Inspection; Filling; Leak Test - Johnson J10RSUR Service Manual

GEARCASE

LEAK TEST

Inspection

Inspect the lubricant for water contamination.
Water can make the lubricant milky in appear-
ance. However, normal aeration can also cause
the same appearance.
To check for water contamination, drain lubricant
into a suitable glass container. Allow the drained
oil to settle for a minimum of one hour to deter-
mine if there is an abnormal amount of water in
the oil. Some gearcase lubricants are designed to
mix with a small amount of water from normal
water vapor condensation within the gearcase.
Refer to LEAK TEST.
Overheated lubricant will have a black color and
burned odor.
Internal gearcase inspection is recommended
when lubricant is contaminated or shows signs of
failure.

Filling

Secure the gearcase in a vertical position.
Remove the lubricant level plug and the lubricant
drain/fill plug.
Slowly fill the gearcase with HPF XR gearcase
lube through the drain/fill hole until it appears at
the oil level hole. Filling the gearcase too quickly
can cause air pockets and the gearcase may not
fill completely. Clean plug seal area and install the
lubricant level plug and new seal, then the lubri-
cant drain/fill plug and new seal. Tighten them to
a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
TYPICAL
1. Oil level hole
166
LEAK TEST
Drain lubricant before testing.
STEP 1
Install lubricant drain/fill plug and seal, thread
pressure test gauge fitting and seal in lubricant
level fill hole.
Pressurize 3 to 6 psi (21 to 42 kPa).
If pressure gauge indicates leakage, submerge
the gearcase in water to determine source of leak.
If the gearcase pressure gauge does not indicate
leakage, increase pressure to 16 to 18 psi (110 to
124 kPa). Check for leakage.
Make necessary repairs and repeat test.
STEP 2
Complete successful STEP 1 before proceeding.
Install vacuum test gauge. Apply 3 to 5 in. of vac-
uum (76 to 127 mm) Hg. with pump.
Check for leakage.
If leakage occurs, apply oil around suspected
seal. If leak then stops or oil is drawn in, that seal
is defective.
Repeat test. Gearcase must hold minimum of 15
in. Hg. (kPa).
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DR33673
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