johnson 140 saga continues

Well I replaced everything and I'm now convinced that I'm never going to get this lower unit back on...I've tried to get it to align for over three hours to no avail. Shift rod height is correct, water tube is going in smoothly but something is preventing it from getting the last 3 inches or so up, it's not the driveshaft because it is just barely touching the crank, splines won't align because I'm not getting it close enough...I'm sure the shift rod is getting hung up its a real nightmare.
Any tips or tricks?
 
you gotta hold your tongue just right sometimes to get em in. your not alone, i remember fighting with mine before using screwdrivers and long needle nose pliers to get it to go in all the way.
 
thebottomfish said:
Well I replaced everything and I'm now convinced that I'm never going to get this lower unit back on...I've tried to get it to align for over three hours to no avail. Shift rod height is correct, water tube is going in smoothly but something is preventing it from getting the last 3 inches or so up, it's not the driveshaft because it is just barely touching the crank, splines won't align because I'm not getting it close enough...I'm sure the shift rod is getting hung up its a real nightmare.
Any tips or tricks?
Click to expand...

Remove the shift cable and move the arm up or down I can't remember exactly, then re-connect after the LU is up all the way, push the shift rod down this helps also then use a needle nose to pull it up to connect it, Lube the splines and rotate the prop or the motor flywheel for alignment all this helps...

See picture red and blue arrows shows shift rod height and drive shaft once completed bolted up.
 

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