Topic: 54 Johnson 25HP gear questions – Antique Outboard Motor Club,Inc

This topic has 6 replies, 6 voices, and was last updated 4 years, 3 months ago by garry-in-michigan.

Viewing 7 posts - 1 through 7 (of 7 total)

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December 29, 2019 at 2:59 pm #190203
olcah
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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
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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
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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
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Interesting that the gear is worn but the clutch dog is good.
December 30, 2019 at 9:32 am #190259
David Bartlett
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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
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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. 🙂
December 30, 2019 at 5:45 pm #190280
garry-in-michigan
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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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