1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

[Coastal238]

Hello all, I am new to this site, however, looks to be a good one, hope you guys can help me. I tried to post this on Saturday but looks like it did not work.<br /><br />Last year I purchased a 1994 Wellcraft Coastal 238 w/ Johnson 225 O.R. so I can take my kids fishing & boating. Soon after we got it we lost reverse. The marina adjusted the cable for us as far as it could go and it clunks into reverse. They told me the clutch dog needs replacing. I briefly opened the oil plug and checked the oil in the lower unit, the oil looks light green/white and I see some small trace amounts of metal particles. The water pump worked fine. The lower unit was last rebuilt by the previous owners marina in 2000 (I have receipts). <br /><br />Looks like if I have to open her up I should rebuild the entire lower unit. I purchased the original OMC manuals and have some basic mechanical skills, is this hard to do for a novice? Besides replacing the clutch dog, water pump and gaskets, I believe I should also replace the forward & reverse gears, what else should I replace? What about the shaft or other parts? Any pointers, items to be aware of or special tools required would be appreciated.<br /><br />Does anyone know where the best, least expensive places to purchase the OMC parts are?<br /><br />Thanks everyone, boat on! fromhowell@aol.com

 

[wilde1j]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

If you're going to rebuild it yourself, get an OEM shop manual first. It will give you a detailed idea of what's involved. Then you can decide whether or not you want to try it.

 

[rodbolt]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

its a simple unit to rebuild, about the only shimming required can be done at the dealer in 15 minutes. you may wish to let them install the driveshaft and propshaft seals as well. the last set of GLM gears I bought the clutch dog had the groove cut on the wrong end but if your paying attention you will catch it.

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

I have the OEM manual, it dosn't look extreamly hard from the book, hope there are no surprises? Is it really hard to get the shaft back into alignment where I would need to go to the dealer? In addition to replacing the clutch dog, gaskets, water pump impeller, do you really have to replace all the gears even if minimal wear? What is normally replaced/done on a rebuild?<br /><br />Also, where do I find reasonable parts?<br /><br />Thanks for any assistance you can provide.

 

[ezeke]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Hope you don't mind my asking, but when the marina adjusted your shift cable, did they remove the lower unit and adjust the shift shaft as well?

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

No the marina did not remove the lower unit.

 

[ezeke]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

It is very possible that you could just need to make that adjustment. I'm fairly certain that you can extend or shorten the reach of the shaft rod by turning it.<br /><br />The correct length is listed in your service manual. You should find a picture and directions for setting the shaft towards the end of the gearcase section. <br /><br />Hope this helps.

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

I looked at my OMC book (P/N 500612), regarding adjusting the shift rod length by turning it but it refers to a special measuring tool (shift rod height gauge). My question is how do you do it without this tool, and where is the base of the measurement taken from, the top of the lower unit?<br />Also, I would imagine I should re-adjust the cable so its not on the end of its adjustment (where the marina mechanic left it, see above) and tested to work with its new settings. <br /><br />Lastly, and while I have the lower unit off, I will change the water pump, anything I should know before I get started? Also, how do I pressure test the lower unit (and what/where do I get the gauge) to make sure that the seals are ok.<br /><br />Thanks for all the help!

 

[ezeke]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

You measure from the top of the lower unit housing to the center of the hole at the top of the shift rod (I stapled a crosspiece to a yardstick that I bought at a hardware store).<br /><br />I use the fitting off the oil fill pump, connect it to a bicycle hand pump that has a pressure gauge, and put a few pounds pressure while looking for leaks. <br /><br />If it holds the pressure on the gauge, I increase to the level suggested in the service manual or around 15lbs. I'm happy if it holds the pressure for 20 minutes. <br /><br />If the gearcase does not hold pressure and you cannot find the leak, submerge the assembly in water and the bubbles will guide you.<br /><br />You disconnect the cable from the shifter and adjust the shift rod until you can shift both ways without the cable. Then you adjust the cable to the shifter, and finally, reconnect it.<br /><br />BTW, don't pressurize the gearcase when full of gear oil - too much hydraulic pressure will blow the seals and you really will have a leak.

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Thank you, I will try this and report back...its too bad you cant adjust the shift rod with the lower unit connected. Should I go with synthetic oil, in the event I do get a small leak during the season, I hear it will still do its job even if water leaks in.

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

I took the lower unit off and the shift rod was only out by 1 turn, could this really make that much of a difference when I re-connect it? I can manually adjust the shift rod BUT, it does not go in gear (forward or reverse) very easy. You have to really tug at it for forward and push down hard for reverse. Is this the way it should be or should it go in easy?<br /><br />One thing I did note was the housing where the shift rod disconnects from the power head moved slightly when I lossened the bolt, is this normal or should I investigate further.<br /><br />I drained the oil, some small amount of milky white but the oil is green and does not smell burned. It does appear that there is not enough fluid, but before I commit to this I have to measure the amount (tomorrow).<br /><br />Next is to replace the water pump, any tips. <br /><br />Thanks for the help...

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Does anyone know if manually shifting the shift rod (w/ lower unit off, see my previous post) is supposed to be hard to shift into forward and reverse gear. In my previous postings, I had a problem going into reverse, so based on recommendations listed here I removed the lower unit and adjusted the shift rod to the proper dimensions (by only one turn lower). I just am not certain this will do it and am concerned that it takes an extra effort to manually get it into forward or reverse gear.<br /><br />Any help is appreciated...

 

[Dhadley]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Make sure you are rotating the propshaft while attempting to shift by hand.

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Why? It does go in gear both ways but takes a good tug or push to get it in. I do recall spinning the prop too while doing this. Just want to know if this is normal?<br /><br />Pete

 

[ezeke]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Shifts easier with gear oil in, but it is still stiff. Were you in neutral when you measured the shift rod? (Just Checking )

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Yes, I was in neutral when I measured the shift rod. Could 1 turn lower (which is about 1/32") really make that much of a difference shifting in reverse? I guess my next move is to replace the water pump, oil her up, reattach, adjust cable and test her out! I never adjusted the cable before, any tips.<br /><br />Thanks,<br />Pete

 

[rodbolt]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

nope, one turn is not gonna fix a bad clutch/gear set.<br /> aint gonna happen.<br /> most worn clutchs come from slow shifting and shifting above 700 RPM.<br /> while the unit is off is the time to go ahead and tear it down for inspection.<br /> yes shifting by grabbing the rod is tough, its supposed to be, your fighting the shift detents in the shifter assy.<br /> doesnt take much jumping out of gear or partial clutch engagement to destroy a gear. the reverse gear can be replaced by itself, the fwd will require a pinion/fwd gear set.

 

[Coastal238]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

Originally posted by rodbolt:<br /> nope, one turn is not gonna fix a bad clutch/gear set.<br /> aint gonna happen.<br /> most worn clutchs come from slow shifting and shifting above 700 RPM.<br /> while the unit is off is the time to go ahead and tear it down for inspection.<br /> yes shifting by grabbing the rod is tough, its supposed to be, your fighting the shift detents in the shifter assy.<br /> doesnt take much jumping out of gear or partial clutch engagement to destroy a gear. the reverse gear can be replaced by itself, the fwd will require a pinion/fwd gear set.

Did you read my previous posts, it did go in reverse last summer after the marine mechanic adjusted the cable setting. It just seamed to me that it was klunking into reverse. Once in gear (forward or reverse), it had no problems. The issue was why did the marine mechanic have to adjust the cable to the end of its setting to make it go in reverse. What has been suggested to me is the shift rod may be out of spec, which it was slightly. I also noticed the bracket on the engine where the shift rod connects/bolts moved some while I was loosing the bolt, I have to check into this further. The unit does go into gear manually, you have to give it a good tug or push though...it does seam easier to do this when spining the prop. The lower unit does hold pressure and the gear oil does seam normal with only some small trace amounts of metal. Looks like I will re-attach, test and report back.<br /><br />Thanks everyone for your guidance.

 

[rodbolt]

Re: 1994 Johnson 225 Ocean Runner - Lower Unit Rebuild

if its not jumping out of gear it may be an incorrect shift rod height. it may also be the busing in the bellcrank bracket is worn out, it may also be the cable inner jacket is worn out,especially if it uses black teleflex cables.<br /> with the shift rod correctly adjusted the lever the cable end attaches to should be verticle. if its much fwd or aft of verticle there may be linkage issues from that lever to the shifter block in the lower.<br /> clunking is good. its designed to clunk. shift quickly and firmly never ease it into gear. more damage occurs the slower you engage the clutch.<br /> its a mechanical slam shift unit. <br /> but you said it was working then ya lost reverse, that tells me something wore or broke and the tech was msking the problem with an adjustment instead of fixing the problem.<br /> once properly set,unless something wears out or breaks, no further adjustments should ever be nessasary.<br /> you wont believe how many cases I have had to replace gear sets on due to worn cables and shift control boxes. and when I am done repairing the damaged case I still have to fix what caused the damage.<br />thats why I love the morse twin controls, I make a ton of money from them .but if it was working then not working any adjusting is like peeing on the windward side . be aware that when you reinstall the unit the rod will rotate and you will have to rotate it back, make sure you rotate it the correct way . the shift rod has 5/16thx24 threads, each turn is roughly .042" (1/24) up or down. the tolerance is roughly.032" so 1 turn is only .010" out of spec hence why I say one turn isnt gonna help.<br /> get it adjusted at the unit properly and reinstalled, then start looking for wear. make sure the cable stroke is the same from N to R and N to F.