Looking for lower unit opinions

[Dpatrickj]

I have an Evinrude 120 E120TLEIE, think it's from 1996. Owned it for almost 3 years and runs perfect. This spring after the first landlocked salmon trip my buddy and I noticed a sort of clanky tapping sound very slight but I'm super sensitive to engine sounds. I did change the gear oil right before the trip and it had a good sheen of metal. Hadn't actually changed it in a while so thought maybe I just waited too long. Now I'm wondering if the sound was from the lower unit. Seems like more metal than normal in the oil. Posting a picture of the old oil, I drained it. Filled it back up and drained and filled again. That was a month ago. I just dumped the pan of oil and the whole bottom of the pan is a fine metal sheen. Trying to upload photos but so far they are all too big! Also in gear I can move the prop back and forth almost 2". Is it time to remove the lower unit and tear it down?

 

[Dpatrickj]

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[Dpatrickj]

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[boobie]

Looking at your pics you better tear down the lower unit. Especially the pic of the drain plugs with all the metal on them.

 

[V153]

Ditto

 

[V153]

Ya when you get metal on the top magnet, purty good chance there's a problem ...?

 

[Dpatrickj]

Yeah, that's what I figured. Thanks

So looking over the OMC service manual it looks like a lot of special tools. are there ways around these tools? I guess either way I'll start breaking it down but I'm wondering if I should just start looking for a replacement gear case. Any thoughts on a new aftermarket gear case ?

 

[boobie]

Tear it down first to see what happened. You may be able to fix it.

 

[V153]

Been awhile since I did one but I think the only thing 'special' ya need is a extra long circlip tool?

 

[Dpatrickj]

Got as far as the long circlip tool today. Doesn't seem to bad so far. There was a large washer behind the prop bearing with a not so circular shape on the inside of the washer? Doesn't seem right... That snap ring is huge! The OMC manual was the best investment so far.

 

[racerone]

Don't worry about the bore of that washer.---They are all like that .---May be for allowing oil to circulate.---Any shop would have the big pliers to remove those rings.----You will likely find the teeth on forward gear damaged and the teeth on the pinion too.----You have to consider the bearings that may also have fine metal bits in them now.

 

[Dpatrickj]

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[Dpatrickj]

So right after the snap rings there's OMC tool for pin shaft. Any decent alternatives or does anyone know what size the nut is? Definitely some broken teeth on forward and the pinion. Looking around it seems like this gear case is pretty pricey. It's , I guess the smaller 13 spline shaft.
hues I need to price out a new gear set and well pretty much all bearings, seals?

 

[V153]

You have to consider the bearings that may also have fine metal bits in them now.

Good point R1.

 

[V153]

Looking around it seems like this gear case is pretty pricey

They pop up around here on Clist for about $250?

 

[Faztbullet]

New one from SEI is $895 and 3 year warranty...SE304 for the for the small dia case and SE306C for the V-6 style

 

[Dpatrickj]

That's exactly what I was looking at but wasn't sure if it was the small one. That's probably about right at what I'd spend in parts and misc., plus all the time I could be on the lake!
Still have to remove my driveshaft... Maybe a open end wrench if I could figure out the size, larger than 3/4". Anybody ever made one?

 

[Dpatrickj]

I have a one price driveshaft, it's says I'd need to buy a different shaft for the new one?

 

[Dpatrickj]

Looking into a used Johnson 120 vro 1994, possible swap