1992 Johnson Evinrude "EN" 40 thru 55 Service Manual, P/N 508143, Page 240Get 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 the test Install 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 lubricant around suspected sealIf leak then stops or lubricant is drawn in, that seal is defectiveWhen the gearcase checks out properly, fill the gearcase with the proper lubricant29Fill the gearcase with 20-22 floz(600-650 ml) lubricant as follows: Secure gearcase in an upright position 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 firstInstall the filldrain plugTighten the oil level and the filldrain plugs to torque of 60-84 in Ibs(7-9 Nm) Inspect the gearcase oil level after the motor test has been performed 30Adjust the shift rod as follows: COA3668