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  1. #1

    Default 69 9.5hp johnson shaft stuck in powerhead

    1969 9.5hp johnson. When I dropped lower unit to replace water pump impeller the shaft stayed in powerhead. How do I 1) get shaft to come out and 2) if it doesnt can I reverse engineer the pump and gear casing elements back together from the bottom.

  2. #2
    Join Date
    Nov 2011
    Posts
    3,258

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    1. Pray

    2. It has been done. File a notch for the pin to pass through the water pump housing and put it back together in the reverse of the way it came apart.

    3. Be aware that RUST is what's holding the drive shaft splines. There is no way of knowing when the rust will complete it's job of destroying the splines and there you will sit dead in the water. Maybe a year from now, maybe tomorrow.

  3. #3
    Join Date
    Apr 2010
    Posts
    5,150

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Mix up some ATF and Acetone 50-50, turn the motor upside down and pour that down the drive shaft and let it soak for a few days. Then clamp a vice grip on the shaft and beat the hell out of it trying to remove the shaft.

  4. #4

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Thanks. Prayer is powerful but hoping atf/acetone will be the answer.

  5. #5
    Join Date
    Jun 2013
    Location
    Duluth Mn
    Posts
    4,303

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Might wanna check this post, if you haven't already.
    http://www.marineengine.com/boat-for...tube-reinstall

  6. #6
    Join Date
    Apr 2010
    Posts
    5,150

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Ever get the shaft out ??

  7. #7

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Working on pulling powerhead. Taking my time and videoing disassembly. Tried just about everything before doing this but options didnt work. Have whole new lower end ready to go once shaft is out.

  8. #8
    Join Date
    Apr 2010
    Posts
    5,150

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Did you try what was suggested in post #3 ??

  9. #9

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Yes I did. Now I have powerhead off and will try heating shaft after using more plaster deep creep for another 24hr soak. Very hopeful at this point

  10. #10
    Join Date
    Sep 2010
    Posts
    21,963

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Wrap driveshaft with brass shim stock.------Clamp driveshaft in a hefty vice.------Put 2 pieces of.1/4 plate between block and the vice.----Use 2 correct length bolts and nuts use them as jacking screws.------Very powerful and controlled procedure.-----Extra hands / helper may be required to get it all set-up.

  11. #11

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Thanks. That's pretty much in line with what I had in mind. Not totally worried about bending shaft as I have another lower unit w/shaft ready to go. Can do water tube as well.

  12. #12
    Join Date
    Sep 2010
    Posts
    21,963

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    The issue will be the condition of the spline in the crankshaft.---Driveshaft is stainless.----Crankshaft is carbon steel.----Rust / corrosion eats right into the metal.------Water soaks into the carbon steel.----Steel is much like a sponge for water.-----If you get it running the crankshaft spline may not last as it will be weakened.

  13. #13

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Thanks for info. Will take a good look today once I get shaft out.

  14. #14

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    The shaft has been exocerised from the powerhead. No damage no bend.
    Thanks to all who gave me hope and methodology on how to get it done. I have plenty of time for reassembly. Will whatever needs to be replaced will be. Piece of cake, right.

  15. #15
    Join Date
    Nov 2011
    Posts
    3,258

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Replace that shift rod boot while you are in there. It won't run with the hood on if the boot fails.

  16. #16

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    Ok. Will do. Starting reassembly tomorrow.

  17. #17

    Default Re: 69 9.5hp johnson shaft stuck in powerhead

    All reassembled. Water tube in as well as lower unit. Changed out just about everything that even remotely looked bad. End result: IT RUNS, IT SHIFTS IT WORKS.
    This job was not for the faint of heart. The videos I took during disassembly were invaluable. Thank you to all who gave tips and advice, you're awesome.

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