Johnson 140 lower unit gear assembly

[morrisstephen]

Help!! I'm trying to rebuild my 1987 Johnson 140HP outboard lower unit. I have a shop manual that illustrated how the parts are assembled. However I,m having trouble attaching the pinion gear to the drive shaft. It appears that the pinion gear just will not line up in the hole to allow the drive shaft to seat. I have checked the assembly and it is put together correct and it appears to be seated in the gear housing correctly. What am I missing?? Please help. I have wasted the whole summer on trying repair this boat!!<br />Thanks

 

[rodbolt]

Re: Johnson 140 lower unit gear assembly

double check that the alignment pin on the shifter housing went into the hole in the gearcase. if it did not it will bring the fwd gear aft and you cannot install the pinion gear.

 

[morrisstephen]

Re: Johnson 140 lower unit gear assembly

Rodbolt, <br />Thanks for the reply. I considered that situation and checked several times. How do you know if the housing alignment pin is seated? And how in the heck do you get it seated? Is the only way to tell the pin is not seated indicated by the pinion gear not lining up with the drive shaft?<br />Thanks again for your help