Johnson Service Bulletin SB-984 - Special Tools for Gearcase Disassembly
Issued October 15, 1963, this four-page factory bulletin introduced replacement coil and front bearing race pullers for Johnson 40, 60, 75, and 90 HP gearcases. The original illustrations, tool combinations, prices, and ordering information are reproduced below.
October 15, 1963
SUBJECT: SPECIAL TOOLS FOR GEARCASE DISASSEMBLY.
USE ON ENGINES: 40 H.P. - Models RK(L)-24 thru 26
60 H.P. - Model VX(L)-10S
75 H.P. - Models V4S(L)-12 thru 16
Models V4A(L)-13 thru 16
90 H.P. - Model V4M(L)-10S
NEW GEARCASE COIL AND
FRONT BEARING RACE PULLERS
... FOR REMOVING COIL AND BEARING RACE
ON ELECTRAMATIC ENGINES - 40, 75 & 90 H.P.
... FOR REMOVING BEARING RACE ON MANUAL
SHIFT ENGINES - 60 & 75 H.P.
New puller jaw sets are now available to take the place of #378450 and #379241 pullers. See Figure 1. These new jaws have been designed for use with the original 40 H.P. Bearing Race Puller #379246.
Effective on October 21 #379246 Puller assembly will have a net price of $10.50.
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SB-#984
FIGURE 1 - DETAILED ILLUSTRATION OF BEARING RACE AND COIL PULLERS.
All parts are available in detail
| ITEM NO. | PART NO. | DESCRIPTION | NET PRICE |
|---|---|---|---|
| 1 | 379829 | Race Puller Assembly - 40 H.P. | $6.75 |
| 2 | 379649 | Race Puller Assembly - 60, 75 & 90 H.P. | $6.75 |
| 3 | 379784 | Coil Puller Assembly - 40, 75 & 90 H.P. | $5.60 |
| 4 | 311006 | Shaft | $2.75 |
| 5 | 311004 | Wing Nut | $0.25 |
| 6 | 311005 | Pressing Plate | $1.40 |
| 7 | 308332 | Pressing Nut | $0.10 |
| 8 | 310934 | Sleeve (5 inch long) | $0.35 |
| 9 | 310682 | Sleeve (3½ inch long) | $0.30 |
* Items 4 through 9 may be purchased in a kit as Part No. 379843 - $4.90.
The following parts are included in items 1, 2 & 3 and are also available separately.
ITEM 1a - Part No. 309876 Shoulder Screw (10-32 thread) - $0.15
ITEM 1b - Part No. 310948 Puller Head - $1.10
The following part is included in item 3 and is also available separately. This is a regular service part and must be ordered thru your Parts Distributor.
ITEM 3a - Part No. 202591 O'Ring - (list price) $0.25
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SB-#984
CUT-A-WAY SKEG - TO SHOW REMOVAL OF 40 H.P. FRONT BEARING RACE
MATCH PULLER COMPONENTS AS NOTED HERE FOR THE INDICATED APPLICATION.
| Remove Electric Coil (40 h.p.) | Use items 3, 4, 5, 6, 7 and 9. |
| Remove Front Bearing Race (40 h.p.) | Use items 1, 4, 5, 6, 7 and 8. |
| Remove Electric Coil (75 and 90 h.p.) Electric Shift | Use items 3, 4, 5, 6, 7 and 8. |
| Remove Front Bearing Race (60 and 75 h.p.) Manual Shift | Use items 2, 4, 5, 6, 7 and 9. |
| Remove Front Bearing Race (75 and 90 h.p.) Electric Shift | Use items 2, 4, 5, 6, 7 and 8. |
Race and Coil Puller Assemblies, (items 1, 2 and 3) are ready to use. To pull the electric coil merely install the Coil Puller Assembly on the shaft (item 4). Next install the correct length sleeve (item 8 or 9) and the wing nut (item 5) on the shaft. Tool is now ready to use as follows.
Back off several turns on wing nut to make sure jaws are completely collapsed. Insert Coil Puller Assembly into coil. Reach thru pinion gear opening of gearcase to hold puller in place and tighten wing nut until jaws are completely expanded. Install pressing plate (item 6) and pressing nut (item 7). Turn pressing nut against pressing plate to pull coil.
After pulling coil, remove Coil Puller Assembly and install appropriate Race Puller on shaft, along with designated sleeve (item 8 or 9) and wing nut. Insert Race Puller Assembly into bearing race and proceed according to instructions for pulling coil.
The amount of tension required to pull either coil or race may be reduced by first placing nose of skeg in boiling water (or oven) for 5 to 10 minutes. DO NOT HEAT WITH BLOW TORCH.
Part #379246 tool which consisted of items 1, 4, 5, 6, 7 and 8 will no longer be available when present stock is exhausted. Those who already have this tool need only purchase items 2, 3 and 9 to cover all applications mentioned here. Slight modification of part no. 311006 Shaft is necessary in order to use short sleeve (item 9). Merely turn 1½" more threads on shaft with 1-13 die.
In some cases it may also be necessary to grind a small flat on the pressing plate to clear the projection at the back end of 60 and 75 h.p. manual shift gearcases. This can be done on a grinding wheel or with a file (see item 6).
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SB-#984
Spare jaws are also available for each of the three Puller Jaw Assemblies.
| PART NO. | DESCRIPTION | NET PRICE |
|---|---|---|
| 309877 | JAW (three required) this jaw was formerly part of #379246 and is now part of #379829 Puller. | $2.00 ea. |
| 310683 | JAW (three required) this jaw is part of #379649 Puller | $2.00 ea. |
| 310949 | JAW (three required) this jaw is part of #379784 Puller | $1.55 ea. |
JOHNSON MOTORS
Robert Compton
Administrative Assistant
RC:eb
NOTE: Post on your Miscellaneous index.
ALL SPECIAL TOOL ORDERS MUST INCLUDE FULL PREPAYMENT
OUTBOARD MARINE CORPORATION PARTS DEPOT
P.O. BOX 470
GALESBURG, ILLINOIS 61401
DO NOT SEND SPECIAL TOOL ORDERS TO THE FACTORY, OR TO YOUR PARTS DISTRIBUTOR.
Related factory bulletins
See also SB-923 - Special Puller Jaw Set, an earlier service-tool bulletin.