DP290 drain plug stuck

[5933khwy]

Hi All. You've been a great help in the past. I have a Volvo Penta 290DP-A drive. I was planning to change the oil in the leg, but the drain plug is stuck. I tried my usual technique with a slotted screw driver and wrench. That didn't work so I followed with an impact driver. Normally, the next thing I'd try on a frozen bolt is heat, but I was hesitant out of fear of melting the o-ring or doing something to the oil in the leg. Any our things I should try before picking up the impact driver again? Thanks!

 

[a70eliminator]

Re: DP290 drain plug stuck

If that screw is even the slightist bit messed up don't even put anything on it till you have the correct slotted driver, I'll just bet thats why you couldn't get in the first place not the right driver am i right?

 

[180shabah]

Re: DP290 drain plug stuck

You are right to be cautious of heat, but do not worry about the o-ring. You will be replacing it anyway.

 

[5933khwy]

Re: DP290 drain plug stuck

For the impact driver, I've been using the largest slotted bit sears sells. It is wider than the typical #2 size. Is there a special tool for this other than a large screw driver? Thanks.

 

[rodbolt]

Re: DP290 drain plug stuck

on the extreme ones I use a 1/2" hand inpact driver with a modified drag link bit and a 32OZ ball peen hammer.
occasionally oxy/acetylyne is involved.
dont worry your heating an oil filled heat sink. trick is try not to heat the plug but the aluminum around it.
sometimes the salt pond work gets a bit interesting and so far in the past 30 years NO school I have ever attended for Volvo,Merc,yamaha,tohatsu,honda or suzuki ever had a smoke wrench in class.
but you will be amazed how much heat you can use without killing it.
just keep the flame moving and dont let it set long in anyone spot.
occasionally I get one with the slot torn up. on those try to clean up the slot with a dremal tool and a small carbide burr, then use a good drift pin punch and catch the edge of the slot and tap it with said 32oz ball peen. usually it will come off.
its amazing how many customers bring something in for a simple task and then say, oh by the way. while its here change the gear oil for me.
thats when you know your in trouble.

 

[180shabah]

Re: DP290 drain plug stuck

....
its amazing how many customers bring something in for a simple task and then say, oh by the way. while its here change the gear oil for me.
thats when you know your in trouble.

Ahhh...the Columbo method. "just one more thing..."