Johnson 40hp 1976 Gearbox removal problems

[Nautique93]

Ive removed the 7 bolts and disconnected the gear linkage as per my service manual- apparently the gear box should now split from the exhaust housing. It is loose but seems to be held up by the drive shaft- does this need to be disconnected at the powerhead or are the splines corroded and holding it in there? If so any tricks for removal?

 

[Nautique93]

Re: Johnson 40hp 1976 Gearbox removal problems

Anyone? I dont want to break anything!!

 

[crxess]

Re: Johnson 40hp 1976 Gearbox removal problems

Does it drop at all? If it is loose it should drop at least a bit. if the shifter is disconnected it should come off.

Drive shaft can bind, water pump tube might be stuck in grommet. try giggling while rotating the flywheel.

Avoid prying.

 

[Nautique93]

Re: Johnson 40hp 1976 Gearbox removal problems

The gearbox is definitely free from the housing- can jiggle left and right, but not clear enough to get a screwdriver in to pry, although i was hesitant about prying if it would fit. I can visibly see the shift rod is disconnected looking though the access hole, I have tryed jiggling whilst rotating the flywheel, I have tryed lightly tapping a block of wood against the fin on the side but am afraid to tap harder incase i damage the fin. I guess i just have to jiggle harder! Thanks for the reply.

 

[crxess]

Re: Johnson 40hp 1976 Gearbox removal problems

Has it been run hot? If so the water pipe may definitely be stuck in the grommets.

maybe using a Wide stiff paint scraper will allow enough prying surface not to digg the casing up.
Looking at a diagram of your motor it really looks like the tube is stuck in the pump housing water tube grommet.

I have to admit, I have pried mine off.........Carefully.

 

[Nautique93]

Re: Johnson 40hp 1976 Gearbox removal problems

Not sure if its been run hot, this came as a spare engine with a boat i bought a year ago. Finally getting around to tidying it up to sell- It runs but has feeble stream of water so im going to replace the impeller. I will try a bit more jiggling, if that doesnt work i will try a paint scraper. Not sure i will get enough leverage but worth a go. Thanks for the ideas

 

[tashasdaddy]

Re: Johnson 40hp 1976 Gearbox removal problems

remove the spark plugs, so you can turn flywheel, the drive shaft is rusted in the crank. put 2 bolts loosely back to catch the lower unit. now vigorously giggle the flywheel back and forth.