Re: 68 20hp Johnson Replacement Gears

[Casey Lynn]

Unfortunately this has been covered several times…….in the old forums.
You can repair the clutch dog and forward gear yourself if you would like to. With a Dremel tool and a fresh grinding bit. Save yourself a ton of money.
Take a file and cut the grinding bit face to around a 3-4 degree angle. Grind an undercut in the dog thrust face and the gear thrust face. Keep matching the gears together on the shaft to make sure you are cutting the gears equally. When done you will have a set that will not jump out of gear (that hit a log feeling). Also learn to make the proper adjustment of your gearcase shift mechanism so that you know you are fully bottomed out in forward gear. The extra drag you feel with you fingers will tell you the adjustment is correct.