Water mixed in gear oil on 96 Force 120

[Trophyman2]

I notices gear oil dripping from the lower unit weep hole so I decided to change the oil and it was white. Replaced with new oil and after a day tubing the oil was white again. Are there common problems with these lower units? Does anyone have a recommendation?

 

[emoney]

Re: Water mixed in gear oil on 96 Force 120

Simplest thing would be the check/fill plug seals. Replace them, refill with fresh oil and check again.

Has the impeller been changed somewhat recently?

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

When I replaced the oil I replaced the plug seals. The waterpump was changed last year and I always winterize with fresh oil. After a few initial runs in the spring I change it again for the summer.

 

[emoney]

Re: Water mixed in gear oil on 96 Force 120

Did you redo the caulk at the back of the pump when you replaced it? Those are the 2 most common spots for water intrusion. Seems like it would be awful early for the seals to be leaking, but if those 2 areas are good, then I would pressure test the LU to find the leak.

Did you install a kit or just the impeller?

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

Thanks so much for your input so far. Yes I did replace using the kit, but truthfully I don't recall using any caulk. Are you referring to gasket sealer? If so, do you think I could get away with dropping the lower unit and applying gasket sealer at those locations and seeing if it works. Never did a pressure test before but would be interested in learning how. I'm very handy mechanically.

 

[jerryjerry05]

Re: Water mixed in gear oil on 96 Force 120

These units usually don't have too much trouble with water in the oil.
Sometimes fishing line gets under the prop and cuts the seal???
Or when the impeller was replaced it wasn't tourqed when reassembled?
Or the seal under the water pump just gives out.

There were a few post's on here about homemade pressure testers.
Try the search feature and maybe they will show.

I think that calk is to keep the exhaust from the other areas.

What you can do is take the unit off,drain it, then put all plugs back in but 1 and
turn the air on your compressor down as far as it will go.
Get a spray bottle and mix some Dawn and water.kinda thick.
Spray all the places it can leak and add a little air,too much and it can blow the seals that aren't leaking.
Keep spraying soap and see if you can see where it's leaking.

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

Thanks to both emoney and JerryJerry05 for your suggestions. Jerry I
drop the uint and drained the oil then I applied a little airpressure
and discovered a small leak around the shift pin seal. While I had it
off I picked up a new impellor kit. When I pulled the housing off I
discovered that the gearcase cover was beat-up pretty badly so I
replaced that too. When I pulled the cover off I could see that the
top shaft bearing will probably need to be replaced soon. My question
now is in regard to the positioning of the gaskets when reassembling
the impellor housing. The instructions call for a gasket then the
impellor plate then a gasket and housing. The first gasket does not
block out the water from getting to the shaft top seal. I used 43055A4
Gearcase Cover assembly and 26-43035A3 Gearcase seal kit recommended
by my local dealer for the 96 Force 120. This doesn't make sense to
me. I would think that the gasket should surround the driveshaft seal
preventing water penetration. I will try to provide a picture using
the old gearcase cover.

 

[emoney]

Re: Water mixed in gear oil on 96 Force 120

I just did mine, Trophy and not that we should ever trust my memory, but what you have sure looks familiar. Seems like there was an O-ring thrown in there, but I could be imagining things.

Jerry will be around and clear it up I'm sure. I know in '96 (mine is a '95) there was a difference inside the gear case, but I think the difference was in the actual gears and not in anything else? Be careful with that shift shaft. I fought that little cam for 10 days getting it back in place because someone before me didn't understand that there was a plastic spacer in the leg and had shoved the shift shaft through it. Needless to say it stuck to the shaft pretty dang good and pulled it out when I went to change the pump. Not a fun time at all. Good luck!

 

[jerryjerry05]

Re: Water mixed in gear oil on 96 Force 120

Tropyman not sure what your asking??

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

Thanks for responding. If you look at the 2nd picture in my previous post where the pen is pointing...I would think that the gasket should surround the shaft area so when the impellor plate makes contact it blocks water from making contact with the shaft and gearcase seal. The gasket provided allows water to make contact and even sit in that area. I realize that there is a seal and an O ring but I water still can infiltrate and corrode that seal. Does that make sense to you? Or is it possible that I have the wrong seal kit.

 

[jerryjerry05]

Re: Water mixed in gear oil on 96 Force 120

Unfortunatly that's probably the right kit.
They make these motors to work in fresh water.
Salt water is rough on them.
Poor design.

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

Again many thanks to Jerry and emoney for their help. Jerry I agree on the poor design. I have been searching the web for more info but I have been somewhat unsuccessful. I will see what happens after a day on the water. If I still have water in the gearcase then I probably will be back for more advice. The next step would be to replace the propellor shaft seals. Thanks again!

 

[emoney]

Re: Water mixed in gear oil on 96 Force 120

Just to confirm, you do have an "O-ring" that goes on top of the water pump, right? That much I know was there, because I remember thinking "doesn't seem like a lot to keep the water out, but I suppose it works".

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

emoney...yes I did install the o-ring. doesn't seem like enough to keep water from penetrating. As Jerry said "Poor design". I think that the gasket that is installed under the gearcase plate would be suitable between the gearcase plate and the impellor plate. The small circular strip would sit on the exposed shoulder around the top of the gearseal. (where pen is pointing on above photo) Thanks for your input.

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

A quick update for those who have been giving me advice. I ran my boat today for all of about 45 minutes. Down the canal then opened it up to cuising speed but only for about 5-10 minutes. The wind and the chop were pretty fierce and I'm a fair weather boater so I turned around and headed back to the boat ramp. When I got home I checked the lower unit oil and it was Amber with a bit of cloudiness. Don't know if that is the remanants of some old oil that did not drain or if my problem persists. I guess I'll have to wait till the weekend and some nicer weather to see.

 

[emoney]

Re: Water mixed in gear oil on 96 Force 120

Might take one or two "flushes" to get all the old out. I'll be crossing my fingers.

 

[jerryjerry05]

Re: Water mixed in gear oil on 96 Force 120

ANY color change is not good.
If it's just been ran,then the oil could have bubbles in it and it looks milky.

When you were checking for the leak did you pressure test it?

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

Yes I put about 8-10lbs of pressure from my compressor to find the leak while being careful not to blow any other seals. When I refilled with oil and replaced the vent and fill plugs the oil did not run out of the drain as fast as it did prior to new seals, however it did come out. I can remember when it was new I could remove the fill hose from the drain and replace the plug with barely a drip. It has been raining here on Long Island this week so I have not had a chance to recheck the color or take the boat out for a long run.

 

[Trophyman2]

Re: Water mixed in gear oil on 96 Force 120

Just a quick update for Jerry and emoney for their help and advice. It seems the seals and new gaskets did the trick. I was able to get out an run about 6 miles round trip at high speed plus some slow cruising with no indication that there is any water getting into the lower unit. Hopefully I can get out a few more times before the weather changes. Thanks for all the help guys.

 

[emoney]

Re: Water mixed in gear oil on 96 Force 120

Jerry does all the work around here, I just provide comic relief. Glad to hear all is well and thanks for the "solution update". Too many folks breeze through here with issues and never report back that "it's fixed".

Of course, we're still a smidge disappointed there were no "proof pics" of the 6 mile trip, but I suppose we can't ask for everything. Sigh.......