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Johnson/Evinrude Marine engines - 9.5 hp outboard how do I locate and replace impeller?

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9.5 hp outboard how do I locate and replace impeller?
by: berry   on: Thursday, March 18 2010 at 08:58:09 EDT

I have a 1969 Johnson 9.5 hp outboard


by: Dan   on: Thursday, March 18 2010 at 08:40:52 CDT

Here is a diagram of your motor. It shows the location of the water pump and impeller.To release the shift shaft on this unit you must remove the bolts holding the lowerunit on and when it comes down about an inch you will be able to remove the lower bolt on part # 52 above.
With this bolt removed the lowerunit will come completely off to gain access to the pump and impeller. Below is another picture of the parts associated with the upper portion of the engine.

When you pull the lowerunit down the shift handle will move to allow a little more room and then the lowerunit will shift into gear allowing still a little more room. Turn the prop to assist in the movement.
If you are sure that you have all the bolts out, then pry on it a little where it separated from the exhaust leg.
The drive shaft may be stuck in the power head, if this happens, well, it ain't good. What you will have to do is pry with two bars from either side to pull straight down. Do not pry anymore then necessary to get the bottom bolt of the shift rod out. Once out you can continue to pry until it's off. There is no other way and if the drive shaft is stuck in the powerhead, you may break a piece or two to remove the lowerunit.


by: berry   on: Thursday, March 18 2010 at 11:17:49 CDT

OK - I know that bolt goes into the lowest position when the engine is in neutral (the lever at the engine head is in the uppmost position). I tried prying but maybe not enough.
Is there any way to lube the drive shaft where it may be stuck in the powerhead?
Also there is a bolt holding the shift lever on to that rod leading down to the lower unit. Will disconnecting this bolt give me any more room? It looks like it is connected to the shift lever by a slotted hole. If I remove this bolt I will be sure to replace it in the same position.


by: Dan   on: Wednesday, March 24 2010 at 17:26:51 CDT

You are right on target, let me clarify some things..
No, you cant lubricate the drive shaft where it "Might" be stuck in the power head. It would be stuck in the bottom of the crankshaft and that is the issue, you can't get to it to do anything about it. Just pry like hell and hope not to break anything that can't be replaced.
The lower bolt on the connector must be completely removed from the connector. The lower rod has a groove around it and won't go past the loosened bolt until it is removed.
The only adjustment is to make sure that the bolt goes back through the groove in the rod when you put it back together.
The bolt on the shift lever is best left alone, the procedure to remove the lowerunit is to remove the lower bolt on the shift rod just above the lowerunit.


by: berry   on: Thursday, March 25 2010 at 13:27:01 CDT

I got it off! Thanks.
I took the impeller apart and found very small buggered up pieces of the top housing in with the impeller chamber.
I assume I will need that housing and the impeller. The stainless steel plate has a slight dish in it. It seems to me that this would make the impeller chamber not work efficiently. Am I right? If so, i guess i will need that plate also.
In addition, looking at the shaft leading up toward the engine I noticed a little steel key sticking out of the side of the shaft. I am assuming this must fit the slot in the impeller when it is put back together.
I hope there is a little trick you can tell me to make sure this key lines up with the slot in the impeller.
By the way I don't see a slot in the upper houseing. I am guessing that it is no longer visible due to the damage to this piece.
You have been incdedibly helpful. Please tell me if I should pay more to the website for your additional help.


by: Dan   on: Thursday, March 25 2010 at 15:28:36 CDT

The drive shaft seems to still be in the powerhead. The drive shaft should have stayed in the lowerunit and came off with that part. This is where I was saying that if the drive shaft is stuck in the crankshaft, just pry until you break something. Well, you did, it ripped through the upper water pump housing.
What we need to do now is, turn the engine up side down and soak the top of the shaft with a penetrate, and take a pair of "vise grips" and clamp them onto the shaft. Use the vise grips to pry against the housing with a couple of bars and remove the shaft. If we can't get the shaft out of the powerhead, we can't fix the motor. This may take a few days of soaking and playing with to accomplish. The end result is we must remove the drive shaft from the power head to reassemble the lowerunit.
Other notes: don't let dirt or debris get into the lowerunit oil area with the drive shaft out. And yes you will need all the parts of the water pump assy, including the housing. When you reassemble be sure to use a good grease on all the bolts and the top of the drive shaft, this will help with corrosion and sticking.


by: berry   on: Friday, March 26 2010 at 10:30:27 CDT

Horrrraaayyy! The shaft finally came loose!. I buggered the shaft with visegrip teeth marks but i smoothed them off with a grinder. The marks do not seem to be anywhere near any critical surface of the shaft.
Now I see why we had to get the shaft out of the power head. The impeller must have the drive shaft installed before re-installing the entire lower unit to the engine, right?
I think I need the entire water pump unit to complete this job properly.
Please advise where I should order the parts I will need online.
Do I need both the impeller repair kit AND the water pump repair kit?
Will I need anything else?
The diagram is very small and I cannot read the part numbers.
I definately could not have done this without your advice!


by: Dan   on: Friday, March 26 2010 at 13:31:13 CDT

There are several places online to order parts, what you will need is the waterpump impeller kit with the upper water pump housing included. Your best bet is to obtain one from a Johnson / Evenrude dealer. You should not need any other parts, but inspect all parts you are coming in contact with while repairing the motor..
I did get the credit when you accepted the answer, until then the expert working on your questions doesn't get a dime..Some people don't or neglect to accept an answer, these go unpaid to the expert..Thank You So much for the kind words, after it all I and most of the experts really do this for fun and with the knowledge that we are helping people in our field.


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