54 Johnson 25HP gear questions

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  • December 29, 2019 at 2:59 pm #190203
    olcah
    Participant

      US Member

      Overhauling the gearset. I have a very good clutch but the lugs on the forward gear are badly damaged. The gear teeth are good. I see reference to machining the gear lugs but not how to do it. I have a small vertical milling machine. Can anyone provide instructions?

      Another possible fix – the lugs on the reverse gear are OK. How should I remove the pressed in bushing from the forward gear? Then I could install that pressed in bushing into the reverse gear and use it in place of the damaged forward gear. For a reverse gear I have a reverse gear from a parts motor. The teeth are rusted and pitted but it would probably be fine for intermittent reverse loads.

      Does anyone have suggestions?

      December 29, 2019 at 3:15 pm #190208
      frankr
      Participant

        US MEMBER PAY BY CHECK

        Lots of us have swapped the forward/reverse gears, as you suggested. It isn’t too difficult to remove the pressed-in bushing. Use an arbor press if you have one, but otherwise a vice & socket or whatever lesser equipment which you may have.

        December 29, 2019 at 3:55 pm #190213
        lloyd
        Participant

          US MEMBER PAY BY CHECK

          I agree with Frank. I have reversed the forward and reverse gears in the past with success. Intermittent use of the worn out reverse gear.at low speeds works OK.

          December 30, 2019 at 8:31 am #190257
          lindy46
          Participant

            Interesting that the gear is worn but the clutch dog is good.

            December 30, 2019 at 9:32 am #190259
            David Bartlett
            Participant

              US Member

              Clutch dog may have been replaced already.

              David Bartlett
              Pine Tree Boating Club Chapter

              "I don't fully understand everything I know!"

              December 30, 2019 at 4:20 pm #190276
              olcah
              Participant

                US Member

                Thank you Frank and Lloyd. Turned up a punch and used an old washer in a vise. Worked slick, the bushing came right out. Then tapped bushing into the aft gear with the punch and a hammer. 🙂

                press-bushing

                December 30, 2019 at 5:45 pm #190280
                garry-in-michigan
                Participant

                  Lifetime Member

                  You may also square up the damaged edge of your “new” reverse gear with judicious use of a Dremel grinder. Try to take the same amount off both lugs to evenly distribute the ware. The gears are case hardened, but the amount lost is OK for reverse as you are usually limited in speed when reversing.

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