Deane and Brenden Pappas shot 6-under 64 and Robert Garrigus, Dean Wilson and Patrick Sheehan were another shot behind. Defending champion Joe Ogilvie and Jesper Parnevik were in a group of ten tied at 66.
Johnsons hole-in-one with a 7-iron was the 18th this year on the PGA TOUR but the first on the Brown Deer Park Golf Course since Woods did it in 1996. His ace came in the final round of a tournament in which he tied for 60th.
The ace followed three straight birdies. He had a bogey two holes later, but sank a putt of just under 10 feet on the par-5 18th to regain the lead.
Kenny Perry, who won the tournament in 2003, shot 67.
Nobody was happier to be playing than Perry, who could finally get away from the criticism thats come his way because he decided to play in this tournament instead of the British Open.
Its nice to get back in my office. Its nice to get back where I dont have to listen to all that baloney, said Perry, who has won three of the last five tournaments he started including last weeks John Deere Classic.
Johnson has struggled this season and was only 2-under at the turn. But on the back nine he birdied 11 through 13, starting with a 15-footer. He hit fine approach shots to set up birdie putts of 4 and 5 feet the next two holes. His next shot and the par-3, 188-yard No. 14 was perfect.
Deane Pappas, who had to win a playoff in a Monday qualifier to get into the tournament, was making only his second PGA TOUR start this season. He birdied the first two holes from 10 feet to give him some confidence and he made seven birdies and one bogey in his round.
His best birdie came on the par-4 No. 13 after a bad drive off the fairway. He made three when he sank a long chip of about 76 feet.
The putts made him the first Pappas atop the leaderboard because he teed off early in the first group of the day.
After Brenden Pappas started his round 20 minutes later and saw how well his brother was doing, he started pushing himself to catch his sibling.
Brenden Pappas round was due to steady play as he hit almost every green and fairway in an easy outing on the links. His play on the 359-yard par-4 No. 9 was typical as he drove his ball near the green and chipped up for a short birdie putt.