Replacing an outboard dog clutch
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- čas přidán 9. 02. 2017
- In this video I replace the dog clutch on a Tohatsu 40C. This involves removing the prop shaft and replacing all the springs and selectors as well as the dog clutch itself.
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Absolutely the best videos on explanation of lower unit work. Every video I see of Dangar Marine has been just great! Thank you for all the extra work required to make these videos!
Nice to learn from the professional, very professional boy, GOA India.
Thank you! Saving me alot of money. My lower unit is currently skipping in fwd gear " clicks" when maually hand turning. Im sure this is my diagnostic. Bad dog clutch.
No problem with my dog clutch, just couldn't figure out how to remove the "doggone" thing to install on my new propeller shaft. Yours was the only video that actually explained in simple detail, actual removal and reinstallation. The spring's function as a pin retainer never occurred to me. I just saw a spring sitting there that seemed to serve no purpose. With your instructions, I swapped out the dog clutch from my broken prop shaft in mere minutes, saving me big bucks for sure! Can't thank you enough! Thumbs up, and subscribed!
You're welcome Jay, glad it helped you get the job done!
Just bought a 79 Evinrude and ALL your vids are VERY useful! Thanks
Great to hear!
love the way you explain the process in good detail, priceless!
WOW! Thank you very much for this information. I bought a lemon of a motor at a auction, with your help we are having lemonade tonight.
You're welcome, glad to hear you are getting the motor up and running. Enjoy!
Crystal clear, thanks very much. Enjoy all of your videos, straight to the point and realistic approaches to repairs. Thanks for taking the time to share your extensive skills and knowledge.
Sioux Lookout, Canada.
Thank you sir, you've just given me the confidence to repair mine myself. All the best to you.
I love Dangar Marine and am so appreciative of your videos. If I lived in Australia I would come visit your shop just to serve you beer when you needed one. Unfortunately, National Geographic has put a massive fear of Australia in me and I don't think I will ever visit. You all have the most deadly everything! Spiders, jellyfish, crocs, snakes, etc...
Thanks Mark, glad you enjoying the vids Fortunately all those poisonous creatures are allergic to beer so we protect ourselves by always having some in our blood streams. ;)
Wow excellent videos I bought an old boat w 1986 suzuki df140. I've replaced impeller, fuel lines, etc. took it on the lake, wouldn't stay idling when put in gear. Then as it grinded to go into gear it just stopped engaging. Hopefully dog clutch. Learning the hard way lol thank you so much for all your videos!! Sure wish your shop was nearby though!
Excellent video! Nicely explained and was easy to follow the steps for reassembly. Nice work.
Nice job,Stu. Very good explanation on how it all works.
Thanks mate, glad you liked it. :)
Great job....I appreciate the info as the mechanic I just took mine to hosed me for $500 and still no reverse!.... looks like I will do my own clutch work now!
Great video! The engine on our 2006 15hp Honda was revved really high then put into the forward gear. A few seconds later we heard the gears grinding and crunching together. I have a feeling I will need to perform the same type of service on my motor. Big thanks for putting this video together.
You're welcome mate, good luck with your outboard. :)
Thank you for uploading videos that are a great help to us DIY guys. Highly appreciated and hope you keep uploading more
Great vid, still haven't done my reverse gear repair on my Suzuki DT40 having watched your previous vid on that reverse problem, now On seeing this vid I will give it a go. Keep up the good work Stu.👍🏻😀
+Paul Sheppard Thanks Paul, good luck with the gearbox repair!
Awesome. Very clear. Really enjoy your videos. Having tried to record my long shaft to xl shaft extension kit install, i learned how hard it is to make a good video.
+Mike H. Thanks mate. It has certainly taken me a while to get the hang of recording things, there's certainly a lot to learn. I'll have to check out your vid!
Used this video to help me replace the prop shaft on my 15hp yammi. Previous owner neglected to tell me about hitting something, I tried to bend and wack it back in round but a new shaft was cheaper than lower end.
A prop nut and two 10m bolts the shaft came out with bearing gear assembly, did not to drop lower end.
Used your video as guide on how it functions for assembly, fastest repair so far. I think a lot of owners are afraid of this task, maybe put a video together off an old lower end showing this sequence.
Thanks again, I'll share your vids with my dad in Fiji next time I visit.
Thanks mate, glad the video helped you. A complete video on replacing a prop shaft is a good idea, I'm sure it is a job that many people need to do.
Enjoy your videos very much. Please change the battery in the clock above the workbench. It's been struggling for weeks now.
+ngneer999 thanks mate. I'm not sure that clock deserve a new battery, it's almost unreadable from any distance!
Very well explained and good shots to further explain/illustrate when required. I learned a lot, thanks.
Doing this exactly as shown on a 1970 40 hp mercury 400. Can't load pictures but great video. Thanks for the video. Helped out quite a lot.
Your a lifesaver Stu! Without your videos, there is no way I would be able to own a boat as being a student i can't afford professional mechanics. Going to give replacing the prop shaft on my yamaha 50hp a go tomorrow!
Thanks Daniel, good luck with the prop shaft!
I have a tohatsu m50d2 and as I was replacing the oil seals around the prop shaft when I put everything back together it’s now stuck in coward and won’t change gears the the shifter will move but won’t come out of foward any advice
Very down to earth....that the bottle of bear in the background confirms!. Great expalnation. thx.
Thanks Robert.
Wow ! I am your fan now !
Excellent video !! I am learning how outboard engine works by your video everyday !!
Thanks mate, glad you've been enjoying them. :)
Gave me some confidence. Need to replace my prop shaft (snapped and lost my prop when trailering on the road) and this looks very similar. I have a Chinese version of a tohatsu 6hp. Just cleaned the carb and got it running on 2 pulls before this happened.
Excellent demo and explanation. Great focus and detail.
Well done as always, love your demeanor as it makes learning easier,CHEERS!
Very good and precise explanation, I have this problem and this helped me fix it with confidence , thank you
Thanks for the great vid! really helps to understand the way things work down there!
Great video Danger as usual... you are the go to man ! Thanks, Bob.
Excellent video that explains the shift mechanism and how the fwd/rev gears engage (or not) on the prop shaft. I am working thru a similar issue now on a Force 120HP motor. Broken shift cam and stuck in reverse. Plan today is to remove the pinion nut to get at the shift cam. Since the motor is 20 yrs old, I have decided to replace the clutch dog and pins, etc rather than both fwd/rev gears even though they show some wear on the contact faces.Wish me luck.
I have a Honda at the workshop at the moment with a similar problem, I'll wish us both luck. :)
Quick question - is there a method to prevent scratching the drive shaft while removing the pinion nut? I was planning to use a pipe wrench but concerned about gouging the shaft. Also, are pinion buts standard thread or reverse threaded?
Just took my broken prop shaft out of my hankgai 6.5 hp. Saw the same wear pattern on the clutch dog. No wonder it was kicking out of forward at random!
this video has allayed some of the fears i have of an impending dog clutch repair. my bf90ax sometimes cant find reverse. i was able to resolve it for a couple seasons with new throttle and shift cables (the old ones were split and stretched) but i think its a deeper wear issue due to its age. hoping to get another season out of it before tearing it apart. your video gives me some confidence that when the time comes ill be able to tackle it. (provided the parts i need are all available. and that damn dog spring will be a beastie). thanks again Stu
Nice work as usual Stu!
Thanks Will!
I have a m40c tahatsu 40hp outboard on my 1700 key west(850lbs). I love this little motor. Easy on gas. Myself and two guys have no problems fishing all day on the Chesapeake bay. Using less than 4gallons of gas. I even have a second motor that ran. But iverheated the top cylinder. Figure it got rust and dirt in the water jacket. Parts motor that ran. Is a good thing.
Love the torque specs !
Glad someone did! :)
"it wont come undone again newton meters !!!" brilliant :-)
A very important measurement to know! ;)
best explanation on the internet;
as usual, thanks Dangar Marine; *avoid the RONA!!*
Your videos are awesome!!! Saved me a couple times already!
Awesome video. I am ready to take on my small outboard now.
Thanks mate, good luck!
You’re very articulate. Thanks for the demo
Glad it was helpful!
Great vid Stu.Tohatsu and the spring pin shift shaft!I wish they went with a honda splined socket style.My TLDI 115 has the most fiddly water pump cup and o ring arrangement I've ever seen. Really cheap parts however.
+Matt Frapple Tohatsu do seem to have really affordable parts, I've noticed that too. I got a Tohatsu carburettor complete for $100 and a Mercury 8hp prop for $200.
As always, an awesome and informative video. Thanks mate
Excellent video thanks for sharing!!👍
awesome your vids help me out so much normally i would just take to some one now i know i can deal with this stuff thanks.
+Coop W you're welcome, glad the vids have helped you.
You are the best marine channel on youtube imho
I agree in only replacing the one gear, the tollerances are not tight anyway, and it takes ages to naturally wear the other gear out. Just use quality oil and decent intervals and it will live a long life.
Nice purring tohatsu
+Fredrik Simonsen You're dead right about good oil and regular servicing being the most important thing.
Your very informative and thorough. Thank you sir
Don't do these video because I am watching them always. There are very nice and helpful and it's fantastic.... thanks alot from my heart 🤝🤝🤝🤝🤝
So nice of you
Great video Stu. I used to be intimidated by the mysterious inner workings of a lower unit. Now I see it's not all that bad. I might have to do this job on my Yamaha 150 eventually. The idle was set at about 1500 RPM when I got it. It would clunk loudly into gear until I lowered the idle. Who knows how long it was previously run like this. Probably have some wear on these same parts. Btw, I think the clock above your workbench needs a new battery. Second hand seems stuck. 😉
+Fireship1 Thanks mate. Sounds like it may be worth taking a look at yours. It isn't rocket science, just keep a mental note of the order everything comes out in and you should be fine putting it back together. :)
Nice work stu your a smart man
+Dean Fulford Thanks Dean, the service manuals are the smart ones!
Very good videos, free lessons.Thanks
Another informative video, thanks from Florida Stu. Ken
+K Dennis Thanks mate, glad you enjoyed. :)
Great video - gives me the confidence to replace the worn clutch dog in my girlfriends 15HP Yama. Thanks for posting!
Capt. Blackheart Charlie
Key West, Conch Republic
What an awesome video. Thank you so much.
Thanks mate, glad you liked it. :)
Very good tutorial video brother thank you
One thing I've learned is that as the dog clutch gets old, it starts chipping and leaving some flakes in the fluid. Especially if you use your boat for tubing and such, where you are constantly shifting into and out of gear through lots of use. These little flakes seem non-ferrous because they don't stick to the drain plug magnet. You can replace the clutch by pulling the prop shaft and not need a whole new outdrive, like a lot of guys will tell you.
Excellent video sir
Great video, thanks for sharing.
Thanks for watching!
Great Job on presentation and knolegable
Thanks mate. :)
GREAT EXPLANATION! THANK YOU!!!
very informative. Thank you
You're welcome.
Years ago I let a mechanic talk me out of doing this job myself. He gave me the old BS line "You don't want to DIY and screw up the double fly bearing spindle axel rod shims on the triple bypassing transposed inducer linkage selector " that bastard scared the crap and $900.00 out of me!! lmao.
+Edwardo Perez Bummer, next time you'll give it a go. You can always take the gearbox to someone afterwards if you hit a snag.
Great video very informative.
+Cliff Mayson Thanks mate. :)
Great videos, thank you!
Awesome video Stu. I've been watching your videos for a long time now. Love it. This video is exactly what I needed for my Mercury 40hp (Tohatsu model). The pin is bent and the spring retainer shattered.
I pulled it all apart and all i need to do now is buy the parts.
Wouldn't mind if you can guide me to a shop or website to buy another pin. Thanks heaps
Hey Ibrahim, glad this video helped you with your problem. I just bought the parts from our local Tohatsu dealer. www.boats.net appears to have an amazingly complete set of parts you can order but I've never used them.
Dangar Marine
Thanks heaps
Love your videos and could care less about the clock. Thanks much!
+Bronco John thanks mate. Ha! I had already forgotten about the clock ...
Helped me out again mate thankyou...I've got a Maxus/parsun 30hp 2stroke but between the rod and the spring there doesn't seem to be a retainer? Mind you when I first knocked the pin out stuff went flying 😅
Great explanation. Thanks
You're welcome!
I'm glad co-host Matt agrees with your philosophy on repairs
He's a good bloke our Matt.
Hey Dangar, I am having trouble getting the prop shaft out. I have removed the bearing housing and lined up the gear selector in neutral and it just wont budge. It is a 90hp yamaha 2 stroke. Love your videos by the way. Cheers Alex
Great video and explanation! But I do have a question, If the clutch is being pushed forward by the spring. Would it be better to store the boat with it in the forward gear and not fighting that spring?
YOU ARE GREAT
FANTASTIC VIDEO!!!!
I've managed to find a nice clean old suzuki DTC 8 two stroke for my boarding boat its fantastic the only thing it does is slip out of astern under load so I might see if I can sort that out
Hey Stu, thanks for your videos they're great info and great to watch. Some time first time.. 😃
My question is about our 90hp 82 model Johnson (golden oldie) lol..
Just wodering about the slight play on the gear selector cable and also the play the cables' plastic shaft (motor end) has within the bracket the shaft sits in.
Having trouble with the cable pushing fully into reverse gear and also the adjustments. Wondering if this motor has the connecting nut between top and lower unit gear selector and could i get the more adjustment there?
TIA..
Leo and Zeljko
P.s. we're disappointed we miss the Meet, it looked like a great time. Looking forward for next one.
Keep videos coming Cheers..😃
you are the man
Awesome video, i really enjoy all your videos. Can you maybe do a video on trouble shooting with a yamaha autolube system and how to test it?
Thanks mate, yes, I really do need to do some videos on testing autolube systems, will do one soon.
Dangar Marine thanks looking forward to it
Thank you for the vid. Il try your hints and tips 2moro
Great video, and so helpful. On my Tohatsu 70 (2 stroke) I've been encouraged to replace the forward and reverse gears also. The forward gear is ahead of the gear on vertical shaft which has a big nut securing it to the shaft.. If I remove that nut, will I be able to remove (pull down) that gear to get access to the forward gear?
You may need to remove the whole driveshaft czcams.com/video/BF3e32Iefo0/video.html
These are great videos. I have a Suzuki df40 four stroke. I hit a rock pretty hard. Prop is fine, the contact with the rock appears to be on the back side of the lower unit. When I first hit the rock, the RPM went real high, and prop stopped. Like it jumped into neutral. I put the boat in neutral, then gently back into forward, and the I was on my way. It was not until I tried to go into reverse that I realized there was a problem. no reverse at all, and not really a neutral as well. It's stuck in forward. The gear shifted was actually stuck at first, but after a fiddling with it, I was able to move from forward to reverse smoothly, but the boat would only move forward. I can hand turn the prop forwards, and there is clicking sound. I can not hand turn the prop in reverse. I can hear it knocking when I try. After watching your videos, I am assuming that the bang from hitting the rock, jammed the dog clutch into forward. So you have any videos on how to get at the dog clutch on a Suzuki DF 40 Four Stroke?
They are all pretty similar, you will just need to pull the bearing carrier out to see what is going on. I would also remove the gearbox and see if I can move the gear selector smoothly with the gearbox off to help isolate the problem.
I need to do this on my old outboard, but I'm doing all the gears as well then thats 100% ready for someone to use.
Danger, Does the drive shaft need to be removed or will there be enough room for forward gear to be scooped out by removing the pinion gear only?
Hi Stu
Awesome guide - how to - Video once again i applaud you. Keep them coming.
Question for you. How can i check a lower unit is working when it is not connected the power head. All i have is the lower section ie gear box selector shaft and drive shaft.
I was told it was working but is there a way to make sure it is before i go and fit it.The unit is an old Suzuki DT40 2 stroke.
Hope you can point me in the right direction or maybe do a video on the subject.
Cheers again mate from bonnie scotland
Andy
Hey Andy, the trick with gearboxes is to select each gear and then rotate the driveshaft while trying to stop the prop from turning (be careful not to cut yourself on it) What I find with gearboxes is that you can select a gear, turn the drive shaft and the prop will turn, but as soon as there is a bit of water pressure on the prop the dog clutch will start to skip because it is only barely engaging. I would also drain the oil to look for water or metal fragments and do a pressure test on the box to makes sure all the seals are good.
I can’t thank you enough for this video I have this problem with my 70hp Mercury our board and need to know where I can get good original part for it ( the clutch dog) and how many hours it will take to finish the job?
You should be able to get the part from MarineEngine.com and it will probably take a 2-3 of hours all up.
Just searching for the Dangar Marine stubby coolers on your website Stu....they must be still on order.. May be a good promotional item methinks
Leave it with me, I'll see what I can come up with!
Another great video, thanking you! Question... if gear box oil is fine, would you reuse the original rubber seals? or put new ones in while you got it all apart anyway?
To be honest, most of the time I would probably just reuse the originals if they are fine, but it is never easier to do them while you are there and they are relatively cheap to buy.
Thanks stu 🤩😍
you saids that the "natural position the gearbox wants to be is in forward". that made me curious as to how I should store the motor. When not in use, would putting it in forward gear increase the longevity of the spring? Im assuming it really doesn't matter.
It's a good point you make. Having it forward would allow the spring to relax a little but I wouldn't lose any sleep over it, I doubt it would shorted it's life much.
Awesome! Thanks a bunch!
@@DangarMarine Steel springs do not lose tension due to creep at ambient temperature. This is only a high temperature effect, despite endless pub talk to the contrary. Elastomer springs do creep....
YAY this makes me happy to see you working on a tohatsu finally
There are a couple of Tohatsus floating around the river so there should be more!
I believe you are wrong. the dog clutch was in correctly with the deeper dogs toward the forward gear. On the OMC dog clutches it is marked PROP SIDE, and those dogs are the shallower ones.
bro your vids rock!
your giving me the impression i need to rebuild my gearbox, i bought a 48spl, had clanking in lower, just changed oil in lower, going out to test her this weekend and if not im using your drywall screw method for the baring carrier
Since the springs natural position is putting the clutch into forward, when not using the outboard should it be left in forward.?
Enjoyed the video. As a retired welder and machinist I think I would have used TIG to build up the worn areas and re- machined them. But, that would depend on the price and availability of a new part. Understanding it may damage the heat treat of the part, but I suspect the part is relatively soft due to the nature of its job. What do you think? Would you weld one?
Because of the way a dog clutch works, it is okay to machine the dogs square again without building up the metal first. They will be a tiny bit weaker but the square edge is the most important thing so it doesn't slip.
Excellent video. Are the Yamahas close to the same procedure
"Won't-come-undone-again Nm" 😂
+Conner Giella A good amount of force to know! ;)
Great video. I'm currently replacing seals in 2005 Mercury 90hp. When I took out the shaft three small ball bearings appeared from somewhere. was hoping I could have picked it up from this video. I presume they are part of the cam follower but can anyone suggest how/where to insert them. thanks
Drop the three balls into the spring hole after the spring and one pin is inserted, then install the pointy pin. The three balls ride between the the two pins, Look at the grooves on the ends of the pins to better understand.
I have a Yanmar 36 HP engine. Forward and reverse is working. RPM is full when forward and reverse speed is given, but propeller speed is only on forward gear. Speed does not catch. There are 3 water outlets. All three work. RPM pays a lot. What a problem.
Awesome video. Question: I have this same motor. Will not go into reverse. I ordered some parts. The dog clutch is worn and the pin is bent. I am concernd the cam may also be worn. How is the best way to get the cam out? Thanks for your help.
Hey Stu, first time I’ve taken bottom end apart on a 2011 Yamaha 30 4 stroke. I cannot find which is neutral on the shif slope and putting prop shaft back in. I looked at you’re other vid, but didn’t show the spot to put the shifter in neutral. Appreciate the help. I see indents but can’t figure which one to use. Thought something went wrong inside, turns out it’s prop chatter. Ugh
Neutral is the midpoint on the wedge, halfway between forward and reverse.
WOW! Nice professional video,learned a lot;
Surprised there are no bearing or gear shims to contend with;
Does one need to check the gears free play at all?
The only thing I noticed about the clock ( I thought it was just a dummy decorative scooter wheel,lol) is that you can´t read it; hope you got it for free.
There are generally shims for the pinion gear to adjust preload and backlash depending on the size of the outboard. I'll do a video on those one day with a larger outboard.