water in lower leg oil issue

[eddylives 99]

We have an older 80's?? Johnson 25 HP motor. It has had water in the lower unit when changed each fall before storage. The unit has been rebuilt by twice now by experienced mechanics.....new seals etc. And the water issue remains......we are at a loss as to why this is happening? Does anyone have any idea why this is happening...bent shaft or?

[naden 131]

maybe a groove worn where the seal rides on the shaft

[Pro fisherman-Stud Muffin 420]

probably a small crack im thinking or bad thread/ seat on plugs. is it a lot of water

???

[eddylives 99]

The unit has been inspected for any types of "normal" issues that cause water in the leg (cracks,grooved shafts etc) and nothing has been detected. As for the amount of water.....starting with fresh oil in the spring (changed before winter storage) there is enough water to turn the oil milky and have water pour out before oil when changing. My father is so annoyed with this he is now threatening to pump the leg full of grease and run it till it fails and make a boat anchor out of it lol. I will have to try and apply a light air pressure to the lower unit while submerged in water to seek bubbles I guess....something I read on a boating forum

[eddylives 99]

I should note that this motor did take a severe hit on a rock pile years ago that destroyed the prop but the water issue started 10 yrs or so later??

[Adrian 132]

One seal that is often overlooked is the "O" ring that seals the shifter rod where it enters the lower unit. It is a little tricky to change, but very often ignored. If you have changed the seal under the water pump and the seal on the propeller shaft, change the shifter rod seal. You can remove it with a straightened fish hook. and you replace it by folding it in half with needle nose pliers (do not damage the "O" ring by squeezing it too hard), and pushing it into the seal cavity with a wooden dowel about 1/4 inch in dia. Be sure to clean all the carbon off the rod, and lubricate it with a water proof grease before putting it back through the seal.