Johnson Outboard Lower Unit Crack Repair/Rebuild #9

Video #9 is on the installation of the water pump, water pump key, and water pump housing. What you will see being completed in this series of videos will be questionable to many. This is the second lower unit I have repaired in this same fashion, and both went on for many more years of service and saved the owners in the $1000.00 range. If you attempt this I cannot stress enough do not force anything, take your time. Please check video #1 for more of a description.

Link to exploded view of the lower unit: http://www.sterndrive.info/outboardmotor/1978_1998_v4_90_degree_.html

This video is very detailed and will also help you in assembly: https://www.youtube.com/watch?v=_2OV7sL8Zgg

Spread a light coat of gasket silicone on the cleaned gasket surface where gasket #13 and the pump cup plate #8 will mount.

Install the gasket.

Fits much better when I put it on the right way!

Spread another light coat of gasket silicone on top of the gasket.

Set the pump cup plate #8 in place, and align the gasket and the plate with the four bolt holes.

Lubricate and install #10 O-ring on top of the pump cup plate #8, and then install the water pump impeller #9 into the water pump cup #8, in the correct rotation, now you’re ready to install the water pump.

Align the impeller inside the water pump cup and slide it down the driveshaft, orient the pump to the flat on the driveshaft.

Slide the water pump key #12 in the flat area of the shaft.

Then slide the impeller and water pump cup over the key.

It’s a little tricky, pull the water pump to you tight to the driveshaft, align and slide the key in.

Lubricate and install O-ring #7 on top of water pump cup plate.

Install the O-ring #11 in the bottom of the pump housing #6 using some gasket silicone to hold it in place.

Slide the pump housing over the driveshaft and into place, aligning with the four bolt holes.

Push down all the way, and install the four #5, 7/16” head, ¼” bolts.

Tighten them down evenly using the criss/cross pattern verify no binding while tightening it down.

Install the spline adapter on the driveshaft and rotate the driveshaft in its normal direction of rotation, and shift from forward to neutral and to reverse several times to verify everything works as it should.

Install the tube guide #2 over the driveshaft, and attach with the screws #3.

The lower unit is now fully assembled, come back for the install video #10.
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