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1998 Johnson 40hp stuck in forward

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BFC

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So I have a 1998 Johnson 40hp (BJ40TLECR) that today got "stuck" in forward gear. Here are the symptoms:

- when the engine is off, the gear/throttle lever works as it should. It moves forward and backwards as it's supposed to. I checked the linkage to the shift rod and it works fine.
- when the engine is turned on the propeller immediately starts to turn and the gear/throttle lever is stuck. It refuses to move backwards. I can't shift to neutral or reverse.

Background: Last spring I changed the impeller. I am wondering whether that had something to do with it. However the boat has been running nicely all summer, so it's kind of weird that this should be an issue.

The outboard has taken a couple of knocks recently. Could the propeller shaft be bent or something like that?

Any advice on what could be going on would be much appreciated.
 
Ok for anybody who ends up in the same situation, I found out what is causing the problem. Somehow (I have no idea how) the lower case gear rod pivot screw has come off. So whilst the gear rod is moving, it's not doing it properly and not moving the clutch dog.
I really can't understand how it has undone itself. But I've ordered a new one and hopefully that should solve the issue.
 
It is not uncommon for people to remove that screw, (Phillips), mistaking it for the oil drain plug. Perhaps a previous owner did, & didn’t tighten it?
As Droid alludes to…I would drain, flush, & re-fill that gearcase, now.
 
Edchris177 said:
It is not uncommon for people to remove that screw, (Phillips), mistaking it for the oil drain plug. Perhaps a previous owner did, & didn’t tighten it?
As Droid alludes to…I would drain, flush, & re-fill that gearcase, now.
Click to expand...
What would you flush it with? Fresh water?
 
Well 1st of all, if we are talking about the same screw (myself, Racerone & Edchris I'm sure are)....

With screw gone, oil is gone & water went in. Not a good thing. Also since I doubt a fish was carrying around a #2 phillips screwdriver & suddenly removed it while you were stopped floating around, I can only assume it was loose & leaking for some time. How/why I don't know.

The point is most likely you may have operated this boat for some time with low &/or contaminated. If it were mine I would tear it down & explore inside. However if the damage is already done & ignored you will eventually be notified.

The flush is done with a few transfusions of new oil.
 
Droid said:
Well 1st of all, if we are talking about the same screw (myself, Racerone & Edchris I'm sure are)....

With screw gone, oil is gone & water went in. Not a good thing. Also since I doubt a fish was carrying around a #2 phillips screwdriver & suddenly removed it while you were stopped floating around, I can only assume it was loose & leaking for some time. How/why I don't know.

The point is most likely you may have operated this boat for some time with low &/or contaminated. If it were mine I would tear it down & explore inside. However if the damage is already done & ignored you will eventually be notified.

The flush is done with a few transfusions of new oil.
Click to expand...
Thanks for the feedback. I am really stumped as to how the screw has come off. This is the 4th summer I have owned the motor. I have never once touched that screw. So I can only assume that it has started to come off loose with time.
 
Did you ever see oil leaking there?

Did you & do you periodically check the oil level?

Was it low or always full?

Was it clean, look like a chocolate milkshake or making metal?

Have you drained it now since this issue? Obviously it can't be full or clean until screw & o-ring are replaced & you've flushed & refilled it.
 
BFC said:
What would you flush it with? Fresh water?
Click to expand...
Jesus, NO. You wouldn’t flush the crankcase in your car with water! It’s upposed to be full of oil, you want the water gone. Drain it. I would remove the leg, fill half full of isopropyl alcohol, & shake it around, (that will absorb remaining water. Drain again, then fill with oil. Run it a bit, then drain again & refill with oil.
As said, it might be too late…
 
Droid said:
Did you ever see oil leaking there?

Did you & do you periodically check the oil level?

Was it low or always full?

Was it clean, look like a chocolate milkshake or making metal?

Have you drained it now since this issue? Obviously it can't be full or clean until screw & o-ring are replaced & you've flushed & refilled it.
Click to expand...
I changed the gear case oil at the beginning of last summer. I am 150% sure I did not open the pivot screw. The oil was fine then.
 
Edchris177 said:
Jesus, NO. You wouldn’t flush the crankcase in your car with water! It’s upposed to be full of oil, you want the water gone. Drain it. I would remove the leg, fill half full of isopropyl alcohol, & shake it around, (that will absorb remaining water. Drain again, then fill with oil. Run it a bit, then drain again & refill with oil.
As said, it might be too late…
Click to expand...
The isopropyl idea is great. I will do that.
 
These lower units are NOT robust.----I suggest you take it apart ASAP.---If water caused major damage it might be terminal.-----The coat to repair / rebuild this will shock you
 
racerone said:
These lower units are NOT robust.----I suggest you take it apart ASAP.---If water caused major damage it might be terminal.-----The coat to repair / rebuild this will shock you
Click to expand...
So you are suggesting to take it apart to inspect for damage? I am just thinking if there is damage, am I screwed and the motor is terminal, or would there be any chance of saving it?

I am just wondering because taking it apart is quite a job (for me). Never done it before although I have watched several youtube videos and I do have the service manual.

I am just thinking the other option is to just flush it, change the oil and keep my fingers crossed and run it for as long as it runs. Then eventually change the lower unit in case it dies.
 
When you flush and drain it, run it all through a coffee filter… see what comes out.
Maybe start looking for a blown up motor and get another leg as a donor
 
So I finally opened up everything. And as predicted there was rust everywhere. Fortunately it is only surface rust and all the components were otherwise in good shape. So I used some rust remover and lubed everything up and now things are spinning freely as they should. Will replace all the seals and put it back together and it should work find.
 
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