2003 Johnson ST 55 HP WRL 2 Stroke Commercial Service Manual, PN 5005483, Page 181Get this manual
GEARCASE DISASSEMBLY
DISASSEMBLY
itWARNING
Gearcase AnodesIf anodes have eroded to two-thirds their original size, they must be replaced
Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa)IMPORTANT: Clean and inspect all components during disassemblyReplace any damaged components, seals, O-rings, and gaskets upon assemblyRemove the propeller and mounting hardwareDrain and inspect oil as described in LUBRICANT sectionRemove gearcase as described in GEARCASE REMOVAL AND INSTALLATION sectionRemove water pump as described in WATER PUMP section1Gearcase anode
Drive ShaftCheck splines for visible damage, twisting and wearSevere spline wear indicates the exhaust housing or gearcase has been distorted, possibly by impact damage
IMPORTANT: Water Intake ScreensCheck for damage and blockageIf screens cannot be cleaned, they must be replaced
Pre-Disassembly Inspection
Before disassembling the gearcase, examine the following: Gearcase HousingCheck for visible damage to skeg, strut, anti-ventilation plate, bullet, and mating surfaceCheck seal areas for visible signs of lubricant leakage Propeller ShaftCheck for bent or damaged shaftCheck for twisted splines and damaged threads Shift RodCheck for misadjusted, bent, or binding rodA misadjusted shift rod height can cause shift difficulty, loss of boat and outboard control, and gearcase damage Hydrostatic Seal GroovesMust be in good condition to help prevent propeller ventilation