Re: '92 DP-C trim ram/piston disassembly question
Well, got mine rebuilt.
*CAUTION* Its more of a PITA then the instructions read! This is a MODERATE level job
Other tools you will need:
1. A vice
2. GOOD o ring picks
3. 24" pipe wrench
4. More scotch bright
5. Compressed air.
6. 1/2 " deep well socket
7. Some good parts cleaner/solvent.
8. Good apray lube
To start off. TO get your end caps off, is going to be one of the harder parts of this project. After using the supplied wrench, and a good wrench from my local Snap On guy, I said screw it. Luckily I am a mechanic by trade, so I was able to go to work saturday and do it there.
I ues a 24" ppe wrench to take the cap off. Yes, I gouged some of the outer edges up, but hey, it beats spending 800 on a new cylinder. After breaking the cap loose. I removed the cotter pin, and pin that holds the ram to the cylinder.
Heres what it looked like:
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Next, I had my wife hold the outdrive up (so it wouldnt smash my hand all to bits) while I removed the ram from the cylinder.
I then took the whole thing to work. Where I put the clevis end in a vice, that I put a rag around as to not ding anything up.
I removed the bolt that holds the valve spring cover on very CAREFULLY! With a rag covering everything as to not loose any of the springs or balls underneith the cover.
Then I set all the parts of the valves aside and cleaned them with some parts solvent.
I removed the cap from the rod and carefully removed all O-rings from cap and ram assembly. IF YOU SET THEM ASIDE, IN ORDER YOU WONT GET ANY MIXED UP!
Then I went to town with the scotch bright. I cleaned EVERYTHING! Every little nook and cranny on the cap got cleaned. I cleaned the rod as well. when I was done. About 1 hour later, I then cleaned everything with solvent, then used shop air and a blow gun to remove any loose particles in/on the rod/cap assembly.
Now, after I have cleaned everything realy good, it was time to install new o-rings. I started with the cap, since it was going on the rod first. Getting the blue seal into the middle of the cap, was the hardest thig to do. I set the cap on a table, and with ALOT OF PATIENCE, a flat head screw driver and a pick. Was able to get it into it. Its going to want to fold over, and not go in right but it will, it just takes some time. Make note of which way the opening on the seal faces. IT SHOULD FACE THE CYLINDER!
I then installed the BLACK o-ring, with the spring around it, on the outside of the cap. No biggie. Goes right on. And the big o-ring on the end of the cap. BAM! You are home free at this point.
This is where a vice comes in handy. Having the rod supported in the vice, I Took a deepwell 1/2 " socket and pushed it through the center of the cap. Why do you ask? Because the new seals are so tight, you might tear them putting the back on the rod. Take cap/socket assy. and put onto rod. I used a bunch of spray lude during this entire project, it comes in handy here as well. Lube the rod and inner cap really well. Its gonna take some force, and push the cap onto the rod. BE CAREFUL NOT TO TAKE THE ROD INTO YOUR CHEST! Now you should have the cap on the rod! Try not to get excited and dance around the shop like I did.
Screw the Valve Assy back onto the rod. I used a little bit og threadlocker on the threads as to not have this thing come apart in the cylinder. EVER. I put the new o-ring on the valve assy and drove home. Once getting home, I wrapped the rod in paper towels and put it into the freezer. Why you ask? To shrink the seals so It will go into the rod easier.
While it was chillin, I went into the garage and started to prep the boat for the new rod. I used a bunch of paper towels and shoved them into the cylinder to soak up and moisture, old fluid, whathaveyou in there. Pulled them out and did it again. Till it was bone dry in there. I used my drill pump/oil changer, to suck the rest of the old fluid out of the reservoir. Don't want to contaminate new fliud, and have to do this all over again. So now that I have a squeeky clean cylinder and all the fluid out of the reservoir. I dipped the rod into some new clean trim fluid. Gently put it into the cylinder. I lock tited the threads of the cap and screwed the whole works together!!!!!!!!!!!!!!! Reinstalled pin, and cotter pin, lit ciggerete and sat back for a moment. I then filled the reservoir with new clean fluid. With my wife at the helm. I then commanded UP! She the hit the trim button, and nothing happened. So I grabbed the lower unit and gave it some help going up. After about 10 minutes of button on/off. It started to raise. Slowly might I add, but it did. Then once at the top, I commanded DOWN!!!!!!!! And It did. We did this cycle, for about an hour, to bleed the cylinders of air. AND THATS IT!
Like I said, this project can be a PITA, if not careful. I will be happy to answer any questions.
Jet
