1992 Johnson Evinrude "EN" 9.9 thru 30 Service Manual, P/N 508142, Page 270Get this manual
35 14Place bead of OMC Adhesive on the upper gearcase in the location shown
36 15Position the propeller shaft assembly in the upper gearcase as shownThe gearcase head has hole in it that must engage pin in the upper gearcaseAllow approximately 1 32 in(0,8 mm) clearance between the forward bearing and the thrust washer
37 16Seat the forward gear and thrust bearing firmly against
the gearcase using OMC Gearcase Alignment Tool PIN 390880Leave the tool in position until the lower gearcase has been installed17From bulk spool of gearcase seal, cut new seal to the length of 1278 in(32 em)
381 18Apply OMC Adhesive to the machined surfaces of the
upper and lower gearcases and to the exposed area of the gearcase head a-ringLay the seal in the groove of the lower gearcaseCut the ends of the seal to fit exactly in the grooveApply RTV adhesive to the ends of the seal for length of 12 in(12 mm) 19Position the lower gearcase on the upper gearcaseApply OMC Gasket Sealing Compound to the threads of the gearcase retaining screwsInstall the two front and two rear screws, then loosely tighten the screws evenly to draw the gearcases togetherPush rearward on the lower gearcase with steady pressure as the retaining screws are tightenedInstall the remaining screws and gradually tighten themalternating from side to side and working toward the rearTighten the screws to torque of 60-80 in Ibs(7-9 Nm)Remove the alignment tool39 20Apply OMC Triple-Guard grease to new pivot pin a-ringInstall the a-ring on the pivot pinApply OMC Nut Lockto the threads of the pinInstall the pivot pinYou may have to move the shift rod in or out to locate the hole in the shifter leverTighten the pivot pin to torque of 48-84 inIbs(5-9 Nm)