1990 Johnson Evinrude "ES" Colt/Junior thru 8 Service Manual, P/N 507870, Page 213Get this manual
Pump pressure up to 3-6 psi (21 -42 kPa)If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakage as evidenced by bubblesIf the gearcase pressure gauge does not indicate leakage, increase pressure to 16-18 psi (110-124 kPa)If pressure does not hold, submerge the gearcase in water and check for source of leakageMake necessary repairs and repeat test Screw in vacuum testerPump out to 3-5 in(76-127 mm) of mercury and see if vacuum holdsThen pump out to 15 in(381 mm) of mercury and checkIf the gearcase fails to hold on either test, put oil around suspected sealIf leak then stops or oil is drawn in, that seal is defectiveWhen the gearcase checks out OK, refill with the proper lubricant 24Fill the gearcase with 2.7 flo oz(80 ml) lubricant as follws:
The gearcase must be in an upright poisiton Remove the oil level and the oil filldrain plugsReplace the seals if damaged Fill the gearcase with OMC Hi-Vis gearcase lube until lubricant appears at the oil level holeInsert the oil level plug firstInvert the gearcase and remove the oil fill hoseInstall the filldrain plugTighten the oil level and the filldrain plugs to torque of 40-50 in Ibs(4,5-5,6 Nm) Inspect the gearcase oil level after motor test has been performedInstallation 1Install new a-ring on the driveshaft