1996 Johnson Evinrude "ED" 40 thru 55 2-Cylinder Service Manual, P/N 507124, Page 202Get this manual
Cleaning and Inspection ill "" Replace damaged componentsShift system failure could cause loss of control over direction of engine thrust
1Discard all seals, O-rings, gaskets, and clutch dog spring
ill compressed airTo avoid personal injury, wear eye protec-
2Clean all gearcase components in solvent and dry with
tion and regulate air pressure to not more than 25 PSI (172 kPa)After cleaning, coat all internal components with OMC Ultra-HPF gearcase lubricant to prevent rusting
3Perform the following inspections :
Gearcase housingall gasket surfaces must be free of gasket materialAll threaded holes must be free of corrosion and sealerUpper driveshaft oil circulation hole must be clear Hydrostatic seal ringsmust be undamaged and in good condition to help prevent propeller ventilation Gearcase anodesif anodes have been reduced to two-thirds their original size, they must be replacedRefer to Section for testing procedure Driveshaftcheck threads and splines for chips, wear, and cracksBearing and gear surfaces must not show signs of metal transfer, corrosion, or discolorationSevere spline wear might indicate an exhaust housing or gearcase has been distorted by impact damage Water intake screenmust be clearIf screen can't be cleaned, it must be replaced All internal componentsmust be visually inspected for signs of wear, distortion, chipping, metal transfer, pitting, galling, and discoloration due to improper lubrication Water pumpcheck impeller for wear, crumbling, and hub bondingCheck liner and wear plate for scoring and distortion