How to Repair a Broken Gear Shifter on 9.5 Johnson Outboard

The Johnson 9.5 is an outboard boat motor used for mid-size and smaller water craft. The gear shifter is a rod that is moved to change gears on the outboard motor. If the gear shifter on the Johnson outboard is ever bent or damaged from a boating accident, it will need to be replaced with a new one. It will take an hour to change the gear shifter on a 9.5 Johnson outboard.

Things You'll Need

  • Adjustable wrench
  • Pliers
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Instructions

    • 1

      Open the clips on the engine cover by hand and take the engine cover off.

    • 2

      Remove the negative battery cable with the adjustable wrench.

    • 3

      Take off the cover bolts on the shift rod with the wrench and remove the retaining pin from the shift rod with a pair of pliers. Remove the ball, spring and the shift detent plate off the old shift rod and out of the gear case.

    • 4

      Take the old shift rod out. Apply marine grease to the new shift rod and slide the ball, spring and shift detent plate onto the new shift rod and set the new shift rod back into the gear case.

    • 5

      Slip the retaining pin back into the new shift rod and bend its ends down with the pliers. Replace the shift rod's cover bolts with the wrench.

    • 6

      Replace the negative battery cable and put the engine cover back on.