Johnson 25HP Impeller - Big Trouble

[Itsanss]

So I’m in a huge mess....

Bought a new impeller for 1987 Johnson 25 HP model J25RCUR.

I took the plastic screens off the sides, loosed the shift linkage, and removed the four bolts and one nut to remove lower unit. The one thing I forgot was to remove the bushing off the end of the shift rod. I’ve pulled the lower unit down about 6” and now the lower unit won’t come down any farther OR go back up. It is STUCK bigger than Dallas. I want to slide it back up to be able to remove bushing, but I’m afraid I’ve really bit the big one here.

a side note...the shift lever just moves into forward gear when trying to raise lower unit.

 

[jakedaawg]

You have it stuck in the pump housing it sounds like. I assume you mean the barrel nut and keeper plastic ring thingy. Is it down far enough to remove the bolts holding pump housing on? Give it a couple good whacks. Its no good where it is.

 

[Itsanss]

I believe that’s EXACTLY where it’s stuck. It’s plenty far down enough to remove housing bolts. I came really close to trying that, but decided to wait for advice. I’ve also taken a rubber mallet and tried to get it off the rest of the way...no go. Might try to take water pump housing bolts out and see what that does...

 

[F_R]

Don't be whacking on the cavitation plate. You will break it for sure.

I'm having trouble visualizing in my mind it coming down 6 inches without disconnecting the shift rod. What am I missing here?

 

[jakedaawg]

Don't be whacking on the cavitation plate. You will break it for sure.

I'm having trouble visualizing in my mind it coming down 6 inches without disconnecting the shift rod. What am I missing here?

On these 25s the shift rod disconnects in side the water intake screen beneath the pump and the rod pulls out through the pump housing.

@ltsanss

I meant give it a couple good whacks back up...

 

[oldboat1]

Might be missing your point, but thinking removal of the housing bolts would be a solution -- as you suggest. Slide the housing up and off the driveshaft, then work on the stuck shift rod bushing. Think you might be able to push the bushing out for access at that point, using the shift lever (but don't force it).

 

[racerone]

Work carefully and gently.-----Make sure the lower unit is in gear by moving the LOWER shift rod up or down.-----Turn propshaft while pushing the gearcase up.----Then perhaps turn the flywheel while pushing the lower unit up.----Make sure lower unit is lined up so that splines will engage-

 

[Itsanss]

Might be missing your point, but thinking removal of the housing bolts would be a solution -- as you suggest. Slide the housing up and off the driveshaft, then work on the stuck shift rod bushing. Think you might be able to push the bushing out for access at that point, using the shift lever (but don't force it).

Sorry I'm just now responding, ya'll. Work has been running me ragged.

I wound up taking off the water pump housing bolts and that allowed me to drop out the driveshaft, which then allowed me raise the water pump housing, which then allowed me to be able to remove the plastic lock and the threaded end off the shift linkage. All was apart then.

I replaced the impeller...the old one was completely toast. Put everything back together...went back together WAY easier than it came apart....usually the case is the opposite. lol

Just now had a chance to test it out. Unfortunately....there is still no **** stream. With some sort of luck, and nothing short of a miracle, the engine still starts and runs fine and shifts from neutral to forward and to reverse and back....but there is still not a stream signifying that the water pump is functioning properly. Unless I'm completely looking in the wrong place for it to come out...

This was supposed to be my easiest and quickest repair/upgrade that I’m doing to get it ready for this boating season and it has been utter disaster so far. :facepalm:

 

[jbuote]

I replaced the impeller...the old one was completely toast.

What does this mean? Was it missing some of the vanes? Chunks missing? Just worn down but intact?

Not a pro, but here are some initial thoughts..

If pieces were missing, then you would want to find them. They may be in the cooling passages blocking flow.
Also, could stick a wire of sorts (weed wacker line perhaps) into the tell-tale. It might be blocked up..
I presume you put the key in the shaft for the impeller right?

Could put a hose on the water tube (with lower off) and see if water makes it through the system or not..
Could also test the lower and water pump in a bucket before putting it back on..

 

[oldboat1]

On reassembly, did you get the end of the water tube in the grommet on the top of the pump housing?

Water level has to be above the pump if running in a barrel. The motor will heat up quickly without water circulation (danger of overheating) -- was the head hot to the touch?

Wedge type key has to be in place, as noted above.

 

[flyingscott]

Is the pee hole itself plugged?

 

[Itsanss]

What does this mean? Was it missing some of the vanes? Chunks missing? Just worn down but intact?

Not a pro, but here are some initial thoughts..

If pieces were missing, then you would want to find them. They may be in the cooling passages blocking flow.
Also, could stick a wire of sorts (weed wacker line perhaps) into the tell-tale. It might be blocked up..
I presume you put the key in the shaft for the impeller right?

Could put a hose on the water tube (with lower off) and see if water makes it through the system or not..
Could also test the lower and water pump in a bucket before putting it back on..

One of the vanes was completely broken off and a chunk here and there. I believe I’ve recovered all the pieces, though.
Blew compressed air through the tell-tale from the cylinder head out the pisser.
Key is in the shaft.

Is the pee hole itself plugged?

Boy how I wish that’s all that it was!






Sorry I’m just responding once again, ya’ll. Been so busy. I wound up ordering an entire pump kit. Everything was correct and nothing was plugged up on the cooling system. Checked the pump in a trash can…it just simply wasn’t pumping water. Last night I finally had a chance to install new water pump. Checked it with a drill in the can and….she pumps!! Re-installed the lower unit and got everything hooked up and buttoned down and this baby is again pumping water and coming out all the necessary holes! Thanks for all the help on this nightmare of an ordeal. This 20 minute, $9 job turned into a two week, $45 job. LOL Now that the easy job is done....onto converting this this to remote steer, throttle, and shift. Should be a piece of cake.

 

[jasper60103]

Thanks for posting the resolution. We don't always get that.
Also glad to hear it was something simple.
I always buy the water pump kit to make sure all is good.
Enjoy your motor!

Thanks,
jasper

...
Sorry I’m just responding once again, ya’ll. Been so busy. I wound up ordering an entire pump kit. Everything was correct and nothing was plugged up on the cooling system. Checked the pump in a trash can…it just simply wasn’t pumping water. Last night I finally had a chance to install new water pump. Checked it with a drill in the can and….she pumps!! Re-installed the lower unit and got everything hooked up and buttoned down and this baby is again pumping water and coming out all the necessary holes! Thanks for all the help on this nightmare of an ordeal. This 20 minute, $9 job turned into a two week, $45 job. LOL Now that the easy job is done....onto converting this this to remote steer, throttle, and shift. Should be a piece of cake.

 

[Itsanss]

Jasper,

My pleasure. I’ve been a forum junkie for 15 years and I’ve seen way, way more threads that have no ending than ones that do. I try to make sure that any threads I start, I also finish...win, lose, or draw. I’m thankful to report this one was a win.

Definitely learned my lesson on the water pump. I bought the impeller by itself for $10. If I had any idea that an entire water pump kit (housing, impeller, gasket, bolts, etc.) was $35 I would’ve done that from the get go. Oh well, like I said, I’ve got an extra impeller now. Haha

 

[oldboat1]

Glad it's working for you, but what was the problem? That is, why wasn't it pumping? Issue with the key, broken or cracked housing, installation problem, something else?

Full kits are not ordinarily necessary.

 

[boobie]

Maybe I missed it, but what was the finial problem ??

 

[Itsanss]

The exact reason is unknown....the housing wasn’t cracked, the key was in place, nothing was clogged, the impeller was the right orientation, etc.

I put the new pump in exactly as the old one came out....the new one works and the old one did not. Lol

And the water level in the trash can was exactly the same. I didn’t add or remove any water between old pump and the new one.

So what the ultimate problem was with the old pump, I don’t know. I’m gonna say that it was thirty years old and just tired and worn out.

 

[boobie]

Thank You.