Johnson/Evinrude Driveshaft/Shiftshaft installation

The replacement complete lower unit does not include the driveshaft or shift shaft. Your 1993 and newer driveshaft may be removed and reused in your new replacement unit.

To remove the driveshaft you may have to disassemble your old gearcase. Remove the propshaft carrier then reverse gear and shift the lower unit into forward gear. Using a 7/8" wrench remove the nut under the pinion gear. You will hold the nut with the wrench and turn the driveshaft counter-clockwise with a pipewrench or suitable device (do not mar the driveshaft near the splines, sealing area, or water pump area).

Once the driveshaft is removed it can be seperated. The upper driveshaft is held in by a spring steel retainer which is in turn held in by a roll pin. If you drive out the roll pin the shaft and retainer will come out of the lower driveshaft. 

   

***If you cannot disassemble your old gearcase in many cases the steel clip will deform enough to "pop" the upper driveshaft free of the lower driveshaft. Again using a suitable device to hold the upper driveshaft, use a hammer to drive the upper shaft up and out of the lower gearcase.

Note: This is not the book recommended method but it is a very common procedure.

Now that you have your old upper driveshaft you can install it into your new lower gearcase. The new lower unit already has the clip and roll pin installed. Apply marine grease to the upper shaft and carefully install the shaft taking care not to damage the seals. Once the shaft bottoms you will have to "seat" the shaft into the lower shaft clip. Using a block of wood, tap the shaft down until it pops into place. The upper shaft will now be locked into place.

*You may notice the shaft wobbles a bit until the water pump is reassembled.

Shift shaft installation/adjustment

Remove the shift shaft from your old lower unit by unthreading it. Apply marine grease to the shaft and insert carefully (do not cut the seals!) into the shift shaft housing. Once it bottoms it you will thread it into the shift mechanism. The shift rod height is critical! Move the gear case into the nuetral detent (propshaft turns free) and use the table below to set the rod height. The measurement is taken from the gearcase top edge to the middle of the shift rod hole.

Filling gearcase

Your new gearcase was shipped to you without oil. We recommend using either Mercury Marine (quicksilver) High performance gearlube or BRP Johnson/Evinrude HPF-XR gearlube. The lower unit must be filled from the bottom up using a radily available pump or squeeze tubes. You will need about a quart and a half

 

Questions? Call (440) 549-5671 or email support@dockpartner.com.

ENGINE FAMILY LONG SHAFT-20"EXTRA LONG

SHAFT-25"EXTRA EXTRA

LONG-30"

V4 CROSSFLOW21 13/16" TO 21

7/8"26 13/16" TO 26 7/8" N/A

V4 AND V6 60 DEGREE

21 5/16" +/- 1/32" 26 5/16" +/- 1/32" N/A

EARLY (1991)

V4 AND V6 60 DEGREE

21 3/32" TO 21 5/32"

26 29/32" TO 26 31/32" N/A

LATE (1992 AND UP)

V4 AND V6 90 DEGREE

21 29/32" TO 21 31/32"

26 29/32" TO 26 31/32"

31 29/32" TO 31 31/32"

LOOPER

While every precaution has been taken in the preparation of these guides, Dockpartner LLC assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Publication of the procedures in these guides does not imply approval of the manufacturers of the products covered. Persons engaging in the procedures herein do so at their own risk.