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'94 Johnson 90hp V4 shift rod stuck on lower unit

F

f3d

New member
I got a free boat (hahaha) and after all the fiberglass work and refitting of the interior I started tackling the maintenance items on the motor, a 90hp v4 from 1994-5.
So far I've:
- tested the tilt/trim (fine)
- dropped lower unit
- drained gear oil (no water or metal shavings!)
- pulled the prop and thrust washer to replace.
- Pulled out the water pump (have new full kit with housing to replace)

I then started wondering about the gears since it didnt seem like it was going into gear from the throttle lever.
I tested the cable from throttle once removed from the throttle/shift bracket on the powerhead & it was all ok.

With the lower unit out, the shift rod will not pull up or push down to put it into gear, its stuck in neutral. Prop spindle and drive shaft spin freely.
i unbolted the gearcase cover bolts just fore of the waterpump and sure enough the cover with the rod pull up, putting it into gear (not sure if up is forward or reverse). But i cant push it down to get into the other gear because it seems the shift rod is stuck where it passes through the cover's double o-ring seal. Im soaking it in penetrating oil but it seems very stuck. Also will not unthread at all, through with the cover unbolted it will turn left/right, hopefully meaning the threads below are not seized.

Is heat a good solution for the double o-ring seal here? How is this thing so stuck in this one spot? Any advice to get this thing operational would be much appreciated.
 
Corrosion of the brass bushing is jamming the rod.-----Unscrew the rod.----Remove shift cover with force.-----Clean up the cover ( bushing ) or replace cover.-----Adjust shift rod to the correct setting on re-assembly.
 
racerone said:
Corrosion of the brass bushing is jamming the rod.-----Unscrew the rod.----Remove shift cover with force.-----Clean up the cover ( bushing ) or replace cover.-----Adjust shift rod to the correct setting on re-assembly.
Click to expand...
Thank you. Is the bushing within the shift rod cover itself? I can’t quite make it out from the diagrams. Also really can’t unscrew the shift rod, may have to cut the cover off to remove it from the rod. Is there anything to do to loosen up the corrosion? Shock or vibration?
 
f3d said:
I got a free boat (hahaha) and after all the fiberglass work and refitting of the interior I started tackling the maintenance items on the motor, a 90hp v4 from 1994-5.
So far I've:
- tested the tilt/trim (fine)
- dropped lower unit
- drained gear oil (no water or metal shavings!)
- pulled the prop and thrust washer to replace.
- Pulled out the water pump (have new full kit with housing to replace)

I then started wondering about the gears since it didnt seem like it was going into gear from the throttle lever.
I tested the cable from throttle once removed from the throttle/shift bracket on the powerhead & it was all ok.

With the lower unit out, the shift rod will not pull up or push down to put it into gear, its stuck in neutral. Prop spindle and drive shaft spin freely.
i unbolted the gearcase cover bolts just fore of the waterpump and sure enough the cover with the rod pull up, putting it into gear (not sure if up is forward or reverse). But i cant push it down to get into the other gear because it seems the shift rod is stuck where it passes through the cover's double o-ring seal. Im soaking it in penetrating oil but it seems very stuck. Also will not unthread at all, through with the cover unbolted it will turn left/right, hopefully meaning the threads below are not seized.

Is heat a good solution for the double o-ring seal here? How is this thing so stuck in this one spot? Any advice to get this thing operational would be much appreciated.

The shift rod is gummed up or corroded where it passes through the O-ring seal. Penetrating oil is a good first step, but applying some heat to the area (carefully) can help break up any corrosion or grime around the seal. Try gently tapping the shift rod with a soft mallet to help it break free, but avoid excessive force. If it’s still stuck, you may need to replace the O-ring seal. I mentioned https://academized.com/research-paper-writing-service to a friend, who was struggling with their research paper workload, and they told me that it helped me to take some of the stress off during crunch time. It’s great for when you’re stuck and need an extra push. If anyone here is in that boat, it could be worth exploring!
Click to expand...
Can I ask something regarding this or should I start my own thread? I am sorry for jumping on this post.
 
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