Create Profile or Login

Forum Menu

Home > Forum Home > General Forums > The Boat Shed > The Outboard Clinic

Suzuki DF20a Gearbox

  New Posts New Posts RSS Feed - Suzuki DF20a Gearbox Forum Search Events FAQ FAQRegister RegisterLogin Login

 Post Reply Post Reply
Post Options Post Options   Likes (0) Likes(0)   Quote Nathan Quote  Post ReplyReply Direct Link To This Post Topic: Suzuki DF20a Gearbox
    Posted: 24 Jan 2024 at 3:37pm
Nathan View Drop Down
Gold
Gold
Avatar

Joined: 30 Nov 2004
Status: Offline
Points: 603
I had a little mishap with the outboard. It fell on to the road. It actually survived pretty well. 

I need to replace the gear box housing. Ive got a new one. It has the rear bearing pressed in. I now need to strip the old one and install the gearbox, shaft etc into the new housing.

How difficult is this job. Doable for an amateur?
Back to Top
Post Options Post Options   Likes (0) Likes(0)   Quote Mc Tool Quote  Post ReplyReply Direct Link To This Post Posted: 25 Jan 2024 at 9:50am
Mc Tool View Drop Down
Gold
Gold


Joined: 23 Dec 2021
Location: Riverton
Status: Offline
Points: 745
you tube is your friend Smile any service info you can get will help . Should be straight forward job  , but you will need to know some specific technique  so plan to not get it done in one sitting as you may need to seek advice as the issues arrive.  
Before you start I would find out things like  , will you need to use a puller , big circlip pliers , are there likely to be corrosion issues  preventing disassembly ( you tube )
You may not find your exact model  ( its there ) on you tube but something close model-wise may have the same gear case , other than that ,dont force anything ( other than pressing a bearing )
 Yep  an amateur can do this Wink

Oh , and you aint the only one  to drag an outboard Embarrassed .......wasnt a good day
I wish I was young again .... Id be heaps smarter than this time
Back to Top
Post Options Post Options   Likes (0) Likes(0)   Quote Nathan Quote  Post ReplyReply Direct Link To This Post Posted: 26 Jan 2024 at 10:36am
Nathan View Drop Down
Gold
Gold
Avatar

Joined: 30 Nov 2004
Status: Offline
Points: 603
Thanks, yeah some great vids online. Its looking doable.
Back to Top
Post Options Post Options   Likes (0) Likes(0)   Quote Nathan Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 2024 at 11:41am
Nathan View Drop Down
Gold
Gold
Avatar

Joined: 30 Nov 2004
Status: Offline
Points: 603
An update on this. Proved to be mostly straightforward:
- Drained the oil.
- Prop and bearing housing came off in one piece easily.
- Water pump undone and then shaft lifted out.
- Pinion gear dropped off (no nut) and then rear bearing lifted out.
- Then reverse the process.

Only a couple of snags. A little spacer that sits behind the push rod fell out without me realising which meant first attempt reinstall failed as gears wouldnt engage. A slow look at the parts diagram and then a frantic search of the bench solved that problem. Also a slow look at the parts diagram at the placement of washers and shims.
Back to Top
Post Options Post Options   Likes (0) Likes(0)   Quote FlawOne Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 2024 at 9:47pm
FlawOne View Drop Down
Platinum
Platinum
Avatar

Joined: 09 Dec 2008
Location: Tat South
Status: Offline
Points: 1122
Your lucky! My Mercury 50hp gear case has been a real pain. First the bearing carrier bent all the hooks I made up then then the pinion nut was so tight to crack it took two people. Don't know why they made it so hard to change the shaft seals on my model.
Back to Top
Post Options Post Options   Likes (0) Likes(0)   Quote Mc Tool Quote  Post ReplyReply Direct Link To This Post Posted: 10 Feb 2024 at 10:19am
Mc Tool View Drop Down
Gold
Gold


Joined: 23 Dec 2021
Location: Riverton
Status: Offline
Points: 745
Originally posted by FlawOne FlawOne wrote:

. Don't know why they made it so hard to change the shaft seals on my model.

probly so you would have to go to a dealer w/shop Wink
I wish I was young again .... Id be heaps smarter than this time
Back to Top
 Post Reply Post Reply
Forum Jump
Forum Permissions View Drop Down


This page was generated in 0.337 seconds.

Most Thanked Forum Posts

3 Manukau Harbour & West Coa...
2 2026 Grunter Hunter
2 2026 Grunter Hunter
2 2026 Grunter Hunter
1 tauranga fishing
1 Manukau Harbour & West Coa...
1 tauranga fishing
1 Hutchwilco Boat Show
1 Hutchwilco Boat Show
1 Flounder on a rod and reel???

Fishing Reports Visit Reports

Saltwater Fishing Reports
Tauranga Fishing Report - 28/05/26

Tarakihi on the bite Trips are few and far between at this time of year,... Read More >

28 May 2026
Freshwater Fishing Reports
Canterbury Fishing Report - 28/05/26

Fresh and salt turning it on! It is not very often I get to say... Read More >

28 May 2026
Saltwater Fishing Reports
Bay of Islands Fishing Report - 28/05/26

Lures paying dividends We finally had a break in the SE winds that have been... Read More >

28 May 2026
Saltwater Fishing Reports
Manukau/West Coast Fishing Report - 28/05/26

Snapper and gurnard in the harbour The weather has finally taken a turn for the... Read More >

28 May 2026
Fishing bite times Fishing bite times

Major Bites

Minor Bites

Major Bites

Minor Bites

All information © 2026 The Fishing Website