Trim fill plug stuck on 91 40hp, HELP.

[rjrobin2002]

I pulled my trim apart and replaced o-rings and seals. I put it back together and was going to start the filling and working the air out of the system.

I can not get the allen head cap to come out to save my life. I tried penetrating oil, heating the casing, taping on it with a hammer, Allen wrench with a cheater bar, and then went in got some 3/8 drive Allen head tools with no luck. My father came over after work and is a 25 year diesel mechanic, still no luck. If we twist any more something is going to break.

Is there another way to fill the unit if your fill plug is stuck for good. Like turning it upside down and using the drain plug? Any help would be appreciated.

 

[tx1961whaler]

Re: Trim fill plug stuck on 91 40hp, HELP.

Both the upper and lower drain screws should be large slotted screws. There is a retaining screw and shift pin that should not be removed.

 

[rjrobin2002]

Re: Trim fill plug stuck on 91 40hp, HELP.

It is an allen head plug that is on the top back side of the trim cylinder. I did not see a top large slotted screw on top. I see a bottum one between the trim cylinder and the motor. Am I trying to lossen the wrong thing?

 

[tx1961whaler]

Re: Trim fill plug stuck on 91 40hp, HELP.

Sorry, my bad. I thought you were draining the gearcase oil! :redface: :redface:

 

[tashasdaddy]

Re: Trim fill plug stuck on 91 40hp, HELP.

i think you will find the fill screw on the side, just below the motor
the motor sits on top of the reservoir for the fluid.

 

[rjrobin2002]

Re: Trim fill plug stuck on 91 40hp, HELP.

So this alen plug on top of the cylider is not the fill plug Tashadaddy?
I only see one plug at the bottum. I will remove the whole unit and see if I find another one.

 

[rjrobin2002]

Re: Trim fill plug stuck on 91 40hp, HELP.

I just found a schematic of my unit and this allen cap apprently is not supposed to be removed. I was trying to fill the unit with with it still on the boat and that is why I did not see the fill plug on the reservoir, it is apparently on the inside and can not be seen with the unit still connected to the boat.
I used the search option and did not find much on this topic other than raise and fill, repeat this 5-6 times. Thanks for the help guys.