1976 Johnson 25hp Jumping out of Gear

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juderopp40

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Feb 3, 2025
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Stillwater OK
Bought tiller motor for cheap, bad dog and forward gear from the jump so I just bought a rebuilt lower off EBay. Ran it some with new lower and it did fine for about 2 hours. Then started jumping out of gear again?? Pulled it out immediately and pulled oil, had a little water in it but not much and no bits of metal…took it in to get resealed. Guy said the dog and gears looked great (got picture). Bout a month later I finally got the lower on and took her out. Immediately jumped out of gear again?? Was out for about 45 mins and only got one pull where I was able to get on plane without popping out. After that I lost forward gear, drove home in reverse.

Is there anything else that can be causing this? Couple things I will mention, the shift lefter seems to not go all the way forward and lock where it should in forward position, as if when I was getting it in forward it was “barely in there.” When I say I “lost forward gear,” this was not the grinding sensation that I knew to be the obvious worn dog and gear from the original lower unit, it’s like the “click” for the forward position for the lever is just out of reach, but like if I disconnect and moved the lower shift rod manually, it would still distinctly snap into place like it should. Is there anything I can adjust on the shift rod or at the connector/linkage where the upper and lower shift rods meet to correct the stroke of the shift lever in relation to the engagement of the clutch dog?
Please give me your honest evaluations of the situation, and let me know if you need more details. I will be grateful for any advice you might have as I’d love to keep this beautiful pre-emissions beast alive without burning up the E- fund lol.
(attached is picture of gears and dog from mechanic)
 

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