TJ40ELESR- Is lower toast?

[tloc1000]

Lower is leaking oil. I knew there was some cracks by the prop but was hoping it was in places that didn’t hold any oil. It doesn’t appear to be leaking from those cracks.

I took the lower off and found a crack where the shift rod goes up through the mid-housing. There are some rubber washers that look like they keep the water out and the lower looks like they worked but it’s leaking oil vs water in.

So so is this lower worth saving or can it be saved?

 

[tloc1000]

I have even more pic but they are too large to post. I'll resize later.

 

[jimmbo]

Your leaks could be nothing worse than the washers under the drain/fill and vent screws. The cracks on gear housing by the prop won't leak oil. However their location, and the ones around the shift shaft, may be evidence of the gearcase striking something. Get the unit pressure/vacuum tested and go from there

 

[tloc1000]

Your leaks could be nothing worse than the washers under the drain/fill and vent screws. The cracks on gear housing by the prop won't leak oil. However their location, and the ones around the shift shaft, may be evidence of the gearcase striking something. Get the unit pressure/vacuum tested and go from there

It looks like its leaking from the shift rod cover and the prop shaft seals.

I​​​​​​ assume I would need to replace all the seals THEN pressure/vacuum test.

 

[tloc1000]

[No message]

 

[jimmbo]

May as well replace the seal under the water pump too them. If you have a lot of trouble pulling the bearing carrier from the case, it usually means the case is distorted from an impact. If so, a new housing, or a complete used unit is what I would reccommend

 

[tloc1000]

May as well replace the seal under the water pump too them. If you have a lot of trouble pulling the bearing carrier from the case, it usually means the case is distorted from an impact. If so, a new housing, or a complete used unit is what I would reccommend

Thanks for the help

 

[tloc1000]

I'm trying to pull the bearing carrier out and it's pretty stubborn. I looked at the parts diagram and didn't see any snap rings or any other way it might be attached to the housing or shaft. Did I miss something? I know the lower is crack so it maybe stubborn due to that.

 

[tloc1000]

Well,. I got it out but the lower is cracked pretty bad. Can I fix with jb weld? The seal is well in front of those cracks.

 

[tloc1000]

Just making sure...the seal kit I got has only 1 propshaft housing seal. It looks like it is replacing the original 2 seals. #2 on the instruction sheet.

 

[tloc1000]

[No message]

 

[jimmbo]

There were kits that used the single double lip seal. Probably because a lot of people would install the dual seals incorrectly. Either both were installed backwards, or both in the same orientation and the seals would leak. One housing with both inner and outer seals probably reduced that error

 

[tloc1000]

I wire brushed the paint off by the cracks and used JB Weld Steel Stick to fill in the cracks. I put it in clamps to pull it all together. The JB Weld is sand-able and paint-able. Hope this holds.


I am in the process of replacing all the seals. I messed up the lower seal for the crankshaft bearing so a new one is in the mail. The seals for the water pump came with the Lower Seal kit that I had ordered but it did not come with an impeller. I ordered one of those also and everything should be in by this week. Hopefully I can get everything back together smoothly.

Im not sure how getting the arms from the shift rod through the shifter cradle will go. Its all in the front for the housing and hopefully it is easy to get back together.

 

[Faztbullet]

Total waste of time as gearcase frozen and carrier tabs caused these cracks as it pushed out. You need a housing....whats the gears and bearings look like??

 

[tloc1000]

Total waste of time as gearcase frozen and carrier tabs caused these cracks as it pushed out. You need a housing....whats the gears and bearings look like??

Gears and bearings look good. No chips or cracks on the gears. Bearings are not broken or seized.

No rust anywhere inside of the housing.

It was a little elbow grease and $8 for the JB Weld. I figured I would try before spending $200+ on a new housing.

 

[tloc1000]

I replaced every seal and put on a new impeller. I didn't have a way to pressure test but did have a vacuum pump to vacuum test. It held 15 lbs for over 2 hours. I filled back up with oil. Didn't have time to go to the lake but I'll try that in the morning.

I was a little worried about taking it apart and putting it back together. Im slower than most and made a few mistakes that I had to fix but over all it wasn't as hard as I thought it would be .

 

[tloc1000]

I didn't make it to the lake but I put it in a barrel this morning. Water stream was good and strong. Last time it had it in a barrel, the water got all oily due to the seal leaks. It was all clean today! Seals seem to be holding!

Now to see why it's running on 1 cylinder...

 

[flyingscott]

A word of caution on running your lower unit like that. Those 45 cid motors do not have great lower units. I think yours falls into the years where they are the worst some nla parts there. You are better off fixing it right with a new housing than risk expensive parts that you may not be able to replace. Or spend a lot more money than just a housing. As for the firing on 1 cylinder look at the ignition module. I believe yours is under the flywheel and they were problematic.

 

[tloc1000]

Thanks FlyingScott. If the back of the lower was the only thing cracked and with the new seals, it holds oil, what else should i look out for?


Would the no firing cylinder still get spark with a bad ignition module? I’m getting spark to the lower cylinder. I’ve taken the carb apart and cleaned but haven’t gotten a rebuild kit yet. That was next on my agenda.

 

[flyingscott]

I would do a compression test and an open air spark test. The spark must jump 7/16" gap. As for the lower unit it is just not great. There is enough things that can fail on that lower just through normal use. I dont know if i would chance a cracked housing.