Part fell into lower unit?

[TwoRivers]

Once again I come seeking wisdom, guidance and understanding.
Working on a 99 Johnson 200hp two stroke. (J200PLEEN).
Changing out seals in lower unit and replacing water pump.
I removed the shift shaft cover before removing the water pump.
The impeller was frozen to the drive shaft and I had to pry on it from two sides.
When it broke loose the plastic key (white one) fell down into the shift shaft compartment and disappeared.
I've turned the unit in every direction and tapped the housing with wooden blocks and rubber hammers but no luck.
Every attempt to find and remove it has failed.
If left in the bottom of the lower unit will this hurt the gears?
Any suggestions for removing without taking the gear assembly out?
Thanks in advance.
rob

 

[racerone]

Flush any oil out of there first.-----You should be able to find it with a strong flashlight.-----YOU HAVE TO FIND IT----------It could cause issues with the shifting and that gets expensive.----

 

[TwoRivers]

Racer.
All the oil is drained but it's sticky down there.
Was thinking of running some kerosene or diesel fuel through the lower unit?
Not sure?

 

[Crosbyman]

small parts may...stick... due to oil try flushing with kerosene to loosen the small part

keep shaking upside down reflush again if need be part may be stuck so turn the drive shaft ..gently both ways

 

[TwoRivers]

Thanks Crosby,
Will give that a try.

 

[racerone]

Part will be confined to the shifty bits in front of the bearing housing.-----Turning the propshaft may not help.------Installing the shift rod and pulling it up may help.

 

[TwoRivers]

Thanks racer.
Will water hurt anything down there?
What if I spray the area out with solvent (brake cleaner, kerosene, diesel fuel, etc) then turn the unit upside down and flush with hose?

 

[racerone]

Flush it out with say varsol.-----Then you will likely be able to see it using a strong flashlight.----Note ---try looking up into that cavity with the gearcase upside down.--------Also note that I would likely take less time to take that unit apart then the time you are taking in the fishing effort.------Nothing to it to remove driveshaft and propshaft.----You do have the propshaft bearing carrier out to replace those seals I hope.-------Just my opinion.

 

[TwoRivers]

Had the carrier out to replace seals but put it back in. Can pop it back out if necessary but would prefer not to.
Took the large snap rings out removed reverse gear and inspected gears. Everything looked good so I put it back together.
I'll try flushing and fishing again before taking it back apart.
thanks again.

 

[racerone]

??----2 large snap rings ?----That suggests to me that the lower unit on your motor is an earlier model replacement.

 

[TwoRivers]

Could be.
This is my fishing friend's motor and he did replace the lower unit several years ago.
Might have replaced it with a different year?

 

[TwoRivers]

Racer,
Do you know what year(s) used the large snap rings. I need to figure out if I'm using the correct parts.
thanks

 

[racerone]

They started with those in 1976 not sure what years they started with the 2 tabs.-----In my opinion the gearcases with the 2 snap rings are more durable.---Not going into the fine details as to why I think that.

 

[TwoRivers]

From the parts diagrams looks like 1989 or older lower unit?
Friend is vacationing in Florida now but I think he tore up his lower unit and bought used replacement four or five years ago.
Had it installed and was working fine until lower unit started taking on water.
Any issues with this set up?
thanks

 

[TwoRivers]

Looks like the water pump kit I have will work with older lower unit and the older model only takes one O ring in the shift shaft case.
Take a deep breath and get back to flushing and fishing.
thanks again

 

[oldboat1]

I'm not sure what the "shift shaft compartment" is on your motor, but are you sure the key went into the gear case? I think it's more likely the key dropped into one of the water passages down there (jmo).

 

[racerone]

There is a large cavity in the front section of the gearcase.----The shift rod goes in there and screws into the shifty bits on the front of the propshaft.

 

[TwoRivers]

Thanks for your response OB1.
The shift shaft compartment is the area to the front of the lower unit drive shaft / water pump where the shifting rod screws into the shifting mechanism.
Pretty sure it fell into that area.
Searched the garage floor just incase my eyes played tricks. Happens. No luck.
I think it would have showed up by now if it was in the water jacket?

 

[TwoRivers]

Racer,
I was typing while you were responding.
That's exactly what it is.

 

[oldboat1]

Thanks to both -- see what you mean!

I don't know what you are using in the way of probes, but I've had a cheap version of one of these for years: https://www.riogrande.com/product/L...VGorICh2hTAQGEAQYASABEgLLIvD_BwE&gclsrc=aw.ds Tough challenge.