Filling; Leak Test - Johnson J2R4SUC 2007 Service Manual

Inspection
Inspect the lubricant for water contamination.
Water in the lubricant can cause a milky 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 on p. 123.
Overheated lubricant will give the lubricant 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.
Using Gearcase Fill/Drain Adapter, P/N 5037486,
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 114 in. lbs. (13 N·m).

LEAK TEST

Check for leakage of the oil seals and O-ring
when applying the specified pressure inside of the
gearcase.
Install leakage tester into the oil level hole. Con-
nect an air pump to leakage tester.
Rotate the driveshaft and the propeller shaft
clockwise several times and then apply the speci-
fied pressure for the test.
Apply low initial pressure of 2.8 to 5.7 psi (20 to 40
kPa) first, then apply the specified pressure.
Leakage test pressure:
•
100 kPa (1.0 kg/cm2, 14.2 psi)
IMPORTANT:
psi (110 kPa) or damage to oil seals will result.
Once stabilized, the pressure should remain
steady for at least five minutes.
If the pressure does not fall, sealing performance
is correct.
Drain lubricant before testing.
004363
GEARCASE
LEAK TEST
Do not exceed pressure of 15.6
006262
8
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