Hello, Garrett here with Boats.net. Today we're going to be working on a 1969
Johnson six horsepower outboard engine. I've got this puppy off of Craigslist
and as you can tell it's a little beat up. So the first thing I'm going to do is
is check out the water pump. It's a simple part and it'll save you from a
burnout engine in the future. So, let's get to it. For the parts on this job,
luckily Johnson offers a nifty little kit that comes with everything you need
to repair the water pump on your outboard engine. You can get that by
checking the link in the description below, or if you have any problems give
us a call at our 1-800 number and our staff would be more than glad to help
you direct you to the part that you need. As far as special tools go, don't have
too many on this job, but I would highly recommend picking you up some marine
grease and some anti-seize lubrication. These two things are worth their weight
in gold working on any outboard engine. Now that we have our parts and tools
squared away, let's go over here and knock this puppy out.
Before we go any further we're gonna make sure that the outboard is in the
forward gear position. Well, we've got that done. Next up is to remove the four
ten millimeter bolts that hold the gear housing in place. We're gonna spin the
motor to the other side and remove the last two remaining bolts. Now, as we're
removing this last bolt we want to make sure that we don't completely remove it
because we want to shimmy the lower unit down just a little bit to disconnect the
shift shift. As we remove the last bolt, once you get it closer towards the end
of the threads, make sure you have a hand on the lower unit that way it doesn't
just fall completely out in case the shift shafts not connected properly. Now
that we have the lower unit unbolted, let's disconnect the shift shaft. It's
held in place by another ten millimeter bolt or you can get a flathead
screwdriver in there and we just want to loosen this up. As we loosen it up, you
should be able to twist the lower unit just just so as we pull down and boom,
we're disconnected. We have the gearcase in hand now. Next step, take it over to my
stand and inspect the water pump. Now that we have our gearcase in our stand,
let's do a quick visual inspection to see what we're working with so far.
Upon a closer inspection, we can obviously tell that it's been broken off
inside the gearcase. We don't want that, so we'll have to grab our easy-out kit,
once we pull the housing off and remove that broken bolt.
I want to tread lightly on removing the remaining three. What I'm going to do is
a little trick called shocking the threads. What I'm gonna do is I'm gonna take
my screwdriver and a hammer. I'm gonna put it on top of the bolt and just tap
it with the hammer. That basically shocks the threads inside the housing and
hopefully will make it easier for us to remove it. Just like that.
To remove our water pump housing we're gonna take us a little flat head
screwdriver and just gently pry on the housing until it frees. And we're
slowly gonna lift it up. Okay we've got the upper housing removed now it's time
to inspect the impeller itself. It's um, it actually looks like it's in pretty
decent shape, although it is very brittle. So we're still gonna replace it with the
kit that we ordered. Next we're gonna want to remove this bottom plate. Let's
remove the Woodruff key. You just use your simple pair of needle nose pliers
and it pops right out just like that. Okay now that we've got the water pump
assembly out of the lower unit, let's go ahead and tackle that broken bolt we
discovered earlier. We're gonna do that by covering up any holes on the water
pump housing. And we're gonna clean up this area where the broken bolt's at. So we
can see exactly what we're working with. Use some contact cleaner. I'm gonna clean
around the bolt-- that broke off bolt-- and see what we have. Okay, before we go any
further, being that this bolts broken like like it is,
I'm gonna file down a flat spot on top of the bolt. That way I can start a drill
bit on it easier. We have the bolt face flat, squared off. Now we're gonna use
the center punch and mark our drill point. Okay, for this particular
application I'm using a 5/64 drill bit. Now this may vary depending on the size
of your bolt, but in this case that's what we're using here. So we're gonna
take our drill bit and we're gonna drill down into the bolt.
There's our bolt. Before we go any further we're gonna want to clean off
any of the metal shavings that may be left behind. That way we don't get any of
that debris down inside the gear case. That's the last thing we want. Now, we'll
take our bottom plate and we'll slide it in this orientation right here.
Notice on the bottom plate there's actually a lip that sticks up. You'll
want that facing directly out towards the ceiling. Next is there a gasket. And
it will go on just like so. You want to make sure that the lip is sticking through
the top of the gasket. Next we want to install our Woodruff key and just push
it straight in. We just want to barely tap it in. The next thing we're going to
do is actually put a light coat of grease inside the cup. Take our impeller
and we're gonna turn clockwise as we push it down and it'll set in just like
that. Now if you pay attention you can see the
key way for the impeller as well as the Woodruff key in the front we want these
two key ways to line up. Next we will just spin the shaft until the cup sets
inside of that gap on the lower gasket. Now our upper housing will simply just
slide right on. Make sure all of our bolt holes are lined up for the plate and the
gasket. And just slide it in place.
Okay before we actually secure the housing in place with our hardware, I'm
gonna take some anti-seize lubrication and apply it to all four of the bolts.
That way we don't have any problems next time it's time to service our impeller.
Now as your tighten these bolts down you don't want to over tighten them you just
want them nice and snug because the housing is plastic and if you over
tighten it you're definitely going to break something. So just good and snug is
all you need. Alright, next I'm going to apply a little thin coat of grease to
the grommet and this is for the water pipe. We're gonna place it on top of the
housing and there's two pegs on the side of the grommet and there's two holes in
the sides of the housing. We want to line those two up. We'll put it directly on
top and just push it straight down. We have the water pump impeller kit in
place on the gearcase. Before we can continue any further ,we're
gonna need to prep the gearcase before we reinstall it to the engine. I'm gonna
do that but putting some marine grease on the top splines of output shaft, inside
the grommet where the water pipe is inserted, and lastly we're gonna make
sure that our shift linkage is in all the way up position. Just do that by taking a
pair of needle nose pliers and just gently pull up on the house-- on the shaft
itself and we're definitely all the way in the top position. Now we're ready to
go ahead and install it to the engine. Okay, before the gearcase can be inserted
we have to make sure three separate points line up perfectly or else the
lower unit will not go in place. The first point is where the output shaft
goes into the power head. Our second point is the water pipe-- this is what's
inserted on top of the water pump assembly-- and lastly our shift shaft. Now
we'll just slide our output shaft in place and make sure we even line up with
that top hole. You may need to twist it just a little bit. With our output shaft
in place, our water pipe inserted into the upper water pump housin,g and our
shift shaft in the collar, let's go ahead and tighten down the locking bolt.
Now we'll push the rest of the way up. Just like that. Before we install our
gear case bolts let's go ahead and put some of that anti-seize on them. That way
it's easier to take back apart. Well okay that wraps this job up. Wasn't that tough
was it? And it's gonna save me some cash because you didn't have to take it to a
dealer. Listen for parts and tools used in this project and more come check us
out at Boats.net and we can get you taken care of. You have any questions or
comments, just drop them in the section below and I'll do my best to answer them.
Just want to say thanks for watching and we'll see you in the next video.