1982 Johnson 9.9 jumps in and out of gear.

[GreenRiverPirate]

I did some work for one of my neighbors and he gave me a 9.9 Johnson. The previous owner had hit a submerged object and broke the bolts off on the exhaust hub that separates the exhaust from the grease. Anyway I welded the hub back up cleaned it all up, (it was under water for several weeks this spring)and re-assembled it. The engine runs flawlessly. It starts on the first pull every time. I ran it in a barrel for a while to make sure it was good before I took it out on the river. When I run it down the river it pops out of gear and back in eventually getting to the point of not going into gear at all. I brought it back home and tore back into the gearcase. I went over the diagram and noticed it was missing the detent spring and balls. So I put new ones it. I adjusted the shifter linkage to it's proper position. Took it back to the river. It went into gear perfect several times. So I took off up river, just as the boat planed off I felt the motor jerk out of gear and back into gear so I turned back, after a half mile of running it won't even go into gear anymore. So I go back to the house. I moved the shifter into the forward position it go's right into gear. I am at a loss here, the lower unit works perfectly until you put power to it.

 

[BonairII]

Re: 1982 Johnson 9.9 jumps in and out of gear.

Clutch dog is probably worn.

 

[GreenRiverPirate]

Re: 1982 Johnson 9.9 jumps in and out of gear.

actually it's not had it out this morning. nice sharp edges. any Idea what the endplay limits on the propshaft are

 

[raczekp1]

Re: 1982 Johnson 9.9 jumps in and out of gear.

hi.i would check all shift conections-starting fom shift handle,spring mounted to engin block(just aroud fuel pump), shift conector beween lower unit and midsection

 

[Haffiman]

Re: 1982 Johnson 9.9 jumps in and out of gear.

After checking that linkage is working without play, check the axial play of the prop shaft. If that gets too much, what you describe may happen.
Check the prop shaft bearing housing for wear behind reverse gear.
Check that the propshaft 'stop' into the reverse gear is not damaged.

 

[GreenRiverPirate]

Re: 1982 Johnson 9.9 jumps in and out of gear.

I know that the reverse stop is in tact, but the propshaft itself seems to me to have a lot of end play. the prop moves in and out when you shift it from forward to reverse.

 

[Haffiman]

Re: 1982 Johnson 9.9 jumps in and out of gear.

In the newer garcases which in principle are the same as the old, a trust washer (#20) was introduced to eliminate the problem you have. Se below diagram:
http://www.marineengine.com/parts/j...J15RSRS&manufacturer=Johnson&section=Gearcase

If you look at the diagram for the 82, that trust washer does not exist!
http://www.marineengine.com/parts/j...15RCNC&manufacturer=Evinrude&section=Gearcase

Check out the wear of the prop-shaft.

 

[GreenRiverPirate]

Re: 1982 Johnson 9.9 jumps in and out of gear.

I believe I may have found the problem, The thrust bearing above the pinion bearing was installed incorrectly. In stead of the needle bearing being sandwiched between the two thrust washers it was placed first, then the washers behind it.

http://www.marineengine.com/parts/j...J10RCNS&manufacturer=Johnson&section=Gearcase

See parts 18, 19, 20. Part 18 was in the position of 19 and visa versa.

 

[Haffiman]

Re: 1982 Johnson 9.9 jumps in and out of gear.

That will not have any impact on the shifting. It will probably ruin the pinion and gears when the bearing fails and the pinion gets pushed up and looses grip. The symptom might be like not shifting though.

 

[GreenRiverPirate]

Re: 1982 Johnson 9.9 jumps in and out of gear.

it's the only thing out f place in the lower unit. It has very little wear on any of the parts except this thrust bearing. If it pushed up far enough it would cause it to skip the teeth. that's what it felt like. It felt like the motor quit pulling for a split second and a loud pop was heard.

 

[Haffiman]

Re: 1982 Johnson 9.9 jumps in and out of gear.

If 'skipping the teeth', what do the gears look like?

 

[Brefeye]

Re: 1982 Johnson 9.9 jumps in and out of gear.

If 'skipping the teeth', what do the gears look like?

I just had a similar problem with a 63 johnson 10 so i took the prop shaft out and reversed the clutch dog. this is how i came to this. I removed the engine cover and drove the boat at half throttle AOK. i increased the throttle slowly until i saw the detent arm move. it did the same thing every time. so i figured what was happening was; as the pressure (linear) from the propeller increased against the torque from the engine it could stay solid and work or something would have to wear or break. in my case the dogs were worn to a curve hence the detent arm was moving.So as the torque increased the clutch dog would would ride over it. Johnson in their infinite wisdom made a reversible clutch of a slightly softer metal than the drivegear. so I turned it around and now it works.
so heres the thing: As the prop shaft moves forward it moves away from the clutch dog which wears the edges(not much)
Changing the gear linkage will have very little effect as there are only three stops. fwd neut rev

so i took it it apart again.
this time i noticed some minor pitting on the thrust washer 33 so i swapped them; fwd for reverse.
so now full throttle all day until something else wears out. oh yeah i have to hold it in reverse but im facing that way when I'm going that way so no Biggie
Love this outboard '63 od24 a true American icon
if anyone has parts for the cover or decals etc im me
Thanks
Brefeye