2002/2003 Johnson SN/ST 2 Stroke 3.5, 6 8 HP Outboards Service Manual, PN 5005466, Page 202Get this manual
GEARCASE CLEANING AND INSPECTION
CLEANING AND INSPECTION&WARNING
Replace damaged componentsShift system failure could cause loss of control over direction of engine thrustTo avoid personal injury, wear eye protection and regulate air pressure to not more than 25 PSI (172 kPa)Discard all seals, O-rings, gaskets, and clutch dog springC!ean all gearcase components in solvent and dry with compressed airAfter cleaningcoat all internal components with utra-HPF gearcase lube to prevent rusting
Perform the following inspections: Gearcase housingall gasket surfaces must be free of gasket materialAll threaded holes must be free of corrosion and sealer Gearcase anodeif anode has been reduced to two-thirds of its original size, it must be replacedRefer to MAINTENANCE section for testing procedure Driveshaftcheck splines for chipswear, and cracksBearing and gear surfaces must not show signs of metal transfer, corrosion, or discoloration Severe spline wear might indicate an exhaust housing or gearcase has been distorted by impact damage Water intake screenmust be clearIf screen can't be cleaned, it must be replacedinternal componentsmust be visually Inspected for signs of wear, distortion, chippingmetal transfer, pitting, galling, and discoloration due to improper lubrication Water pumpcheck impeller for wear crumbling, and hub bondingCheck impeller and plate for scoring and distortionE u