2006 SD Johnson 4 Stroke 9.9-15HP Outboards Service Manual, Page 209Get this manual
GEARCASE CLEANING AND INSPECTION
Pinion Bearing
Inspect the pinion bearings in placeIf necessary, remove the bearings using Universal Pinion Bearing Remover and Installer kits, PIN 5005927 and PIN 5005928Assemble tools as shown:
CLEANING AND INSPECTIONWARNING
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 spring
Clean all gearcase components in solvent and dry with compressed airAfter cleaning, coat all internal components with HPF PRO gearcase lube to prevent rustingPerform 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 chips, wear, and cracksBearing and gear surfaces must not show signs of metal transfer, corrosion, or discolorationSevere 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 replaced All internal componentsmust be visually inspected for signs of wear, distortion, chipping, metal transfer, pitting, galling, and discoloration due to improper lubrication Water pumpcheck impeller for wear, crumbling, and hub bondingCheck impeller cup and plate for scoring and distortion Shift camInspect the stepped surfaces for excessive wear, chips, or other damage