1969 Johnson 9 1/2 hp Trouble

[Dakota0379]

Hi y'all.....new here

I have searched the forum until my eyes blurred over looking for an answer to my issue, but to no avail, so figured I would make a thread. Please bear with me as I am also new to having a gas motor, so terminology may be wrong.

My brother used the motor fishing the other day, and I got a call from him looking for a solution to a problem. He said it lost forward and reverse on the motor. It would start fine, and throttle up, but not engage the prop

When he got home, he brought the motor in the house, and I looked at it and noticed a bolt missing that holds the shaft on, so the shaft was a little loose (in the process of removing the other bolts (figured I could just take it apart to fix it) I broke another one :facepalm: ). I have looked at the parts diagrams of the motor, but not sure how to proceed

So I guess my questions are:
1. What could be the cause of no forward or reverse, and how to fix it?
2. How do I take the lower shaft apart?

Any info would be greatly appreciated

Thanks
Dakota

 

[bonzoscott]

Re: 1969 Johnson 9 1/2 hp Trouble

I'm not sure what you mean "bolts that hold the shaft". I can assume you mean the lower unit (six 7/16 bolts - thread upward into the mid section). If that is what you're talking about, you'll want to remove that (lower unit). Do searches on broken bolt. Hopefully there is enough of the bolt still sticking out to get a hold on. Then PB blaster, maybe heat, etc.
Shifting problem - sounds like your shift rod came apart. Once you unbolt the lower unit, it should still be held together by the shift rod. The rod is two pieces, held together by a coupler in the middle. You should be able to see the coupler and I think it is a 3/8 bolt - between small space - mid section and lower unit.

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

yes that's what I meant, the lower unit (I think). The screw that broke is in the middle of the body from the prop toward the engine (one of 4 bolts). Looks like there will be enough to be able to grip it with vice-grips to get it out.

Now the piece that the prop is connected to has 6 screws holding it on, so I have to remove that first before I can remove the rest of the unit?

Thanks for the info, will give it a try

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

Before you get carried away, have you verified that the shifting mechanism at the top end (under the hood) is together and intact?
Also, are you able to post pictures of specifically what you are trying to take apart?

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

Before you get carried away, have you verified that the shifting mechanism at the top end (under the hood) is together and intact?
Also, are you able to post pictures of specifically what you are trying to take apart?

yes the shifting mechanism at the top is all connected and looks to be working right

and here are some pics (I hope)


this is the whole shaft (as I called it)


This is the top section of it that had the missing bolt (and then I broke another)



And this is the lowest portion that is held by 6 screws that are so far resisting any efforts to be removed

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

To get the lower unit off put the shift selector in reverse, remove the four 7/16 bolts. (first pic) The lower unit should drop down about an inch or so, you can then access the 3/8 shift rod coupler bolt. (second pic) Once that bolt is removed the lower unit will come all the way off.

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

Okay, so I managed to get it apart, and discovered the problem....the shaft is broken





So now what can I do?

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

The easiest fix is to find a complete lower unit (or complete parts motor) and install it on your motor. You could replace the driveshaft only but thats a lot more work and you will need a seal kit as well since you will have to take the gearcase apart to replace it.
There are a lot of these old motors around so finding a lower unit shouldn't be hard. I think any Johnson or Evinrude 9.5 from 1964 through 1973 will fit.

 

[dockrat100]

Re: 1969 Johnson 9 1/2 hp Trouble

http://www.ebay.com/itm/309639-John..._Accessories_Gear&hash=item3f1b796700&vxp=mtr

Replace driveshaft, motor on!

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

http://www.ebay.com/itm/309639-John..._Accessories_Gear&hash=item3f1b796700&vxp=mtr

Replace driveshaft, motor on!

Hard to argue with that price.

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

WOW

found lower unit on ebay for $150 too.
http://www.ebay.com/itm/1964-1973-9...1748223518104349835&pid=100011&prg=1005&rk=2&

now trying to decide which way to go.

What does it take to replace the seals in the gearcase? and I think those are the screws that are extremely stubborn right now

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

Although it's a little more work, I'd go with the $15 driveshaft. When you have the gearcase apart inspect all the parts (clutch dog especially) and check the water pump impellor too. Once it's all back together you will have peace of mind and it's going to be a lot cheaper than a used lower unit assembly. Lots of experts here to help you along the way too.

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

the shaft for sale on ebay is a short shaft (oh and up to $27) and my motor currently is not, so I need to replace the shift rod connector as well.....

where can I find a seal kit I will need if I do it this way?

Oh one more thing....it looks like water got into the gearbox somehow (gear oil is milky),
If you look at the first photo I posted above, you can see where it was repaired before. Could water have gotten in through that? If so, can it be fixed?

I also wanted to thank all of you for the information and help you have provided me so far too

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

where can I find a seal kit I will need if I do it this way?

You can buy the seal kit right here on iboats for around 24 bucks.
It's possible that your gearcase is leaking where it was previously repaired but it's far more likely that one or more of the seals is shot. Unfortunately since your motor is a longshaft it's going to be more difficult to find a driveshaft for it.
Have you checked out LeeRoy's Ramblings? There is a complete informal history of these engines and all kinds of other info on them too. It's a good read.

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

Okay.....I have gotten the lower housing off so I can check the gears. There doesn't look like there is much wear on them so I think I am okay as far as they go. I have ordered a drive shaft and the seal set for the lower housing. Oh and I got the repair manual too.
I have switched to the standard shaft (shorter and we do a lot of river fishing)

I am just wondering if there is anything I should do (or look out for) as I am putting this back together?
Since it is apart is there anything else I should be changing?

 

[AEROCOOK]

Re: 1969 Johnson 9 1/2 hp Trouble

I've never done a long shaft to short shaft conversion on one of these motors but I cant help but think there's more to it than replacing the driveshaft and removing the housing extender? What about the water tube and shift rod?

 

[Dakota0379]

Re: 1969 Johnson 9 1/2 hp Trouble

got the water tube on order and the shift rod coupling too (I could prob take the extension off the water tube, but its on there pretty tight; decided not to do it just in case I want a long shaft again I don't want to damage it)
just ordered the water pump kit too
Anything I may be overlooking? Or that I should do while it is apart?