Clutch Dog Replacement

[Captn Dave]

I have a 1989 225 Johnson and have trouble engaging reverse. I believe it's the clutch dog and/or reverse gear. <br />It was a real PITA installing the lower unit when I replaced the water pump two years ago. Probably from sagging mounts. <br />Can the the clutch dog be replaced without removing the lower unit?

 

[DHPMARINE]

Re: Clutch Dog Replacement

Wish I could say ya don't hafta ... but you do.The dog is pinned and retained to the prop shaft.To get the prop shaft out,you have to remove the pinion nut and drive shaft.To remove the drive shaft you have to remove the water pump and upper drive shaft bearing housing...and so on.<br /><br />Were the sagging mounts keeping the shift rod from entering the lower engine cover? Is so,I did one once by forcing a wedge between the swivel bracket and the exhaust housing.NOT the prefered way to service,but sometimes the only practical way.<br /><br />DHP

 

[OBJ]

Re: Clutch Dog Replacement

Curious wave....trouble engaging reverse gear as in hard to engage or slips out in reverse? Any metal in the gear oil?<br /><br />Have you tried to manually engage reverse with the control cable disconnected?

 

[seahorse5]

Re: Clutch Dog Replacement

Wave,<br /><br />I'll be you will find salt buildup in the shift rod cover o-rings that will start to freeze up and limit full reverse engagement that over time will wear the clutch dog and reverse gear lugs. Slow shifting and mis-adjusted cable and linkage will do the same thing.<br /><br />Reverse gear will also have to be replaced.

 

[Captn Dave]

Re: Clutch Dog Replacement

Thanks all for the replies.<br /><br />DHP. I believe the sagging mounts were causing the bend in the shift shaft to hang-up on the upper part of the tube it rides in. I had one side of the cowl removed when I was trying to install the lower unit. <br />I had this lower unit off before and never had this much touble. <br /><br />Suring that time, after spending about six hours and finally getting the lower unit installed, reverse wasn't engaging cleanly when the engine was running. <br />I removed the lower unit again suspecting that maybe I had rotated and changed the length of the shift rod, I then finally had a shop install it to make sure everything was okay.<br />The guy at the shop even said he had a heck of a time installing it.<br /><br />It shifted okay for that year and then towards the end of last season, reverse wasn't engaging cleanly. You could hear the ears on the clutch dog "grinding against" the reverse gear. <br />I now suspect that maybe old cables was causing the problem.<br /> <br />This past weekend I went out and started the engine with the shift cable removed and even with manually moving the lever on the engine, it was not a clean clunk into reverse. I'm sure if there was water pressure on the prop, it would make things even worse.<br />I believe that I rounded off the ears on the clutch dog and reverse gear.<br /><br />Thanks again for your help guys.

 

[Captn Dave]

Re: Clutch Dog Replacement

I removed the lower unit and the four bolts to the bearing housing. The manual calls for a special OMC puller. Is there anything else I might be able to use to pull the bearing housing?<br />The motor has always been flushed after every use so there's hardly any corrosion.