2000 Johnson/Evinrude SS 2 thru 8 outboards Service Manual, Page 231Get this manual
1441 4Pressure and vacuum test the gearcase as followsINote Pressure and vacuum test gearcase before filling Remove the oil fill drain plug and screw in pressure test gauge Pump pressu re 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 indi 16-18 PSI cate leakage, increase pressure to (110-124 kPa)If pressure does not hold, submerge the gearcase in water and check for source of leakageMake necessary repairs and repeat test Install vacuum testerPump out to 3-5 inches (76-127 mm) Hg and see if vacuum holdsThen pump outto 15 inches (381 mm) Hg and checkIfthe 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 the proper lubricant5Fill the gearcase with 2.7 floz(80 ml) lubricant as follows: The gearcase must be in an upright position Remove the oil level and the oil fill drain plugsReplace the seals if damaged Fill the gearcase with OMC Ultra-HPF gearcase lube until lubricant appears at the oil level holeInsert the oil level plug firstInvert the gearcase and remove the oil fill hoseInstall the fill drain plug Tighten the oil level and the fill drain plugs to torque of 40-50 inIbs(4,5-5,6 Nm) Inspect the gearcase oil level after motor test has been performed 45