Rebuild Johnson Evinrude 6 Hp or 9.5 Hp Lower Unit Gearcase Part 1/2

This video details the COMPLETE rebuild / reseal of a 1979 Evinrude 6 horsepower lower unit. Also detailed, is the removal and replacement of the brass shift shaft / rod bushing and o-ring. If you have water in your Lower Unit oil then this video will show you how to repair the gear case. This video will also show you help you with a johnson evinrude water pump replacement.
The process shown in this video is VERY similar to the disassembly and reassembly of all Johnson Evinrude OMC lower units pre-1982 under 25 hp.
Make sure to bookmark my new website thisoldoutboard.com
#ad As an Amazon Associate and member of the eBay Partner Network I earn commissions from qualifying purchases using the links below at no additional cost to you.
*** SEAL KITS ****
HP YEAR PART NUMBERS
5.5 (1*) 1955-1967 amzn.to/2vkdfRB
6 (1*) 1955-1967 amzn.to/2wrMACh
6 (2*) 1967-1968 amzn.to/2vkAD0Y
6 (3*) 1968-1979 amzn.to/2vhLkmH
7.5 (1*) 1955-1967 amzn.to/2wrMKtn
9.5 (M Suffix) 1958-1967 amzn.to/2vMWT77
9.5 (B Suffix) 1967-1973 amzn.to/2vk2FtG
10 1958-1967 amzn.to/2vCF8XB
18 1958-1973 amzn.to/2frfJJH
20 1966-1973 amzn.to/2frfJJH
20 1979-1982 amzn.to/2frfJJH
25 1955-1959 amzn.to/2vklNI9
25 1968-1978 amzn.to/2frfJJH
25 1979-1982 amzn.to/2vhKGpx
NOTES
(1*) : 1967 D Suffix Only
(2*) : 1967 S Suffix Only, 1968 C Suffix Only
(3*) : 1968 A & R Suffixes Only
***** IMPELLER / WATER PUMP PART NUMBERS ***
3 Hp -- 1957 - 1961 -- amzn.to/2xWqLiT
4 Hp -- 1981 - 1982 -- amzn.to/2xWqLiT
4 Hp -- 1983 - 1988 -- amzn.to/2gWpA8w
5 Hp -- 1965 - 1968 -- amzn.to/2xWqLiT
5.5 Hp -- 1958 - 1964 -- amzn.to/2xWqLiT
6 Hp -- 1965 - 1978 -- amzn.to/2xWqLiT
6 Hp -- 1979 -- amzn.to/2xVzpxS
6 Hp - 1984 2004 -- amzn.to/2gWpA8w
7.5 Hp -- 1957 -- 1amzn.to/2xWqLiT
7.5 Hp -- 1980 - 1984 -- amzn.to/2gWpA8w
8 Hp -- 1985 - 2004 -- amzn.to/2gWpA8w
9.5 Hp -- 1964 - 1973 -- amzn.to/2gWwLO3
9.9 Hp -- 1974 - 1999 -- amzn.to/2yEMPwV
10 Hp -- 1959 - 1963 -- amzn.to/2gWwLO3
15 Hp -- 1974 - 2007 -- amzn.to/2yEMPwV
18 Hp -- 1960 - 1973 -- amzn.to/2gxPGBF
20 Hp -- 1966 - 1973 -- amzn.to/2gxPGBF
25 Hp -- 1969 - 1978 -- amzn.to/2gxPGBF
25 Hp -- 1979 - 1984 -- amzn.to/2yGxpc8
25 Hp -- 1985 - 2004 -- amzn.to/2xVjHxU
**************************************************
Evinrude Johnson Outboard Shop Manual 1.5 to 125 Hp 1956-1972: amzn.to/2vhwb51
Roll / Split Pin 303261 - PIN, DRIVE, DRIVE SHAFT 5 INCH
Impeller Gasket - amzn.to/2CCXDvi
Bushing Removal Tool - ebay.to/2PgeDPE
6 Hp Brass Bushing - ebay.to/2JB989p
************ NEEDED TOOLS *********************
3M Gasket Adhesive - amzn.to/2vkl5ug
Thicker / Better Spaghetti Seal - amzn.to/2vhDTfw
Hand Impact Driver - amzn.to/2vhPGKK
Pick Set - amzn.to/2wrYCLZ
Magnetic Tool Tray - amzn.to/2CR0qEn
*******************************************************
Video on disassembling the gears and prop shaft components:
• Disassemble Johnson Ev...
*******************************************************
*Above are Amazon Associate Links

[@classicbikerx3588]

You have so much fantastic info here! Having all of the links to the parts is key, too. You should link part 2 of the vid

[@WayneTheBoatGuy]

Thanks for this video! I was recording a KZbin video of starting up my 6 hp Evinrude and when I ran it for about 5 minutes the water in my tub was much oilier than it should have been. Clearly the seals and O ring need to be done. I decided not to make a video of that - because your video covers it very well!

[@goto8438]

thankyou for your clear, easy to understand videos. they are some of the best I have seen on youtube. I just found my fathers old 1975 6hp evinrude in the garage. it won't shift properly into forward it was supposed to have something wrong with the gears although there is no damage on the casing from an impact. I shall give it a go fixing it using your videos as a guide. cheers.

[@thisoldoutboard]

Here is printable step by step instructions for disassembling the gear case drive.google.com/open?id=15etoE22gHN5wkbFlPu76mDB1AvWDAfQ9

[@OutBoardTink62]

Just for the record that slotted stainless split pin is called a rollpin and the half circled piece as you describe it is called a shift cradle and also the metal clip piece as you call it is a detent spring to help lock in the FWD,NEUT,REV. shifting process.Just a note from an outboard mechanic & collector for too many years,LOL......... Glenn in N.Y.

[@wvbonbonqueen]

We are new to your channel and are also new to working on our boat motor too. You have the best instructions and links to your parts too. We are fixing a 1977 Johnson 25 hp, Model # 25E77S and was wondering if you have any specs or information to help us get it back into the water again. We just bought it this yr. and are trying to get it pushing water, like it is supposed to, it runs, no water pumped thru the motor, so we didn't run it but just enough to see/hear it run. We removed the impeller, and it is BAD, so we are starting there. Thanks for the great information and the good links for your parts. Keep 'em coming, PLEASE? lol

[@thisoldoutboard]

Sharon. Thanks for the comment. I have a 3-part video series that walks you through replacing a 25 hp water pump impeller. The first video is here: kzbin.info/www/bejne/bWW6YWWMrZ2ZasU Other than the water pump, what issues are you having?

[@wvbonbonqueen]

@@thisoldoutboard We are trying to find the right impeller for this motor, and so far, your links are a big help in looking them up. We aren't sure if the pump is working as the impeller is trash. lol So we shall go from there, to the pump, if it needs one. Like I said before, it does start and run, which for us is a very good sign. I will be looking into those other videos to see what we need to learn to better repair this motor and be able to use it soon. Thanks again.

[@jackball2166]

I have a 7.5 aqua sonic evenrude 1955 model and can’t find the brass bushing for the shift rod. Do you know if I need one if I have the tool to remove it? Just placing orders on parts so I have them in advance

[@jrharrison3]

Here is a diagram: www.marineengine.com/parts/johnson-evinrude-parts.php?year=1957&hp=7.5&model=7522&manufacturer=Evinrude&section=Gear+Case 1955 = 1957 diagram

[@Mark-wx1ho]

Just about to rebuild my 67 6hp Fisherman. I dont know whether its a suffix B so cant determine which seal kit to buy. There are no stickers or plates on the outboard. IS there any other way to tell? THanks.

[@Mark-wx1ho]

Sorry, suffix D or S.

[@russellmanweller6694]

Please tell me a 6 hp Evinrude lower unit will fit on a 9.5 Johnson. I found one cheap and want to know if I should buy it. They look identical from picture. Thanks. the 9.5 is a 1969 but don't know what year the 6hp is yet.

[@thisoldoutboard]

I put this page together to answer those types of questions thisoldoutboard.com/johnson-evinrude-lower-unit-compatibility/ Scroll to the bottom to see the chart

[@russellmanweller6694]

I don't know this was you but I actually use your stuff alot. Thank you so so much. This stuff is invaluable.

[@Venomrs4]

Great video Sir! Just wondering, how did you get the pinion gear off the bottom of the driveshaft?

[@thisoldoutboard]

They can be a pain to get out sometimes. Im sure there is a “correct” way per some service manual but I usually can take a couple of screwdrivers and gently pry up on it using the edge of the housing. Be carefull doing this and make sure you lift evenly

[@lester007able]

I want a three blade prop for my 6 hp... thoughts?

[@thisoldoutboard]

glenn horton you have two options regarding three blade propellers for the 6 Hp. One is an 8X7 (part number 387334) propeller and the other is an 8 & 1/4 X 5 (part number 0386587). The first number is the diameter and the second is the pitch. Think of a propeller as you would a car's axle ratio. The lower the ratio, the more pulling power from a standstill. The same is true with a prop. The lower the pitch, the better your hole-shot. However, this comes at a price: top speed. The lower pitch makes the engine reach maximum rpm at slower speeds. Conversely, a higher pitch will deliver greater top speeds, but slower acceleration. Be aware that lower-horsepower engines can bog down if fitted with a propeller with too high a pitch and diameter, and that can wear heavily on internal engine parts.

[@jikepisode8190]

Have a Johnson 6.5 and it does run while the primer is on. When turned off it shutdown. What can be the problem?

[@thisoldoutboard]

Fuel pump issue

[@herscheljennings2249]

I need a seal kit for a 1978 Evinrude 6hp,Where can I get one?..Thanks

[@thisoldoutboard]

thisoldoutboard.com/johnson-evinrude-lower-unit-seal-kits/