2002/2003 Johnson SN/ST 2 Stroke 3.5, 6 8 HP Outboards Service Manual, PN 5005466, Page 188Get this manual
GEARCASE
LEAK TEST PROCEDURE
Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of failure
LEAK TEST PROCEDURE
Drain lubricant before testing
Filling
Secure the gearcase in vertical positionRemove the lubricant level plug and the lubricant drainfill plugSlowly fill the gearcase with EvinrudeJohnson utra-HPF gearcase lube until it appears at the oil level holeFilling the gearcase too quickly can cause air pockets and the gearcase may not fill completelyClean plug seal area and install the lubricant level plug and new seal, then the lubricant drainfill plug and new sealTighten plugs to the recommended torqueModel Oil LevelFillDrain Plug Torque
Install lubricant drainfill plug and seal, thread pressure test gauge fitting and seal in lubricant level holePressurize to psi (21 to 42 kPa)If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakageIf the gearcase pressure gauge does not indicate leakage, increase pressure to 16 to 18 psi (110 to 124 kPa)Check for leakageMake necessary repairs and repeat test