1969 Johnson 20hp Gear Box Blues. What went wrong and How to Fix it. Metal flake in the oil

In this video I will discover what happened to the gear box on my 1969 Johnson 20hp outboard motor.
Follow the links to products and items used in this video:
Prop drive pin and cotter pin www.ebay.com/itm/304040544114
Amsoil Synthetic Marine Gear Lube amzn.to/2Umz8k0
Impact driver set amzn.to/3ioBO8Q
Gear Oil Gasket Maker amzn.to/2Ug7cOU
O ring kits amzn.to/3wO9IsT
Engine assembly lube amzn.to/3rlMbym
Box of rags amzn.to/2Ug7EN6
Brakleen part cleaner amzn.to/2VPIBk9
Video equipment used
Cannon EOS M50 Mirrorless Vlogging Camera Kit with EF-M 15-45mm Lens, Black
amzn.to/3tcSCTE
Comica BoomX-D D2 2.4G Wireless Lavalier Microphone System Digital 1-Trigger-2 Wireless Microphone Transmitter & Receiver SLR Clip-on Micro phone,Lav Mic for Smartphone Camera Podcast Interview
amzn.to/3edmYB4
email me at
[e-mail]
mail me at
RMD Creations
PO Box 387
Wellman, IA 52356

[@enoswebster6902]

well that oil was black can't believe you still ran the 18 mile and made it that pin fix was super great job

[@74charger44]

This was, in my opinion , the best video so far.

[@Michaelsbackyardmarina]

Thank you for the kind words and thanks for watching

[@malcolmcook4690]

I’ve had the same problem with my johnson 20hp gear box so doing the upgrade and it’s done just tested it and it is working perfect your amazing mate i watch all your videos thumbs up all the way 👍👍👍

[@Michaelsbackyardmarina]

Thanks for sharing. It's awesome when it works out. Thanks for watching and commenting.

[@saenole66]

Great instructive video. Fun to watch you bring these old soldiers back to life.

[@Michaelsbackyardmarina]

Thanks for watching. Fun to bring them back around

[@mikedurhan9941]

Great repair job, Michael. And a great video. BTW: No need to pull the cotter key and pin to remove the shifter fork. Just leave it attached to the shift rod and swing it up and out of your way. (Just saves time.) Again, thanks for all you do to help all of us with our old motors.

[@Michaelsbackyardmarina]

Thanks for the tip! I sorta realized that afterwards. Thanks for watching

[@jeremyaustin9103]

Hello from the UK Great job...and really appreciate the science and accuracy. great channel

[@Michaelsbackyardmarina]

Hey, thanks! Really do appreciate the kind words. thanks for watching and commenting

[@mitchz.6234]

AWSOME job Mike.....always wanted to see the inside of outboard gear box....Thanks again!!!

[@Michaelsbackyardmarina]

Glad you liked it! Yep not as scary as you think they would be.

[@timothymckeown8118]

Got my prize package yesterday! Thanks again Michael, Timothy Mckeown.

[@Michaelsbackyardmarina]

Fantastic! Hey thanks for participating and watching

[@SMCscottydogg]

I have learned so much watching your videos. I’m so glad I’ve subscribed awhile ago

[@Michaelsbackyardmarina]

Welcome aboard! Thank you for watching and commenting

[@tuyo_adventures.2185]

I Did a similar repair on my 61 Evinrude but using a replacement Kit instead with a new gear and two bushings PN 390970 because I couldn't find the bushing anywhere, for this specific application I had to grind the pin down, works like a charm, Also the only gasket maker besides the impossible to find original stuff that I found in this Permatex Form-A-Gasket Sealant PN 58931, all others failed miserably, Thanks for the knowledge share.

[@Michaelsbackyardmarina]

Awesome, thanks for the form a gasket tip, thanks for watching

[@jpawlacz]

I have a 1969 Evinrude 9.9hp and had the pin issue also. I was able to use a spot welder to attach to the pin and remove it, and reset it. Great video as always.

[@Michaelsbackyardmarina]

Thanks for sharing

[@johnwyatt8528]

Great video, it showed me everything I was needing to see to fix my 1967 Johnson FD-21R outboard that I got with an Alumacraft boat that I bought for $400. It's likely been several years since the outboard has been used, or even ran for that matter, so I checked the lower unit to see what the gear oil looked like and only got a few drops of water so I will be putting in new seals and while I have it apart, I'll go ahead and replace the water impeller and the seals in that section as well. It runs too good not to do it right and mess up a good running outboard by being cheap.

[@Michaelsbackyardmarina]

Sounds like you got a good plan there, thanks for watching

[@anthonylatronica5108]

Mike that was a very creative mod to fix the bearing in its proper alignment. Nice job

[@Michaelsbackyardmarina]

Thank you for the kind words and thanks for watching and commenting

[@penny200100]

Stuff The Haters, Mike, You're Doing A Marvelous Job, Mate!

[@Michaelsbackyardmarina]

Thank you so much, thanks for watching and commenting

[@tonyrome3119]

Excellent job

[@Michaelsbackyardmarina]

Thank you very much!

[@TimsWorkshopTJY]

Hi Mike, Nice gearbox detail review and fix. Cool you had replacement parts to get it back on the water. Looking forward to seeing what the gear lube looks like after the run. Got my Starcraft licensed finally and will be shooting a video soon with it on the water again. It's been a couple of years

[@Michaelsbackyardmarina]

I will definitely be doing a follow up after the run in on the gear lube. Thanks for watching

[@marioflavin2141]

Love the shirts man very informative thanks.

[@Michaelsbackyardmarina]

Thanks and thanks for watching

[@sk8forever12]

First off just want to say, LOVE the videos! Howver im having a hard time with my 1979 25hp evinrude. Great motor, howver im having spark issues. Just threw a "new" powerpack in it and still no spark or intermittent spark. I would love to see one of your videos about how to test powerpacks and coils using a multimeter. Thank would be awesome! Thanks and keep up the great vids!

[@thomascoey8530]

Love this video ! I do like to learn. Thanks bro !

[@Michaelsbackyardmarina]

Glad you enjoyed it! Thanks for watching

[@wadeballinger6877]

Very informative !!!

[@Michaelsbackyardmarina]

Glad you liked it, thanks for watching

[@k6outdoors]

Nice work! Fingers crossed the improved design will keep the bearing from spinning!

[@Michaelsbackyardmarina]

Fingers crossed!

[@mikegrieshaber169]

Fantastic video 🎣🎣🎣 Thanks again Mike

[@Stewsdrums]

He is ten times better teacher than this old outboard or kodibass

[@Michaelsbackyardmarina]

Very kind words and Thank you. I also follow Kodibass and TOO

[@Michaelsbackyardmarina]

Glad you enjoyed it

[@mikehalverson6775]

your doing a good job

[@Michaelsbackyardmarina]

Thank you so very much. Thanks for watching and commenting

[@buddybaumann528]

👍 great tutorial

[@Michaelsbackyardmarina]

Thank you! Cheers!

[@user-po5cf3dn4k]

Awesome video ,I think this I'd what's going on with my out board,55 evinrude

[@Michaelsbackyardmarina]

Cool thanks, thanks for commenting and watching

[@danielrobert7181]

Well, I have done the same intervention on that disappearing bearing stopper pin. I used a proper-sized drill bit cut and ground to the right length as my new pin. It’s been 3 boating seasons since and ... no problema signor ! By the way, sure Amsoil products are very high quality but where I live (Quebec) the boating season is about like yours so one would have to boat overtime to accumulate more than around 50 hours on that motor yearly so I suggest any brand name gear oil will do. Thank you for your videos.

[@Michaelsbackyardmarina]

Thanks for watching and glad yours is still going strong, I sold the motor along with the boat this summer, makes me a little sad to see one leave my hands.

[@Jimmyzb36]

Great video! Good advice on using an impact driver. One tip for that,,, I usually take the bit that I'm going to use and give it a tap with a small hammer then add the driver to it.

[@Michaelsbackyardmarina]

I should have shown that on camera, I did exactly what you said to do.

[@Jimmyzb36]

@@Michaelsbackyardmarina I wish we were neighbors!

[@stevanrose7439]

Very good information I feel I can tear my lower end apart and get it back together. Kinda like nothing to loose because it won’t push the boat as it is now anyway.

[@Michaelsbackyardmarina]

Go for it. You miss all the shots you don't take as they say.

[@justinowen1402]

I finally sold my 25 johnson last week. Got a 35 thru the hub exhaust. Man the power difference is alot.

[@Michaelsbackyardmarina]

oh yeah!!

[@gillgetter3004]

I think that’s a great fix, can’t count how many times I have used those tension pins for repairs on all types of mechanical stuff! I was tooling across the lake toward the ramp and my engine slowed way down then made a terrible sound, shut it off. Got to dock with trolling motor, pulled boat on and there was a big wad of mono and a reel jammed against prop! Removed it, new seal, took apart reel greased it and still use it today. Never know what will happen!!!!?

[@Michaelsbackyardmarina]

Very cool story, thanks for sharing. Thanks for watching

[@rickbrown7067]

Awesome fix Michael, your camera is getting good shots. Nice job. Changing your gear oil after will be great to flush out the case.

[@Michaelsbackyardmarina]

Exactly, thanks for watching and commenting

[@rickbrown7067]

@@Michaelsbackyardmarina Hi Michael, Love to see the running of the motor in the water and the result. Hopefully you will post that. Love your channel. Have a great summer. Rick

[@JamesSmith-oc6jc]

Nice repair on that engine.

[@Michaelsbackyardmarina]

Thanks 👍

[@russellbailey4443]

Mike your a SFG thanks for sharing you knowledge

[@Michaelsbackyardmarina]

I appreciate that

[@user-xe9dm8rz4g]

I noticed in the heat selection that you left out two balls and spring that catch when you switch the forward neutral and reverse? Are those necessary to have or better to leave out?

[@cornhoolio6456]

Have you ever considered 3d printing old starter brackets for these older motors? You would make a fortune with the prices people are asking for the stock ones!

[@victorsampietro9018]

Michael…which video has you showing how to take tiller apart on 18 HP evinrude 1969 and cleaning and lubed

[@scottsasanecki4106]

great video. I appreciate your expertise and work man.

[@Michaelsbackyardmarina]

I appreciate that! Thank you for the kind words and for watching

[@johngonsalvesiii8142]

I enjoy your videos and do agree with your fix with the pin and bearing . But I come from the overkill school. It would be no problem to machine a key slot and install a key way the proper size and never ever worry about that again

[@Michaelsbackyardmarina]

If I had a mill on the floor I could have done that for sure.

[@harrycarlock800]

Very good Video. I have not seen any videos on the Leaf Valves. I Have a E6Rcud and would love to see videos on that Engine if you have any.

[@Michaelsbackyardmarina]

I haven't done and 1987 6hp Evinrudes. The 9.9 may be similar that I have done.

[@richardcranium5839]

a couple of comments for ya. i learned to assemble things with whatever lube they normally run in. if you pack a grease in a tight fit it keeps thinner oil out and will cake up sometimes actually causing siezure. i think the assembly lube you used will be fine. although note lithium compounds are generally water based. also the pin i believe is short for a reason. if you look at the end of the shaft and the end of the bushing its in a blind pocket. by the pin having clearance in the key slot it allows air out so the bushing doesnt get air locked and starved for lube. poor set up imho. also if the face of the thrust part of that bushing wears the oil channel gets smaller. i would have opened them up a bit and drilled the bushing in a different spot to hold a longer pin. i'm sure your fix will work, just some potato chips for thought.

[@Michaelsbackyardmarina]

Thanks for sharing. It has lasted since 1969 so all the engineering can't be all bad.

[@alejandromendoza7191]

Great video. Quick question. My identical outboard is not going into reverse and forward. Would that be caused by a bad Pawl? I’m stumped. Thanks!

[@Michaelsbackyardmarina]

Sounds like if you split it open you will see something that is worn, thanks for watching

[@barrymccolman3824]

what did you do with the 2 ball bearing and spring detents that goes in the propellor shaft spline area, under the shifter, clutch dog. there should be a hole straight through to accommodate. The clutch dog shouldn't move so freely.

[@regio81]

Cool fix , crazy there the shift dog doesn't have the two bearings and spring in there that help ot lock in foward, neutral and reverse.

[@Michaelsbackyardmarina]

One of the gear boxes of the three did have the balls and spring.

[@uhoh71]

I was going to comment and mention they were missing. Maybe they didn't put them in all of them. Never seen one without them though.

[@regio81]

@@uhoh71 kinda weird what would keep it from popping out of gear so easily 🤔 the grooves on the lever for fwd, neutral and Rev aren't enough to lock in place. I'm definitely doing that pin mod though .

[@MuddyTirez]

I have dove into the same hobby wish I found you sooner. Where are you getting upgraded props for this same engine?

[@Michaelsbackyardmarina]

Solas.com

[@justinowen1402]

I had a 25 johnson with the same kind of gear case. My pin was sunk almost flush too I think it got that way from someone assembling it when it wasn't in the Grove and when they tighten the case it pushed it down. Mine had a pinch mark on it but it hadn't spun yet like your.

[@Michaelsbackyardmarina]

that is probably what happened. thanks for watching

[@justinowen1402]

@@Michaelsbackyardmarina yw I like alot of your content. Always something good to learn

[@jeffwhicker2153]

Michael, might you be able to tell me what currently available lower unit oil will mix safely with Pennzoil 4949 Marine High Viscosity 80-90 weight lower unit oil? I was refilling my lower unit with it and I ran out before the unit was completely filled, im guessing maybe half way. And now I can't find this particular Pennzoil oil anywhere!

[@Michaelsbackyardmarina]

I would not mix the oil. Just drain and start fresh. Thanks for watching

[@jeffwhicker2153]

@@Michaelsbackyardmarina Thanks for your reply & advice.

[@davidcorliss8350]

Hi Mike ? For u I have a 1974 25hp evinrude that impeller shafe will not come out with the lower unit. How do u get it out

[@Michaelsbackyardmarina]

without being there it's hard to tell you what to do, sorry, thanks for watching

[@justinowen1402]

Isn't there supposed to be a tension spring and 2 ball bearings on the clutch dog so it will stay in forwards or reverse. Mine had them but I didn't see them on yours.

[@Michaelsbackyardmarina]

there were there it was just all in pieces. Thanks for watching

[@martinflanagan2506]

Another great repair with that new dowel pin, that factory dowel pin was way too low. Learn lots from from your video's.

[@Michaelsbackyardmarina]

Good to hear! Thanks for watching.

[@stevanrose7439]

I’m wondering if that factory pin maybe got rounded off a little when the bronze bushing spun. To bad it couldn’t come out but I bet it’s stainless steel so a magnet 🧲 wouldn’t touch it. If it was not a tight fit.

[@shotslife]

Hahahaha, you don’t know how many times I have had to redo videos because the camera was off!

[@Michaelsbackyardmarina]

The worst part is I absolutely hate repeating myself, LOL

[@rocko112camaro]

Q: Do you know where I can get an Anchor Block and Pin part# 0378577 for a 1970 Johnson 20hp 20r70e? The cover with the pin is broken. Or any idea where I can get 1 fabricated or made? Watch your vid on the 20hp you brought back to life. Thanks,

[@Michaelsbackyardmarina]

I have one attached to a hood if you are interested. email me. my email is in the description.

[@mohabirsomwaru7624]

I have done the same thing 30 years ago. I put in that extra pin and level the gear box

[@Michaelsbackyardmarina]

cool, is it still in operation? Thanks for watching

[@mohabirsomwaru7624]

@@Michaelsbackyardmarina I sold it a long time ago it was working great

[@fishlovme]

I owned a 33 HP Evinrude from I think 1971 or 73. Those 33 HP motors were tanks but they were known for having clutch dog issues. Have you noticed in the 20 HP any clutch dog issues?

[@Michaelsbackyardmarina]

No clutch dog issues so far.

[@trentongarces1500]

where did you get the spare prop?

[@Michaelsbackyardmarina]

Solas.com

[@uhoh71]

The brass bushings around the driveshaft are known for galding in these motors, more so than the bushing you were working on. Hopefully you spun the driveshaft with the gears out and checked for binding.

[@Michaelsbackyardmarina]

Oh yes, she spins smooth and free.

[@michaeltooley7573]

Hi Mike! Question? If the indexing pin you put in is smaller than the width of the groove in the bearing! Doesn`t that create the same exact problem you are trying to fix? It`s not going to take much back and forth in that groove with a smaller radius pin, stopping and starting to put you right back where you started! Right? Not criticizing! Just asking!

[@Michaelsbackyardmarina]

Not at all. I have over 3 times the amount of pin sticking up. Keep in mind if all is working as it should there shouldn't be any back and forth and if there is this will stop it. Thanks for watching

[@robertrabhudsonhornet5869]

Hi I am wanting to know what happened to Frankenstein last thing you was going to put on a Handel an putting it on a boat ?

[@Michaelsbackyardmarina]

I was waiting on a boat to put it on. Finally bought one but it needs some work before it hits the water.

[@robertrabhudsonhornet5869]

OK cool I will want for the video on that boat being worked on an seen that boat on the water with Frankenstein I know it's going to be fantastic.

[@davekimbler2308]

Those lower units are the easiest to work on ! First there’s no need to pull the pin in the shift rod , just pull the rod upwards . Next the pin is worn down to much , you need a new alignment pin and bushing . Next don’t reuse the spaghetti seal and use RTB gasket maker with the new spaghetti seal ( put RTB around the prop shaft bearing for a good seal ! The pin is used to keep the prop shaft from moving in and out , yours has a groove in it but they also have them with a hole for the pin to set in ! After sealing the case do a pressure test (about 7 lbs for 10 to 15 minutes ) to make sure your lower unit is water tight ! I was cringing when you sunk that drill bit so deep ! Being you’ve dropped the lower unit I’d check the impeller out , just in case !

[@Michaelsbackyardmarina]

Thank you for the tips.

[@emfelling8384]

by the way were do you sell your motors i would like to know trying to get a new motor and you seem like a good guy to buy from

[@Michaelsbackyardmarina]

I do sell them when I am done proving they are in good working order. I'm in eastern Iowa

[@emfelling8384]

@@Michaelsbackyardmarina ok do you sell them on facebook or craigslist?

[@lenwilson2141]

For pins I use drill bits as they can be bang on,,,! And make a bush with arrive ln sIde it to allow oil in and use 75 90 oil cheers!

[@ratin2373]

Muito bom

[@Michaelsbackyardmarina]

Obrigado por assistir e comentar.

[@malcolmcook4690]

Just been 30 miles and all good 👍

[@Michaelsbackyardmarina]

Excellent

[@malcolmcook4690]

@@Michaelsbackyardmarina love your channel and watch every episode send me one of your shirts bro please

[@malcolmcook4690]

@@Michaelsbackyardmarina I’m in the uk I’ll pay for post just to get a shirt 👍

[@stevanrose7439]

My 25 eve rude won’t stay in forward gear when under a load Any suggestions.

[@Michaelsbackyardmarina]

Chances are you have worn drive dogs on your gear or clutch dog shifter is worn out

[@stevanrose7439]

Thanks for the reply. I’m gonna take it apart to find out. I hope if it’s needs gears ⚙️ they aren’t to expensive to buy or hard to find. It’s a 70s vintage I believe. Once thanks again Michael I enjoy your videos.

[@normsebby3421]

your pin needs to be 360 bronze so it can always be drilled out.....after your 1/8 drill hole fill it with hydraulic oil then start an 1/8 drill rod in it and tap with a punch and hammer and the existing pin will come right out....that way u can use a full size pin having no play in the bushing slot.....old toolmaker method for removing bushings from blind holes.

[@Michaelsbackyardmarina]

Sounds like a plan, I shouldn't have to go back into it I hope.

[@jimlove4541]

Wouldn't a tool and die man weld on to the pin and use a screw puller? And a screw into the tension pin with a puller will remove it. I like the idea of two pins!

[@randymiller1604]

You should use 80 W 90 gear oil 140 is too thick we always used OMC premium Blend

[@Michaelsbackyardmarina]

I use Amsoil 75W 90 Marine gear oil in all my outboards. I have never used 140 before.

[@randymiller1604]

Earlier the discussion about the 15 horse

[@randymiller1604]

A ways back talking about turning a 9.9 Johnson into a 15 horse they all started out at 15 horse in the 9.9 is a D tune 15 horse

[@normsebby3421]

buy a small smithy milldrill lathe to make hard to find parts

[@Michaelsbackyardmarina]

That would be cool. I would love to get me a small CNC mill. That would be my jam for sure.

[@jimlove4541]

If you had put the sealant on the outside of the old o ring the exsess wouldn't end up in the box.

[@tommyhuffman8781]

#amsoil should sponsor you :)

[@Michaelsbackyardmarina]

No kidding. I bring them up a lot. Thanks for watching

[@craighanson2983]

Perhaps it's a oil groove?

[@Michaelsbackyardmarina]

I'm sure it is.

[@ronniegauci3843]

Man you can talk.

[@Michaelsbackyardmarina]

Boy can't I. I just have knowledge I want to share, that's all. Thanks for watching

[@Stewsdrums]

@@Michaelsbackyardmarina and thank you for your wonderful teaching, way better than this old outboard and kodibass

[@davesmith43]

What are your videos you’re right on the mark are used to work on those upwards all the time for a living. One problem you’re talking a little bit too much with all due respect

[@Michaelsbackyardmarina]

It's just me man. Thanks for watching

[@outboardfixer]

Well I hung in for 8 minutes.....

[@Michaelsbackyardmarina]

good job, thanks for watching

[@outboardfixer]

@@Michaelsbackyardmarina

[@curtbrown9702]

U tube will not be the same without you. So make sure the cameras ON.

[@Michaelsbackyardmarina]

for sure, thanks for the encouraging words, thanks for watching

[@user-xe9dm8rz4g]

I noticed in the gear selection that you left out two balls and spring that catch when you switch the forward neutral and reverse? Are those necessary to have or better to leave out?