1969 55hp Johnson Model #55ESL-69A

[LennyT]

Shifting problems and milky kinda sludge coming from exhaust. Ran fine last summer but sat in storage over winter and spring. Only goes into forward and neutral. Removed spark plugs and cranked it over, it stayed in forward. Disconnected wires at powerhead. Ran jumper to green wire and still stayed in forward. Ran jumper to both green and blue wires and it went into neutral. If I just run a jumper and hit the green wire it clicks like it wants to shift and same if I hit both together. Could water getting into the gear case and mixing with the lube keep it from shifting? What should I try next?? Please keep in mind I am a virgin by your guys standards!

 

[Joe Reeves]

Re: 1969 55hp Johnson Model #55ESL-69A

Lenny.... THat unit will not operate properly unless all is as it should be INCLUDING having the unit filled with OMC Premium Blend lube, also know as Type C lube. The following may be of interest to you.<br /><br />(Hydro Electric Shift)<br /><br />The shifting setup of the lower unit is what's called a "Hydro Electric Shift", which is quite complex consisting of voltage being applied to solenoids in the lower unit which in turn change oil passages via a oil pump that supplies various pressure on a spring loaded shifter dog. The wires leading to the lower unit (at the powerhead) are "Green" and "Blue". The engine must be running or cranking over in order to shift out of forward gear.<br /> <br />You CAN NOT use HI VIS lube in that lower unit. You MUST USE what OMC calls "Preminum Blend" lube, commonly called "Type C". (A thinner lube) <br /><br />In neutral, you need 12v to the "Green" wire. <br />In reverse, you need 12v to both wires, the "Green" one and the "Blue" one. <br />In forward, there should be no voltage to either wire. (The spring loaded shifter dog forces the unit into forward gear) <br /><br />To check the lower unit for proper shifting to make sure you have no trouble there, remove the spark plugs to avoid problems and to allow a higher cranking speed. <br /><br />This next step eliminates the actual shift switch in case problems may exist there.... Disconnect the blue & green wires at the knife connectors (the rubber insulated boots) leading to the lower unit at the powerhead, then using jumpers, take voltage direct from the starter solenoid to apply voltage to the "Green" wire for neutral, then both wires 'Green" & "Blue" for reverse (Remember the engine must be cranking over in order to shift).<br /> <br />With no voltage applied, the unit should be in forward. No need for a ground jumper... the lower unit's already grounded. You may crank the engine with the key switch or by energizing the starter solenoid with a jumper wire.

 

[LennyT]

Re: 1969 55hp Johnson Model #55ESL-69A

Thanks for the info Joe. I did fill it with Type C lube before I started my testing. After that though I still notice the oily sludge coming from the exhaust. Doesn't this indicate that there is probably a leaky seal in the lower unit? Thus it is allowing water to mix with the lube and preventing it from shifting? Should I redo the lube again and this time run it dry (no water) to see if it shifts?? Also, if the lower unit were going out wouldn't I have noticed shifting problems last year and wouldn't there be like metal shavings present when I drain the lube?

 

[OBJ]

Re: 1969 55hp Johnson Model #55ESL-69A

Lenny,<br /><br />You need oil in the lower unit so unit will shift. There is a pump in the front of the gearcase that makes the gears shift depending on which side of the shift piston the oil is on.<br /><br />If you want to check the seals in the lower unit, a quick way is to do a pressure test. Drain the oil out and rig a bicycle pump to one of the plugs (drain or vent). Pump up the pressure to about 10 to 15 psi and see if it holds. You can also submerge the lower unit in water and look for bubbles. This is the sure way to find a leaky seal. Be sure to turn the prop shaft and drive shaft while the pressure is on. A vacuum check should also be done to see if the seals on the outside are good also. All your seals are doubled. An auto A/C hand held vacuum pump works well for this operation.<br /><br />This oily sludge coming from the exhaust, what color would it be? Dark black or milky white?<br /><br />Lastly, you won't always see metal in the lower unit oil if the lower unit is having shifting problems

 

[LennyT]

Re: 1969 55hp Johnson Model #55ESL-69A

Well this is becoming fun!! I did the pressure test and all seemed okay. The oil came out pretty much like it went in. The oil coming from the exhaust now is black, it was a milky color but I believe that was from a friend putting the wrong type of oil in. I guess I finally got all the old stuff out of there. I guess my main fear is that the lower unit needs to be replaced. Are there any other checks I can make to see what else might be causing it not to go in reverse? Bad solenoid, etc.??? Manual is on order. Thanks again guys!!