1996 Johnson Evinrude "ED" 9.9 thru 30 2-Cylinder Service Manual, P/N 507122, Page 261Get this manual
1351 14Place bead of OMC Adhesive on the upper gearcase in the location shown1361 15Position the propeller shaft assembly in the upper gearcase as shownThe gearcase head has hole in it that must engage pin in the upper gearcase INote Allow approximately 132
in(0,8 mm) clearance between the forward bearing and the thrust washer
1371 16Seat the forward gear and thrust bearing firmly against the gearcase using OMC Gearcase Alignment Tool, PIN 390880Leave the tool in position until the lower gearcase has been installed17From bulk spool of gearcase seal, cut new seal to the length of 1278 in(32 em)1381 18Apply OMC Adhesive to the machined surfaces of the upper and lower gearcases and to the exposed area of the gearcase head a-ringLay the seal in the groove of the lower gearcaseCut the ends of the seal to fit exactly in the grooveApply RTV adhesive to the ends of the seal for length of 12 in(12 mm) 19Position the lower gearcase on the upper gearcaseApply OMC Gasket Sealing Compound to the threads of the gearcase retaining screwsInstall the two front and two rear screws, then loosely tighten the screws evenly to draw the gearcases togetherPush rearward on the lower gearcase with steady pressure as the retaining screws are tightenedInstall the remaining screws and gradually tighten them, alternating from side to side and working toward the rearTighten the screws to torque of 60-80 inIbs(7-9 Nm)Remove the alignment tool1391 20Apply OMC Triple-Guard grease to new pivot pin a-ring Install the a-ring on the pivot pinApply OMC Nut Lock to the threads of the pinInstall the pivot pinYou may have to move the shift rod in or out to locate the hole in the shifter leverTighten the pivot pin to torque of 48-84 inIbs(5-9 Nm)