1994 Johnson/Evinrude "ER" 9.9 thru 30 outboards Service Manual, Page 272Get this manual
1401 21Carefully slide the driveshaft into positionRotate the driveshaft until it engages the pinion ] 22Pressure and vacuum test the gearcase as follows:
INotel Pressure and vacuum test gearcase before filling Remove the oil level plug and screw in pressure test gauge Hold down firmly on the driveshaft and 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 indicated by bubblesIf the gearcase pressure does not indicate leakage, hold the driveshaft down and increase pressu re 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 Screw in vacuum testerPump out 3-5 in (76-127 mm) of mercury and see if vacuum holdsThen pump out 15 in(381 mm) of mercury and checkIf the gearcase fails to hold on either test, put lubricant around suspected sealIf the leak then stops or lubricant is drawn in, the seal is defectiveWhen the gearcase checks out properly, fill the gearcase with OMC Ultra-HPF gearcase lubricant23Fill the gearcase with lubricant as follows: Be sure the gearcase is in an upright position Remove the oil level and oil filldrain plugsReplace the seals if damaged Fill the gearcase with OMC Ultra-HPFgearcase lube until lubricant appears at the oil level holeInsert the oil level plug firstInstall the fill drain plugTighten the oil level and fill drain plugs to torque of 84-86 inIbs(9-10 Nm) Inspect the gearcase oil level after the motor est has been performed24Install the water pump as described in Water Pump Servicing, this Section