1969 Johnson 6HP Outboard Lower Unit Water Pump Service Part 4

Lower Unit reassembly after water pump impeller service for most Johnson / Evinrude /OMC outboards is performed using similar steps to these.
Part 4: On the lower unit, pull the shift rod out to its fullest extension. Insert the drive shaft into the exhaust housing, and align into the power head. The long water tube that comes down from the engine into the water pump housing stays inside the upper section when you removed the lower unit. When mating the lower unit back with the upper section, you have to align the water tube so that it fits into the little stub opening at the top of the water pump housing on the lower unit. With the drive shaft beginning to align to the power head and the water tube beginning to seat into the water pump housing, fit the shift rod from the lower unit into the brass clamp. Screw the brass retaining screw into the clamp until it is snug. Use the shifter to pull the lower unit the rest of the way until it seats with the exhaust housing. Bolt the lower unit into place, and you're done.

[@ardyrides834]

Good video information here. I just purchased a 1965 Johnson 6hp it looks exactly like the unit your video shows here. I will be replacing the impeller as shown here.

[@BenjamIncredible]

James - Thanks for sharing this! New to boat motors and picked up my first 69 6hp Evinrude this summer. Used the heck out of it with motor lately for duck hunting a treacherous river. If the motor fails i'm making smoke signals hoping for a rescue chopper. You've single-handedly shown me exactly what I needed to know for piece of mind.

[@yamati150]

Great video and thank you!! My (new to me) didn't spit water in the first 30 seconds and I know it's been sitting dry for years. Impeller kit is ordered and I'm looking forward to replacing it and getting my little boat on the water!

[@6tringplayer483]

Do not forget to install the roll pin in the upper part of the drive shaft near the spline. It helps to compress the lower seal in the power head.

[@surge1899]

I have a 72 6hp Johnson and your video helped me replace my impeller. thank you.

[@phillipjones795]

Great video, James. Your patience is admirable. I am starting to bring current the deferred maintenance of my newly acquired 6R73 Johnson and you have given me the confidence to move ahead on it in the coming months. Not just a lower unit that had a rat's nest of fishing line wrapped around the propeller shaft that damaged the seal. The carb has a loose low speed adjusting pin and worn hoses, and a starter rope that barely retracts. I have several tasks ahead of me, including replacing the water pump impeller and maybe finding a newer model housing. Your clear explanations of the lower unit connections really help! Thanks!

[@highlandoutboards]

Phillip Jones You're welcome! If you would find any other repair topics helpful, let me know!

[@geraldunkel1490]

Good demo. Proper lighting and best possible focus. Good grammar and use of correct part terms.

[@questionreality6003]

thanks for all the video angles of the parts -!

[@slofr8dan]

Very informative. I have a 1977 Johnson 6hp and this has helped me a ton!

[@highlandoutboards]

Awesome feedback, you guys. This was a very tricky procedure to figure out. Glad to help the community!

[@kodibassInsideoutboards]

I stand the little guys on there head, nice video thanks

[@Mav400]

Thank you! Really helped me with my 6R72 Johnson! Thanks!

[@georgekeats1478]

Great video. I am doing this job right now and needed to check what gear the lower unit should be in. Mine was in reverse and after two failed tries to reassemble it I searched for a video and found yours. Thanks for the help and I admire that you are able to film work and comment all by yourself. Great job and thanks a ton!

[@highlandoutboards]

Very happy to have been a help for you. I started getting my 8 year old son to do the camera work when two hands are needed or when they're covered in gas and oil :) Good luck with your outboard repair, George!

[@georgekeats1478]

highlandoutboards After I watched your video and put the gearcase in the right gear my son and I were done in 15 minutes. It's all back together now and waiting for the warm weather so I can tank test it and then boat test it. Thanks again. Keep up the good work. I also have a few videos on youtube of outboard repairs...but I am only an amateur. Just a tip. I reassembled the gearcase to the exhaust housing by standing the motor on its cover. It was a lot easier to see down (or up) into the exhaust housing to mate the driveshaft with the powerhead.

[@MrBlackbamboo]

excellent vid

[@highlandoutboards]

Great suggestion! Thank you!

[@huntup1]

Great Video! It helped me out big time. Thanks

[@saltypro]

Well done thanks

[@lerch122]

thanks for the info,now i shall do mine

[@JohnStardust]

thank you! :)

[@mechengvids2955]

It looks like the roll pin at the top of the drive shaft is missing on your motor. Mine of a similar vintage requires that pin to compress the spring of the face seal at the bottom of the crankshaft in the powerhead.

[@chrisoglesby4028]

Hey james great video. I have a 1975 johnson 6hp engine that I'm rebuilding. I have just recieved a water tube that I needed to replace. Having a hard time getting it into the upper grommet. How can I get it in there and keep it from coming out? Thanks

[@jeaservices]

I'm working on a 1967 6hp Evinrude. I found my roll pin at the top of the drive shaft looking like it was sheered off, a replacement pin is longer. I noticed yours looked sheered off too, but you didn't mention it. they say it compresses a spring. Are some of them different? I also have an aluminum housing, and I had no insert for the impeller. Is that just the way they are? Thanks!

[@kyrahmorris4305]

I did all this everything went together fine but now it will engage neutral and reverse but not forward. Any suggestiins

[@pablocovar6554]

What size it the impeller I seen a 14mm, I have the same motor

[@romanteni]

This is amazing. Thanks a lot man. I just bought a small little 1979 just like this one, and opened it up and OH MY GOSH. I need to replace the whole waterpump, it has rusted to the point where metal broke off. (the engine runs great tho!!!) I took everything off except the very bottom metal plate, how do I take that off?

[@highlandoutboards]

romanteni If you can send me a picture of the piece that's giving you trouble, it would help me to make sure i give the best advice. If it's the metal plate i think you're talking about, try heating it lightly with a heat gun or hair dryer, then apply gentle pressure with a screwdriver.

[@romanteni]

It is called the housing and retainer ass. Part# 0382796, and its like 130$?!!! wow. Mine had so much sand and rust, and a few of the interior walls actually crumbled. Since this area seems to just house the water and then it only goes up through the small hole, how important is it that all those other small compartments don't break off? I don't see a purpose for them... If you have a fb account I can send you some pictures once I take them.

[@highlandoutboards]

you can often find better prices for vintage parts on ebay. try an ebay search for 382796 and you'll see one for about $75. The molded shape of the plate is important to its operation, but will probably not prevent cooling operation entirely. This plate also holds a drive shaft seal and possibly a bearing just for your awareness.

[@rm42749]

Excellent instruction video. Are you in highland Michigan?

[@highlandoutboards]

bob Last We are in Dripping Springs, Texas in the Austin area. A chain of lakes out here called the Highland Lakes is the inspiration for the shop's name.

[@flyinphil42]

I have a 9.5 sportwin shortshaft, I took the copper water tube out by mistake when I removed the leg. I am wondering do I need to take everything apart to line up the water tube to the powerhead ?

[@highlandoutboards]

Well... if you turn the powerhead upside down and rest it on the floor, you might be able to use a flash light and see the grommet that the copper tube inserts into. Worth a try before you remove the powerhead.

[@timothymears6875]

Where can you find a new spaghetti seal for a 1967 20hp Johnson or can you use something in it's place and can you use RTV along with the seal?

[@highlandoutboards]

The gearcase spaghetti seal material is sold in 50 foot rolls. Go to boats.net or another parts dealer and search 0309044. I think you need to include the leading zero in this part number search.

[@timothymears6875]

Thanks for the help. And is it ok to use RTV.

[@highlandoutboards]

The sealant I recommend for the gearcase is 3M-847 formula

[@MrBlackbamboo]

I can't get the lower unit to snug up? after replacing impeller any idea why it wont go in

[@highlandoutboards]

Sometimes there is a roll pin going through the top of the drive shaft near the splines. The ends of the roll pin protrude a little on either side of the shaft. These protruding ends may need to be aligned to a slotted "washer" up near the power head. Alignment is done in the blind by rotating the driveshaft until the pin slides through its slot.

[@MrBlackbamboo]

thanks a million thats' the problem its only sticking out one side which makes it to long thanks again from Scotland

[@rebeccaeverett4460]

highlandoutboards Hi, My driveshaft has a hole for the roll pin but there wasn't one there when I pulled it apart. Do I need to put a roll pin in there or not? Someone said that it holds the thrust spring assembly. Mine is a 1973 model 6302S. Thanks, Rebecca