1996 Johnson Evinrude "ED" 9.9 thru 30 2-Cylinder Service Manual, P/N 507122, Page 237Get this manual
25Apply OMC Gasket Sealing Compound to the threads of the bearing housing screwsInstall the screws and tighten to torque of 60-80 inIbs(7-9 Nm) 120 126Install the driveshaftRotate the driveshaft to allow the splines in the pinion to engage the splines on the driveshaft27Pressure 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 evidenced by bubblesIf the gearcase pressure gauge does not indicate leakage, hold the driveshaft down and increase pressure to 16-18 PSI (110-124 kPa)If pressu re does not hold, su bmerge the gearcase in water and check for source of leakageMake necessary repairs and repeat test Screw in vacuum testerPump out to 3-5 inof mercury and see if vacuum holdsThen pump out to 15 inof 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 OMC Ultra-HPF gearcase lubricant1221 28Fill the gearcase with 8-9 flo oz(230-260 ml) lubricant as follows: