What is the trick to removing the leg from a 25 hp johnson 2005, cant find were to disconect the shift linkage

It sounds like you may be having issues with the shift linkage or the gearcase on your Evinrude 140hp VRO outboard motor.
The sliding leg may be hitting something or getting caught on something as you try to slide it into the housing. This could cause it to go into neutral or prevent it from aligning properly.
Here are some possible steps to troubleshoot the issue:

1. Check for any obstructions or debris that may be blocking the sliding leg from fitting into the housing. Remove any debris if found.
2. Check the shift linkage for any damage or looseness. The linkage connects the shift handle to the transmission and could be causing the issue if it's worn or out of adjustment. Adjust or replace the linkage if necessary.
3. Check the gearcase for any damage or wear. The gearcase contains the gears that drive the propeller, and if it's damaged or worn, it could cause shifting issues. If you suspect the gearcase is damaged, it's best to have a professional mechanic take a look.
4. Lubricate the shift mechanism with marine grease or oil. This can help smooth out any rough spots and make it easier to shift.

If none of these steps resolve the issue, it may be best to have a professional mechanic take a look at your outboard motor to diagnose and repair the problem.

There is no gap as they use the flat plug that does not have an adjustable ground electrode. If it is older 35 thousandths will do the trick

There is a rod that goes down to the lower leg . It is exposed just under the engine but quickly disappears into the leg. Check to see that it is moving feel and not binding up. Next with the motor off try rotating the prop and then shifting that rod is what actually sifts the linkage in the lower leg to forward and reverse. If you can shift the motor with the cables disconnected from the motor then the cables may need to be adjusted or replaced. Pay attention here... if you adjust the cables and the engine does not attempt to start then you need to readjust. There is a built in kill switch on the shifter that will not allow electricity through to the starter if the neutral position isn't in true neutral position.

Under the lower carb, you'll find the linkage connector.
There is a screw, holding a lever on the shift lever ( coming from the SB side ).
Unscrew a few urns and you'll be able to slide the lever to free the vertical shift rod.
You'll gain better access with the removal of the air intake baffle and the lower carburettor.

Remove Linkage Under Carburetor
Remove Bolts Securing Gear Box Remove Gear Box
Do Not Turn Shift Linkage
Remove Water Pump Housing
Fit New Impeller
Re Fit Gearbox Follow Procedure In Reverse

Line up the water pump housing with the drive splines and look straight down on it all -there will be a clearance cast in the pump housing some where. It's a matter of perspective. Or you have the wrong pump.

Look on the side, of the lower end, (dirveshaft housing) for a small cover, with usually two screws holding it on. Then underneath the cover there is a fitting that connects the linkage. Put a mark with a magic marker on the linkage rod to remember where they line up. Put the motor in neuteral, (not running) and loosen the fitting, it should all seperate after that.

first go to www.crowleymarine.com to get a picture breakdown of your water pump. website instruction, click on part catalog tab, click on omc Johnson and evinrude tab. choose product line, year tab, engine size, choose model. click on gearcase. the picture showes all parts you have and the correct order they go. ok now we are ready to disasemble the lower gearcase from the motor.(1) trim the outboard down using the tim and tilt system (2) shift remote control into forward gear, this lines up the shift rod so you can reach it. a picture of the linkage is refernce number 50 on the picture from crowleymarine.(3) Remove engine coul, under the carburators you will be able to see the shift rod. if you can't see it follow the shift cable to the shift linkage to the shift rod(4) the shift rod has a hole in the top, that a long screw goes through, connecting shift rod to shift linkage. remove this screw(refer to picture downloaded)(5) again refer to the downloaded picture remove these bolts that i list. number 66 there is 4. #77 there is 1. pull off #76 trim tab.#68 there is 1. #70 there is 1. lower unit will drop after you remove all bolts. remove the impeller housing. look at impeller you will see the fins are bent in one direction. put new impeller in with fins bent in the same direction. reinstall housing and gear case following my dirction in reverse order.

Make sure that throttle is all the way back to idle or it will not be allowed.