2001 Johnson 9.9 Gear Case Question...

[Walleye-Seeker]

I have a 9.9 Johnson, and it was leaking gear lube from behind the prop. I bought lube & 2 seals from the dealer to install today. This morning, I pulled the prop, shaft bearing housing, cleaned & installed the seals. Before installing, I heard a 'plop' in the old lube in the drain pan. I found a small steel ball (about 4-5mm - about 3/16" in dia. I was very concerned that a bearing came apart. I found an exploded diagram on the net that suggested it may have come from the input (vertical) gear shaft. Nothing looked out of place (I did pull the outer gear to have a look. I suspected that it had been in there, and just fell out since I changed the lube. The motor worked / shifted fine before. I reassembled, and filled with lube. Took down to my pond, and tried it out (carefully.) All seemed to work great, best part- no leaks after I was done testing! My concern is that, one day I will be out fishing, and that little missing steel ball will cause me to be stranded (and worse- destroy my lower unit.) Anyone know how critical it may be? I really don't want to leave my boat at the marina for weeks. Thoughts???

 

[bktheking]

Re: 2001 Johnson 9.9 Gear Case Question...

I'm thinking a detent ball has fallen out, they help keep the clutch dog in neutral and there is not just one, there are 2 of those suckers. Ever see what a detent ball does to the pinion or the gears when it get's chewed up, it no nice???? You need to fix it. Wonder why it fell out, did you have the clutch dog out of the lower unit?

 

[Walleye-Seeker]

Re: 2001 Johnson 9.9 Gear Case Question...

Thanks, I did not have it out. The gears were in good shape (no visible wear or chips.) I think it worked it's way out when I was cleaning the lower unit housing to remove some contaminated grease. I've never worked on a lower unit before. I looked at the bottom of the vertical shaft, and found that the spring had not fallen out. (I assumed that if the bottom detent ball had fallen out, the spring would have been falling out as well.) How would I go about putting it back in? There is no room to work inside the housing, do I have to remove the lower unit? I do not have a manual, and the Marina has not been answering their phone to find out if they're open today so I could get one. Can anyone post the section of the manual I need to to an R&R on the 'clutch dog' assy?

 

[bktheking]

Re: 2001 Johnson 9.9 Gear Case Question...

Here is some info

http://www.sschapterpsa.com/ramblings/Lower_unit.htm

I will email you the info from my manual, PM me your email address.

 

[kenmyfam]

Re: 2001 Johnson 9.9 Gear Case Question...

Find where it came from and fix it. Simple as that.

 

[Walleye-Seeker]

Re: 2001 Johnson 9.9 Gear Case Question...

Alright, I guess I'll break down & drain it again- to go exploring for the ball's rightful home. Hope I don't ruin next few week's trips by having the motor tore down w/o knowing how to reassemble. i'll be sure to follow up with more questions / comments. thanks to all who replied.

 

[Walleye-Seeker]

Re: 2001 Johnson 9.9 Gear Case Question...

Glad I Did! I tore it back down, and it was one of the detent balls. Evidently, when cleaning the opening, the shaft came a little too far rearward, and allowed the ball opening to become exposed. I don't believe it would have damaged the engine, but I might have had considerable issues with getting the motor to stay in gear. Thanks to everyone. Oh, a little trick for anyone having the same issue, I tilted the engine 'up' for re-assembly (still mounted on transom.) I used a length of electricians tape around the shaft to hold in the detent balls & spring until I got them lined up on the shift 'dog.' I pulled the tape off while holding the shaft down, then gave the end of the shaft a light tap with a soft rubber hammer to allow the detents to collapse the spring and shaft slid into place. Whole job took only about 15 minutes since I just did the R&R on the prop seals yesterday. Also, I found a puller is not necessary if you can rotate the flange of the housing 90 degrees then pull straight out while rotating left/right back & forth.