OK, well my first question is, do you already have the gearcase apart? If not, I would replace the upper seal, reinstall the driveshaft, then pressure test to see if in fact there are more leaks and where they are…. All the new seals and orings in the world are not going to repair a grooved shaft, porous/cracked casting.
I am frustrated when folks are encouraged to pull these clam shell gearcases apart and reseal them. Sealing one of these units up properly (zero leaks) is no easy task! So, I would ask how bad was the gear lube that was in the gearcase? Just milky? Or, was there actually raw water inside. It’s probably not worth pulling this thing all apart for a minor leak (milky gear lube). Chances are good you will find more problems or make things worse by going inside and trying to reseal it. Perhaps the upper seal is all that was wrong…
As for Ben’s video on youtube, that method will only work on the 9.9/15hp gearcases where the shift rod can be removed without gearcase disassembly, there is no way of removing your shift rod without complete disassembly. The only thing I would comment about Ben’s method is that the shift rod bushing should probably be replaced after gouging it up putting threads in it.
You may have missed the reason for the proposed teardown. Short story: impeller replacement in a new to me motor with history unknown. Lube in gearcase suspect, looked too perfect. Probably never been run…
Did not realized one screw is in water jacket, as hard as i tried, busted head off. I cant believe someone actually engineered it that way. Ended up with a damaged pump housing and bits of metal in the gearcase getting the remaining screw out. Driveshaft seal was BAD, driveshaft in great shape. 000 steel wool and pb blaster cleaned it right up. Impeller may have been original. Worried about getting all the tiny bits of metal out of the gearcase.
I was 100% successful in getting the shift shaft bushing out with zero damage. I did not use a tap, I used a 5/16 allthread with the threads ground down slightly at the tip. Came right out. I have already checked, shift shaft fits in bushing, no interference, etc. (Bushing is NLA, as far as I can tell.)
O-ring was in decent shape, but is getting replaced anyway. Prop shaft seal in great shape, not replacing. Prop shaft seal carrier o-ring is also getting replaced.
Ben’s video is very straightforward. I see no reason for concern and I plan to pressure test once I am finished with reassembly.
So no, I didn’t tear it apart just to reseal it. Despite my best attempts at keeping the internals clean, I was certain I saw a small chunk of the driveshaft seal collar fall into the case. (I had to dismember the seal to get it out). So rather than have chunks grinding up my gearcase, I agreed with the assisting members and pulled it apart. I’m very happy I did and with the advice I received.
Thank you
Best Regards
John Gragg
RIverside, CA
Just starting in the hobby, please be patient.
48 Sea King 5hp GG9014A. Sold
49 Sea King 5hp GG9014A
48 Johnson TD20. Sold
49 Johnson TD20. Sold
54 Johnson QD15. Sold
55 Johnson CD12. Sold
57 Johnson RJE-19M
57 Johnson RDE-19
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