1994 Johnson/Evinrude "ER" 9.9 thru 30 outboards Service Manual, Page 248Get this manual
Installation 1On models with gearcase extension kit make sure the driveshaft tube extension, water tube extension, and gearcase exhaust seals are in placer:jl2Coat the driveshaft splines with OMC Moly LubeDo not coat top surface of the driveshaft as lubricant here may prevent seating of the driveshaft in the crankshaft3Pull up on the shift rod and engage REVERSE gearMove the shift lever on the motor to REVERSE positionf214Lightly apply OMC Triple-Guard grease to lower outside diameter of the water tubeCarefully install the gearcase making sure the driveshaft splines engage the crankshaft, the water tube enters the impeller housing grommet, and the upper shift rod enters the shift rod connector i in the connectorApply OMC Gasket Sealing Compound to
shift rod connector screwInstall and tighten the screw with washer to torque of 60-84 inIbs(7-9 Nm)
'" 5Align the groove in the lower shift rod with the screw hole
When installing gearcase to gearcase extension, do not tighten the retaining screws until the gearcase and the extension have been placed in proper position with the exhaust housing and powerhead assemblyf316Apply OMC Gasket Sealing Compound to the threads of the gearcase and extension retaining screwsInstall and tighten the screws to torque of 96-120 inIbs(11-14 Nm)Install the propeller as follows: Apply OMC Triple-Guard grease to entire length of the propeller shaft Install the thrust bushing onto the propeller shaft with shoulder of the bushing facing aft and fish line trap groove facing forward Install the propellerPropeller should seat onto the thrust bushing Install the spacerengaging the propeller shaft splines Install and tighten the propeller nut to torque of 120 in.lbs14 Nm).Continuetotightenthenuttoalign next cotter pin hole Install and secure the cotter pin8Adjust the shift detent as described in Section 4&