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To rebuild or not to rebuild (lower unit)? THAT is the question!

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  • To rebuild or not to rebuild (lower unit)? THAT is the question!

    Hi guys:

    Greetings and a big howdy from Tucson.

    Although not a "marine" mechanic I've restored literally dozens of motorcycles over the years - even a 2 stroke, 3 cylinder air cooled Kawasaki.

    I've been going through my new to me '87 90hp. ETLH and shifting into reverse gear is NOT very crisp and takes several tries, although it does work. Shifting into forward is fine.

    I've talked to several mechanics locally - but about the best I get is a dazed and confused look like they just came down off a good acid trip. Suffice it to say we don't have the sharpest tools in the shed when it comes to marine shops in the middle of the desert.

    Upon initial inspection there was a LOT of fuzz on the drain bolt magnet, although no chunks. I'm suspecting it was not serviced frequently since the gear oil was quite dark as well, although I did not detect any water intrusion.

    After stripping down the lower unit to where I can get a set vise grips around the top of the shifter rod splines (don't worry, the jaws are protected with a thick piece of leather to prevent damage) I can now shift it manually.

    I've got a lot of play or slop when in the neutral position - the detent does not seem to be very strong. It shifts only with a bit of coaxing where I would think it should be crisp and immediate. Forward or reverse feel exactly the same. Sometimes it shifts well and other times it takes some "nudging".

    I am suspecting that the shifter and cam are worn and need to be replaced - since I've got to go in there anyway I figured I might as well replace all the other wear components while I'm at it. Obviously I need to inspect the gears and especially reverse for any damage, in other words a complete lower unit rebuild.

    The question is: When lower units fail do they tend to just up and quit - or is this slop a sign that it will indeed fail soon, but may last years as well.... I'd rather not go to the expense and trouble of a rebuild.... but I also don't like rowing from the middle of Lake Powell!

    Attached is picture of my "yacht" which is about half way finished at this point, I've been working on it since last September. Furniture, fuel tanks, etc. and railings have been installed since these pictures were taken. I call it a Trailer on a Toon. Enjoy.
    Attached Files
    Last edited by RonKMiller; 04-13-2011, 09:16 AM.

  • #2
    Looks a little top heavy, may need a couple of out riggers to help keep it upright.

    If you do not move the motor into gear crisply then the gears tend to grind , the more this happens the more metal is removed from the gears. Probably what you were seeing on the magnet.
    Take apart and inspect to see what all is damaged and hope the metal was not coming from bearings or getting in them causing problems.
    Check the shift dog for wear. Make sure you have a service manual to do this properly.

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    • #3
      Thanks, I'm thinking the shift dogs are tired... Understood about the slow shifting causing issues - time for a tear down... got the manual.

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