Shop and giving me the contact information. Jason, did a great job on my block and was able to clean it up going .020" oversize. Jason fixed me up with WSM pistons, gaskets and seals. Jason is great to work with and I told him I got his name from...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Does the same hold true for the connecting rod big ends, or do you definitely leave them alone? Inspecting my connecting rod big ends, they seem to have even less discoloration than the crankshaft journals.
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    Johnson 150 Rebuild/Remanufacture Guidance

    So if I understand correctly, polish up the crank journals by wet sanding with a 220 silicone carbide strip of abrasive and work up through finer abrasives? Honestly, I would have no idea how to put a crosshatch pattern over that narrow journal and the rod bores. If you could point me to...
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    Johnson 150 Rebuild/Remanufacture Guidance

    I now have this powerhead pulled apart and I am waiting on return of the block. I have a question in regard to the crankshaft bearing journals. All 6 are very smooth with no uneven wear, scoring, or pitting. However, the surfaces have some tan or light brown surface coloration. Should these...
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    BTW I got that alternator installed on my 40 Rudy

    Congratulations! That is an impressive retrofit! What was the output on the OEM flywheel alternator? I never liked the fact that my 1986 Johnson 150 (J150TXCDC) flywheel alternator only put out 9 Amps. The same year J150STLCD put out 35 Amps. I wonder if I could swap out flywheels? Cheers...
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    Johnson 150 Rebuild/Remanufacture Guidance

    ct1762, racerone, Faztbullet, thanks for all your help in getting me through this powerhead removal. So I'm at a crossroads, do the rebuilt myself or send the powerhead out? Mechanically, I am thinking I could get through the rebuild. The big question I have is, how hard is it to get the...
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    Johnson 150 Rebuild/Remanufacture Guidance

    Well, late Sunday evening we had a minor miracle occur here and the powerhead popped off after cutting the two bolts approximately 1/2" below the powerhead mating surface, lots of various penetrating oils, and some heat in the area above the cuts. I utilized my Dremel motor tool with the Heavy...
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