Lower Unit Water Intrusion

[npd4432]

This is driving me crazy!! I have replaced the gaskets on the drain and air plugs, changed the driveshaft seal and pressure tested and suction tested. Both tests check out good. I am still getting water intrusion. The only gasket I could think of is the shift shaft o-ring. Could this cause the intrusion?? If so how do you change that thing?? I have the new o-ring but cant for the life of me figure out how to remove and replace the old one. 1983 Evinrude 75 HP E75TRLCTE.

 

[ob]

Re: Lower Unit Water Intrusion

Shift rod "o" ring replacement will require removing the lower unit.Other possible leak sources are the propshaft seals,propshaft bearing carrier "O" rings and bearing carrier retaining bolt "O" rings.

 

[cedar999]

Re: Lower Unit Water Intrusion

I just removed the o-ring from the shift shaft housing on my 1980 Johnson 60hp last night. I have no experience with outboards and no special tools. I have the manual but it does not explain how to do this.<br /><br />I used a small screwdriver and just pried it out. Took a little time, but really wasn't that bad.<br /><br />I will pick up the new one today (83 cents!) and try to install tonight, I imagine I will need to oil it lightly and then shove it into the housing and work it into the groove with some non-sharp object, but really don't know what to expect.<br /><br />Anyone have a better way?

 

[h_lankford]

Re: Lower Unit Water Intrusion

Like you, I had unexplained water intrusion until I replaced the shift rod O ring. The original one fit fine on the shaft, but it was way too small outer diameter and did not fill up all the available space in the slot! (Bad part selection by the factory, 1986 Johnson 60.) I snagged it out with a hook of steel wire (copper was too flexible). The new one looked way too big to install, but I oiled it and crammed in the shaft hole and when it reached the groove to bed into, it popped into the space and fit perfectly. End of problem.

 

[npd4432]

Re: Lower Unit Water Intrusion

Looks like I am going to have to pull the lower unit off AGAIN and try to replace the shift rod o-ring. I hope this works. Being that I am getting the water intrusion when only on the "muffs" and not in the water, the propshaft seals and bearing carriers are probably out. Is this correct??

 

[h_lankford]

Re: Lower Unit Water Intrusion

for clarification, I removed the O ring from the inside. I removed the cover assembly and pulled out the O ring from that way. There is a gasket for this cover assembly so I actually replaced 2 things: O ring and gasket. So, you could have 2 potential sources of leak in that area. You 'd think it would leak not just on muffs.