Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

[CocoaBear]

I'm trying to remove the lower unit and have no problems except with the SHIFT ROD. I have a manual and I've seen the parts breakdown but I can't seem to figure out where the rod is and step by step how to disconnect it. The starter on this motor is on the port side. The VRO system is also on the port side. All of the control cables are on the starboard side.

Thanks in advance.
Steve

 

[CocoaBear]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

It's hard to believe that with so many experts on here this question can't be answered. I've read the post about the 60 HP which is a 3 cyl engine mine is 2 cyl and there are no control rods or really anything underneath my carbs. All of the parts diagrams don't help much and the manual doesn't show anything. I get the part about purshing in on the shaft to seperate the two halfs of the cam, but I can't eve find the shift rod to see which of the hitch pins on which shaft to remove and push on. I think the 1990 year was pivital and there were many changes made or many options, I've read every forum post on three different sites and nothing sounds like mine. It appears that the shift rod is inside the shaft leaving the power head. HELP! I've got to get this water pump replaced. HELP!

 

[AEROCOOK]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

If you remove the 3 starter motor mounting bolts and move the starter out of the way you should be able to access the pin / bolt that attaches the shift rod to the lever. It would be a really good idea to disconnect the negative cable at the battery for safety before you begin.
I used a 1/4" drive ratchet with a 6" extention, a universal / swivel adapter and a 7/16 socket when I last did one.

 

[CocoaBear]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

Thanks, I'll give it a try when the lites better tomorrow, but now I can only see 2 bolts on my aft side of the starter, is there one on the front side. That side of the motor is almost impossible to see with the starter in place.
I appreciate your help.

 

[AEROCOOK]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

There is a 3rd bolt that faces forward near the top of the starter, it's the hardest one to get off because you cant get a socket on it. If you have a boxed end ratcheting wrench it will speed things up for you.

 

[CocoaBear]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

Thanks so much for the advice and patience. I can't understand why all of the information kept saying to look under the carbs. It ain't under the carbs it's hiding behind and beneath the starter, forward the block. Is this engine bassackwards to the other Johnsons and Evinrudes, I know it's only used on the Bass Pro packages. There repair sites don't even want to know about it, I called to order parts and they said that BP only used them 3 or 4 years and they didn't want to have anything to do with them. They're Mercury lovers!
Thanks again
Steve
I'll have it all out tomorrow.

 

[AEROCOOK]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

The shift rod bolt is in fact under the carbs at the front of the motor but theres more than 1 way to gain access to it. Some folks may remove the carbs to get to it while others may drop the lower motor pan but I found that moving the starter worked best for me. Based upon the model number you provided, you have a Johnson "TRACKER" which is the same as a regular Johnson except for paint and graphics.

 

[CocoaBear]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

You're going to think I've lost it but I've been working on the starboard side for so long that when I went around to the port side and removed the starter, the VRO equipment was blocking the view of the carbs and I didn't have brains enough to realize that was the front of the engine on my left where the front had been on my right. This is embarrassing as in "stupid is as stupid does". Mechanical work is not new to me I've torn several truck engines and car engines down and rebuilt them and still do most of my own work on our vehicles. Marine stuff is foreign for me.
Thanks again.

 

[Haffiman]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

Remove the lower engine cover on PORT side, then free access.

 

[tav]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

a few years to late on this topic....but i 'm going thru the same thing...i have a 2004 40hp 2 stk. can't see the rod on the starboard side but i bearly see it from the port. so takeing off the thwe starter wil give me more access? what actually holds the rod toghter cotter type pin or nut and bolt?

 

[racerone]

Re: Lower Unit Removal, 1990, 40 HP Johnson TJ40ELESR

A wee bolt is in there.----Don't lose it.--------Do not turn the shift rod while working on the lower unit.