Different lengh shift shafts on 20" gearcases?

[archcycle]

Replacing the gearcase on a 1990 Johnson 140hp 20" with a 1985 90hp gearcase.

It seems the shift shafts are not compatible.

On the 1985 the top bend forward toward the shift arm is at an angle that doesn't meet up with my shift arm. Even pinned to the back of the tube it's angled too far toward the bow to allow the arm to slide over it. Maybe 20* or so difference in the angle putting the hole about 1/2" farther forward when I line up the shaft from the gearcase I removed with this one.

So I swapped in shaft from the gearcase I'm replacing and found the 1985's shift rocker must sit about 1" higher than in the gearcase that I'm replacing because even bottomed out the shaft can't get down to spec height.

I measured out the difference I'd need to chop and have machined to the 5/16x24 thread. Only found one machine shop in town that can lathe it down (it's a little over 5/16 and has a taper before the threads) and then put those threads on it and their minimum charge is $75.

Now looking at my plan it seems like I must be overlooking something simpler or cheaper..

 

[flyingscott]

Have you tried to dry fit the 85 lower to the 90 I am not sure they are the same

 

[racerone]

Answer this ??-------Is the gearcase off the 140 HP a V-6 gearcase , yes or no ?--------

 

[archcycle]

flyingscott Yes it all bolted up right with the shifter in F but it was pinned there. racerone Yes the old one is a true V6 case. I had replaced it with the large housing V4 geared case some time ago but the drive shaft snapped (thread on that one somewhere..) and I went back to the V6 geared large case. I don't remember if I had to swap shafts there but today I do have 3 shafts and two gearcases. Right after posting this I drove down to one shop that didn't pick up the phone just to be sure and they bent the short one to the same spec as the longer one off the V6 case for just $10. Will see how this goes when I get home in a few hours. It looks like it should work.

 

[archcycle]

Top of the shaft was too wide to fit into the shift arm. Few minutes with a dremel grinding stone took care of that.

 

[tommarvin]

Your quote, "Now looking at my plan it seems like I must be overlooking something simpler and cheaper" This is the best quote I have heard in the forums so far.

Archcycle, I love you man, Get the right lower unit, or get another motor, and stop the aggravation. peace