1991 Johnson/Evinrude EI Outboards 2.3 thru 8 Service Manual, Page 225Get this manual
41 28Pressure and vacuum test the gearcase as follows:
INotel Pressure and vacuum test gearcase before filling Remove the oil level plug and screw in pressure test gauge Pump pressure up to 3-6 PSI (21-42 kPa)If pressure 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 outto 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 defectiveReplace defective components, test, and fill ,gearcase1421 29Fill the gearcase with 10-11 flo oz(290-325 ml) lubricant as follows: Deluxeuse OMC Premium Blend gearcase lubeS thruuse OMC Hi-Vis gearcase lube Secure the gearcase in an upright position Remove the oil level and the oil filldrain plugsReplace the seals if damaged Fill the gearcase with 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 60-84 inIbs(7-9 Nm) Inspect the gearcase oil level after motor test has been performed