posted 04-06-2009 03:36 PM ET (US)        

I pumped in the new HP lube, but only got about 24 ounces in before it flowed out the open inspection port. It is supposed to hold about 32 ounces. could the difference be old lube that didn't drain out?

posted 04-06-2009 11:27 PM ET (US)            

It is better to change the gearcase lubricant in the fall so that when the boat sits all winter there will be fresh grease, free of any water.

The brown streaks in your lubricant were probably portions of the grease which had become contaminated with some water. Or, perhaps more than one kind of lubricant was used previously. If you consistently use the same lubricant brand and grade, you will have a consistent color and will be able to recognize any color changes as a sign of water intrusion.

It is typical that there will be some fine metal particles on the drain plug magnet. I don't know precisely at what point one would become alarmed by the presence of fine metal shavings. I guess if the amount of shavings is excessive it should be considered abnormal. A few fine particles is normal.

Check the specifications of your gearcase to see exactly how much lubricant it is supposed to hold. My V6 OMC motor gearcase is specified to hold 33-ounces. After the gearcase has has been thoroughly drained, it takes 32-ounces (or as much as I can get out of a 32-ounce bottle) to refill it. I try to drain the gearcase on a warm fall day so that the lubricant will flow more easily. It you drain it on a really cold day it seems to take forever to get all the old lubricant to drain out.

If your engine calls for 32-ounces and you could only add 24 before it overflowed, I think the most reasonable explanation is that you did not get all the old lubricant out. Make sure you have the motor trimmed so that the drain hole on the gearcase is at the lowest position when you are draining. It is also not a bad idea to trim the engine up and down slightly to make sure no grease is staying in the gearcase.