Degree of difficulty rebuild of lower unit

[npd4432]

I have a lower unit with a busted case and need to replace it, everything inside gears, clutch dog, bearings, seals are good as the lower unit was sabatoged by an angry ex-wife(not mine) with a hammer. I have been searching without any luck for a complete used unit, but have found several empty casings for sale.

How hard is it to change everything out from one case to another. I have what I would consider moderate mechanical ability as I have already rebuilt and installed carb kits, changed water pumps and housings, replaced lower unit seals, replaced T&T units and all around have diagnosed numerous problems on my motors. Any special tools necessary?? Let me know what you think.........

Motor is a 1992 40 HP Evinrude Model # TE40ELENM

 

[trendsetter240]

Re: Degree of difficulty rebuild of lower unit

You will need a couple of specialized pullers to remove and install the bearing housings and seals. The gear case is usually a little too much trouble for the backyard mechanic and not possible without the correct tools.

Best bet is to keep looking for a complete lower unit. However, if you do decide to tackle this project then an OMC service manual is a must. Not a seloc or clymer manual.

The OMC manual will list all the tools required and provide step by step instructions.

 

[npd4432]

Re: Degree of difficulty rebuild of lower unit

I would have guessed that, but if worse comes to worse I will try to tackle the job, and will get a manual first, it may be a good learning experience as this is how I learned to repair my other stuff.

Any suggestions on where to get the used unit, already checked e-bay and c-list.

 

[trendsetter240]

Re: Degree of difficulty rebuild of lower unit

Well, you could try posting a wanted add on clist. In the past I've searched for weeks for a parts motor with no results. I posted a wanted add and had a few emails in the next few days from guys with the parts i needed.


Good news is that gearcase is the same as most other 40-50 HP Johnsons/evinrudes from 1992 through 2005. So you don't need to limit yourself to just 1992's.

 

[npd4432]

Re: Degree of difficulty rebuild of lower unit

I have been getting conflicting information on the replacement, here is the interchange list from the top secret file:

.....(This chart for direct bolt on with no part changes)............

Horsepower--------------------------------------Years that interchange

40/48/50/55/60..... (small diameter housing)..................1976-1988
40/48/50................................................ .................1989-1992
40/48/50................................................ .................1993-2005


I see some as listed 89-05, some as 89-92 as listed above and others. It appears one of the only differences between the 89-92 and the 93-05 is the driveshaft as this seems to be one of the only different part #'s from the two schematics I compared on Evinrude.com. The 92 driveshaft is pn0433067 and the 93 driveshaft is pn0435269. The only other differences in part numbers between the two are the bearing housing assembly, the shift rod cover and shift rod o-ring.

How hard would it be to swap out the driveshaft I have from my 92 to the 93-05 case as I have found a few 93-05 cases that are complete??