1996 Johnson/Evinrude Outboards 25, 35 3-Cylinder Service Manual, Page 211Get this manual
32Using brass punch and mallet, seat the bearing housing in the gearcase
33Place new O-rings on the bearing housing retaining screwsApply OMC Gasket Sealing Compound to the O-rings and threads of the screws
34Install one screw in the bearing housingRemove the guide pin and install the second screwTighten the screws to torque of 60-84 inIbs(7-9 Nm)
35Coat the lower driveshaft splines with OMC Ultra-HPF gearcase lubricantInstall the driveshaft into the gearcase with the water pump key end downBe careful not to damage the seals with the splinesTurn the driveshaft to engage the pinion36Pressure and vacuum test the gearcase as follows: 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 (21-41 kPa)If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakage as evidenced by bubblesIf the gearcase pressure does not indicate leakage, increase pressure to 16-18 PSI (110-124 kPa).lf pressure does not hold, submerge the gearcase in water and check for source of leakageMake necessary repairs and repeat the test Screw in vacuum testPump 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 lubrication around suspected sealIfthe leak stops or lubricant is drawn in, that seal is defectiveWhen the gearcase checks out properly, fill the gearcase with OMC Ultra-HPF gearcase lubricant