1965 Johnson 40 hp shifting problems

[cpasseno03]

Hi, Well now that the ice is mostly clear up here, I had the boat in a few times, trying to straighten out things from when I switched powerheads a while ago. The latest problem is shifting, works great in reverse, and neutral. But when I put it in forward, it pulls itself back into neutral. You have to hold the lever forward with a healthy amount of force to prevent it. and even then it kicks from time to time, sometimes horribly. By kick I mean it literally just kicks, almost as if you just ran over a rock. And when it slips out it rarely goes all the way, just far enough to stop moving and make a loud clickity clickity like driving a stickshift without a clutch. I have tried quite a bit of adjustments and what not, but nothing works. The lower end lube was dark and really thick, so I put in new, which is now greenish grey and also pretty thick (from the cold?) but there was no metal shavings. Any ideas???<br />Thanks a bunch in advance!!<br />Craig

 

[DJ]

Re: 1965 Johnson 40 hp shifting problems

I think your clutch dog has seen better days.

 

[Hooty]

Re: 1965 Johnson 40 hp shifting problems

How'd it work before you replaced the power head? Is there adjustment in the shift linkage?<br /><br />c/6<br /><br />Hooty

 

[cpasseno03]

Re: 1965 Johnson 40 hp shifting problems

Ive been thinking of looking for a new lower unit. I think I know of one from a similar age 35 horse, would that mate up? The cable and lever adjustments are all set pretty well. The lever on the motor has a little bit of adjustment on the shaftm which I adjusted too, so as to get a little more pull on it. Still nothing. It worked before the new power head, but then my cable broke, and I put on a new one that might slide a little easier. But it did used to kick a little bit, but not often. Whaddya think? new lower end?<br />Thanks<br />Craig

 

[OBJ]

Re: 1965 Johnson 40 hp shifting problems

Howdy Craig.<br /><br />As djohns said, sounds like the clutch dog has seen better days and most likely the forward gear also. These are easy to look at. The split gearcase is a snap to pull apart. Might want to take a peek in there and see what things look like. Getting another lower unit???? I would want to know the condition of the clutch dog and gears first. May end up in the same boat, no pun intended.

 

[cpasseno03]

Re: 1965 Johnson 40 hp shifting problems

I guess I will have to take a look in there, never gone into one before, anything I should look out for? I usually steer clear of transmissions and the like, I have bad dreams of gears and springs shooting out everywhere This particular motor has quite a bit of time on it. The powerhead was quite worn, about an eighth inch of play in the bore. I would think another lower end would have much better chances. When you say clutch dog, you refer to some odd part in the gearcase, not the shaft the pushes/pulls the shift rod or anything in that area? I guess I'll have to take a peek in there tomorrow.<br />Thanks!<br />Craig

 

[cpasseno03]

Re: 1965 Johnson 40 hp shifting problems

Hey, I tore it apart, that thar clutch dog was worn. So instead of trying to grind it smooth and all that farting around, went and talked to my freind who had an old similar motor layin around. Switched lower ends and now she works perfect!! Thanks for all the help, this site has got to be the best tool when working on a boat. You cant ask a manuel a question, and even if you could, they cost money!<br />Thanks again<br />Craig

 

[cz1234]

Re: 1965 Johnson 40 hp shifting problems

I have the same motor, the same problem. However last year I was able to use a dremel to get the forward gear and the clutch dog to mate (that doesn't sound right does it ;-) but it did the trick for a while.....<br /><br />Now I am at the point that I really cannot take any more material off either part. I know EXACTLY what I need but I do not want to spend big $$$ for parts...like everyone else. The problem is that the lower unit is not the original. I know this because when I found a clutch dog for a 40 HP motor it wasn't the same size as mine. I took a measurement from the existing clutch dog. It is 1.5" in diameter...the 40 HP clutch dog was bigger... So this is a 35 or 30 HP lower unit...<br />Any chance someone has manual that will indicate what lower unit I have?

 

[Paul Moir]

Re: 1965 Johnson 40 hp shifting problems

I'm sorry I gave you some bad information last time. I never noticed the difference in size between the two clutch dogs.<br />I've got three clutch dogs that I know where they came from. 2 are 1.5" in diameter (actually, 1.497") - one from a '62 28hp and the other from a '63 28hp. The third is from a '65 33hp and is a little larger - about 1.7". The two earlier L/Us have tapered roller bearings on their pinion gear, while the 33hp has the seperate thrust and needle bearing setup. Outwardly, all three lower units are alike and exchangable.<br />Further dimentions on the 28hp dog - <br />Ears - ~0.406"<br />Width (total) - 1.096"<br />Shaft diameter (at splines) - ~.95"<br /><br />Hope this helps some!