Help with pressure test on a 2002 Johnson 90 hp v4 gearcase

Jaredcd7

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Feb 2, 2022
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I recently did a inspection and reseal on my sons Johnson 90 HP v4 engine, which went fairly well except the 2 seals which came in the reseal kit for the propeller shaft weren't the correct size. After 2 weeks of trying to contact the seller which we purchased the reseal kit from with no response I went ahead and purchased the 2 seal separately out of pocket. Long story short I completed the reseal and went to put a pressure test on the gearcase which wouldn't hold any air at all. After I sprayed the whole gearcase down with soapy water I found that there was air coming from a little 1/4" barbed fitting on the outside of the gearcase directly behind the shift rod plate. If standing standing directly behind the gearcase upright as it would be mounted the barbed fitting would be closest to the boat side right below the mid section of the engine. What is the barbed fitting for , and what seal leaking or anything else would cause my air test to leak there? Any help or advice would be much appreciated as this was my first experience working on a outboard gearcase.
 

Crosbyman

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parts diag. shows a CAP for that nipple is it missing ?
 

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racerone

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Dec 28, 2013
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It feeds pressure to the speedometer.------If that is leaking there could be a crack in the gearcase.----Are you in an area with a cold climate ?-------Remove shift rod cover.------Find a screw ( 8 ) there.-----Perhaps the seal ( 9 ) on that screw is leaking.
 

Jaredcd7

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Sorry guys I've been working a lot the last couple days was actually the bolt that's inside of the cover that wasn't there originally I don't I don't know when he bought the boat I guess it wasn't there so but I got one and installed it and no more leaking so it passed pressure test. Thank you all for your help I couldn't have done it without the information you guys gave me
 

racerone

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So was there a lot of water in this gearcase ??----Did you inspect all the gears / bearings / shafts ?-----These gearcases are not as robust as earlier models.
 

Jaredcd7

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There was very little water but a weird groove was worn into the driveshaft right about where the waterpipe o ring is located. This motor sat for a while and I think when my son purchased it that the seller pulled one over on. Put lipstick on a pig for say.
 
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