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Stuck gearcase removal on '59 3hp Johnson

S

Simoniburg

Member
Everything on this old motor seems to be stuck. I had a heck of a time getting the lower unit and crankshaft to separate. After getting advice from this forum I used wedges and patience along with alot of lubricant to finally get it apart. Now I'm having trouble pulling the gearcase & propshaft (one piece) in order to replace the seals that are most likely 66 years old. Anyone have any ideas on how to get this stuck gearcase loose?
 
The two screws came out easily, but the entire gearcase unit itself won't budge. I've applied plenty of rust-busting solvent and although the on-line manual says to "lightly tap" the unit which allegedly "will slide out," that is NOT happening - even after striking the edge rather hard with a hard rubber mallet several times. Your previous advice about using wooden wedges (and patience) to separate the crankshaft and lower end worked beautifully. (Thankyou again!) I bought, and want to replace the two seals in the gearcase while I'm this deep into the rebuild but have definitely hit a roadblock again. Perhaps I will try a little heat application around the outside edge of the unit with my propane torch? Or, just leave well enough alone since there did not appear to be any water in the oil when I opened the drain plug?
 
P.S. By the way, the Impact screwdriver from Amazon that you listed above is a handy tool indeed. I have one and use it quite often. Too bad it's not applicable to this current dilemma!
 
Put it back together and get it pressure and vacuum tested as suggested and 5-8 psi is plenty. If your going to get into this hobby full tilt, I suggest you buy a stevens pressure and a vacuum tester, pricey but the best in my opinion.
 
Thankyou, fitz. At this time, and point in the rebuild, I've decided to move on because the drained oil was clean AND I can always come back to this "issue" w/o too much problem in the future. Plus, after putting the lower end back together I will/can run a pressure test in order to determine whether or not the seals are leaking or not and if a replacement is actually necessary. I just like to do things right from the onset and thus struggle a bit with "now or later"? Or, heck, maybe never. Will keep you all informed.
 
Perfect logic Simon, I have a number of them in that status. I'm getting ready to enter into retirement after 45 years with the same company. I've been collecting for years. Planned on being single till I was in diapers, and twist wrenches on my cherished herd of old outboards. NOT! I met my bride who requests my attention in other venues. If I die before her, I hope she doesn't sell my collection for what I told her I paid for them. I sneak out to the shop and usually have 3 engines in some sort of work in progress, I don't care if it takes 6 days or 6 months, it's just about making these old beauties start on 2 pulls in there original patina. I'm OK with butterface outboards. They're only original once.
 
I like your attitude! I actually have the Evinrude Lark 40 that my dad first learned to ski behind! I'm 64! Hang onto all your treasures! The old ones are so cool!
 
Fitz, you sound like a great guy and your last response gave me goosebumps, with a sly smile alongside. Why? Because I can relate so well to what you said. Celebrated my 30th wedding anniversary last July and #31 will be here on the 30th of this month, this year. Meanwhile, the "boss" has recognized, acknowledged, and "accepted" my joy in "playing" with these old motors and THAT is a good thing. I'm jealous though of your collection inasmuch as I got "hooked" only 10 years or so ago after stumbling across a '58 5.5 hp Johnson for $50.00 at that time which, since then, I have come to know inside out pretty well after taking it apart and putting it back together countless times, while "learning." After retiring 6 years ago I now find myself looking and watching for these old motors to pop up here and there, exactly what occurred with this 3 hp Johnson. After the $35.00 original purchase, I'm now into it "only" another $150.00 (and counting) on gaskets, bearings, plugs, impeller, paint, etc., all well worth it. Would I ever trade my wife for my love of these motors? No! Hell no! ...... but I might think about it. jk If you ever want to sell any of your motors, please let me know. Meanwhile, if you continue to love that newfound bride with even the least of the same intensity you possess for your love for those "antique" outboard motors, you have many years of "Wedded Bliss" ahead of you!

So what the heck? I thought this was a boat repair forum. Forgive me for running "aground." :unsure::)
 
He!!....my wife buys old motors FOR me! She loves it....we repair and sell for nice profits. 26 years now for her. Working on another sale w/ trade in, just tonight while we ate pizza on a date, ha! Yep....I think she's the perfect girl for me!....old motors and a younger wife, make for a good life! 😂
 
A Classic song for sure. I remember it well. Those days when we were young, a bit dumb and bullet proof. Today? Old, but now gold and just a bit more frail. Got some paint on a few parts today. They're hanging and drying now.
Too hot outside here in Southern Oregon today so I worked on the motor in the garage which remains comfortable. Carburator was rebuilt a couple of weeks ago. Decided to leave the old seals alone in the lower end. One day at a time.
 
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