Clutch dog remove and replace

[bonz_d]

I have a 1987 50hp Johnson that has a bad clutch dog and maybe reverse gear. Forward works just fine reverse will not engage unless slammed hard into full revese. I also have the correct OMC repair manual for this engine and have read thru the procedure to do this but I do not feel convident in doing this repair. I have done the split gearcase units before but never the one piece units. Also in the manual I see there are a number of specialty tools used for this which I do not have.

This lower unit is useless as-is so there really is nothing to lose by trying to do this myself and for the cost of repairing this in a shop I could locate a complete blown engine with a good lower unit.

So for those that have done this repair just how difficult is it to remove and replace just the dog and reverse gear and are those tools really needed?

 

[racerone]

Have you checked shift rod height ??--------Not that difficult.---You do need the big internal circlip pliers to get those snap rings out.---Dealer help there is an option.----The whole unit needs to come apart to get at the clutch dog.---Go for it.

 

[bonz_d]

Yes, rod height was checked and set before I put this on a running engine to check it. The engine was bought as a parts unit and was told then that there was a problem with it. I too 1st thought that maybe the rod wasn't adjusted properly, which it wasn't.

Does the whole prop shaft have to come out or can just the reverse gear and clutch dog be removed? I'll need to look closer at the manual I'm sure.

 

[racerone]

I believe post # 2 indicates that the whole lower unit needs to come apart.---No short cuts are indicated in post # 2

 

[bonz_d]

Thanks, just checking as the exploded parts view in the manual it looks as if the gear and dog will come out before the shaft. Now I guess the first thing I'm going to have to do is located a snap ring pliers big enough to remove that snap ring.

 

[bonz_d]

After looking closer at the manual I understand better now how this is put together. Thanks for the heads up racerone!
I got the bearing carrier removed, it came out rather easily. Those snap rings are a different issue. I stopped at Harbor Freight and bought a cheap set of big pliers but they are not sturdy enough to get the rings out. They will not compress the rings enough to clear the groove. Any clues as to what brand and model snap ring pliers to look for w/o spending $100.00?
I have found some OTC model 500 that are not real expensive does anyone know how well they will work?

 

[AlTn]

tool topia...search...ap 9402...can't speak to effectiveness of either brand

 

[JesterGrin_1]

Since this seems like a project everyone needs to know I feel it would be Nice if someone did a good tutorial on this? And if there is is one please by all means point it out? Thank You.

 

[bonz_d]

There are only a couple youtube videos that I was able to find and they weren't that good. As to pulling it apart it seams the hardest part is those snap rings!