1996 Johnson Evinrude "ED" 9.9 thru 30 2-Cylinder Service Manual, P/N 507122, Page 236Get this manual
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G2' 14Position one pinion thrust washer on the pinionOil
and install the thrust bearing Install the other thrust washer on the pinion
113( 15Install the pinion in the gearcasefN=J If the pinion binds upon assembly, angle the forward gear
to allow engagementIf binding is still present, the forward bearing cup is not properly seated1141 16Pull shift rod up and install cradle on yoker;;;l 17Oil new a-ring and install on the pivot pinApply OMC Nut Lock to the threads of the pivot pin Use the yoke locator to locate the pivot pin hole in the yokeInstall and tighten the pivot pin to torque of 48-84 inIbs(5-9 Nm)r:J6l 18Coat the threaded area of the shift rod with OMC Triple-Guard greaseSlide the shift rod down through the shift rod bushing and thread it into the yoke until seatedThen back out shift rod until slotted face of connector faces the driveshaftr:tJl 19Using long-nose pliers, place the clutch dog in the cradle with grooved side facing the forward gear 181 1Notel Groove on the clutch dog must face the forward gear20Apply OMC Needle Bearing Assembly Grease to the propeller shaft spring and two detent ballsInstall the spring and balls in the propeller shaftAlign the two detent balls with the two grooves in internal splines of the clutch dog 21 Aid installation of loose detent ball with flat blade screwdriverPush the propeller shaft into the clutch dog, forward gear and the forward bearing22Hold propeller shaft in place and move shift rod up to NEUTRAL position23Slide the reverse gear onto the propeller shaft24Lightly apply OMC Gasket Sealing Compound to the aft support flange of the propeller shaft bearing housingInstall the bearing housing into the gearcase6-20