1969 Johnson 55 HP Hydro-Electric Gearcase: Solenoids = 3.9 Ohms

[leifferd]

I just replaced seals in the lower unit... drive shaft and prop shaft. Had a little trouble getting the wires to the shift solenoids back in and may have been too rough on them, being that they are 45 years old and looked a little sketchy in the first place. Took the boat out today and now I only have forward gear. I had F-N-R before replacing the seals. Checking the resistance between the solenoid wires shows 3.9 ohms on both blue and green (to engine ground). The manual says this should be 5 - 6 ohms. Sound like the wires / connections to the solenoids?

Also, is there any trick to properly placing the solenoids down into the case or do you just drop them in and wiggle until the plunger sits? I'm hoping I didn't change the plunger rod length by twisting it when I was making sure it plunged smoothly. I didn't realize it was threaded until it was too late. Is there a way to properly set this?

Thanks for any insight!

 

[F_R]

Before you get too worried, do one more electrical test. Test the voltage at each of those wires (wires connected), while in Forward, Neutral, Reverse. The problem may be ahead of the lower unit (Switch, cables, etc).

 

[leifferd]

Thanks. With the plugs out and turning the engine over with the starter, correct?

 

[F_R]

No, don't make it complicated. Slide aside the rubber insulators that cover the terminals on the cable going down to the lower unit, then without disconnecting the connectors, attach your voltmeter + lead to one of them. Turn key switch on, and shift into neutral. Then do the same, shifted into reverse.

Result should be near battery voltage on the green one in neutral, and near battery voltage on BOTH the green and blue ones in reverse. No voltage on either in forward.

You do know that the motor defaults to forward gear when not running---don't you? In other words, it won't shift unless running. And lower unit full of oil.

 

[leifferd]

Here's what I measured with the key on between the knife connectors and engine ground:
Forward 0V Green, 0V Blue
Neutral 11.4V Green, 0.2V Blue
Reverse 11.4V Green, 11.4V Blue

Yes, I know the motor will default to forward. I had F / N / R before I disassembled to change seals. Now I only have forward. Looking like maybe the wires themselves or connections at the solenoids? Any tips for re-connecting the leads to the solenoids?

Thanks for the help!