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2004 Johnson/Evinrude 25hp lower unit removal.

B

brian__c

Contributing Member
I am having a tough time removing the lower unit of my 2004 Johnson 25hp. I'm looking at the
service manual from a slightly older model and it says:

1.) Remove the prop
2.) Remove the water intake screens on both sides of the gearcase to provide access to the shift
rod connector.
3.) Hold the lower connector with a 1/2" open wrench and turn the upper connector with a second
wrench. When the shift rod disengages, remove and keep the plastic keepers between the
connectors. (I don't have plastic keepers on my shift rod).
4.) Remove the bolts holding the gearcase to the exhaust housing.
5.) Remove the screw and bolt hold the gearcase to the exhaust housing
6.) Carefully withdraw the gearcase from the exhaust housing.

I have completed all the steps (except for the part in step 3 that refers to plastic keepers), but when I try to remove the lower unit, its gets "stuck" after its separated by about 6". The upper shift rod connector ("nut") is still connected to the shift rod and it appears it is getting "stuck" and not allowing the gear case to be removed.

Can anyone tell me what I'm doing wrong?
 
The plastic keeper is holding it !!!--------------You slide the nut up to see the black keeper, it is tapered and split and needs to be removed. -------then the nut comes of and it all falls apart.
 
Racerone,
Yes, were right on. Once I pushed up the nut, I could see the black keeper. Once the keepers were removed, the lower unit came right out.

I serviced the water pump and painted the lower unit. When I reinstalled the drive, I have a hard time getting the lower unit back on. The last 1/2" was a bear, until I tried moving the fly wheel, then it slid right in.

The problem I'm having now is that the motor will not shift into reverse. It will shift between Forward and neutral, but when I try to put it in reverse, there's resistance and it pops back into neutral. Any ideas?

Brian
 
OK, Thanks again.

Before I removed the lower unit, it would shift freely between F<--->N<--->R without the motor running. I'll try to turn the prop to see if that helps.

Getting the motor running is my next challenge (will turn over but not start). Plenty of info in the archives on that one.....

Appreciate the help.
 
I may have inadvertently turned it when I was tightening the nut to re-connect the lower and upper shift rods.

Should I try turning it manually with needlenose-type pliers?
 
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