1994 Johnson/Evinrude "ER" 2 thru 8 outboards Service Manual, Page 207Get this manual
11Position the pinion into gearcase12Install the driveshaftRotate the driveshaft to engage the pinion13 Install the pinion retaining ring with sharp side of ring facing out14Lightly apply OMC Triple-Guard grease to new gearcase head O-ringInstall the O-ring in groove of the gearcase head15Install the gearcase head on propeller shaft until it seats on gearcase16Install the impeller pin the propeller shaft1221 17Lightly oil the impeller blades and install the impeller in the gearcase head while turning in clockwise direction, making sure the blades seat18Position the impeller cover19Apply OMC Gasket Sealing Compound to pu mp cover screwsTighten screws to torque of 60-84 inIbs(7-9 Nm)20Pressure test the gearcase as follows:
Remove the oil level plugAttach pressure tester to the gearcase using OMC Pressure Gauge Adapter, PIN 115330 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 test12