1994 Johnson/Evinrude "ER" 2 thru 8 outboards Service Manual, Page 217Get this manual
1444Pressure and vacuum test the gearcase as follows:
INote Pressure and vacuum test gearcase before filling Remove the oil filldrain plug and screw in pressure test gauge 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 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 defectiveWhen the gearcase checks out OK, refill with the proper lubricant5Fill the gearcase with 2.7 flo oz(80 ml) lubricant as follows: The gearcase must be in an upright position Remove the oil level and the oil filldrain plugsReplace the seals if damaged Fill the gearcase with OMC Ultra-HPF 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 inIbs(4,5-5,6 Nm) Inspect the gearcase oil level after motor test has been performed1 456Apply OMC Triple-Guard grease to the entire length of the propeller shaftInstall hub and secure with drive pin Install shock absorber and the propellerInstall and secure the cotter pin