Service of DP-A Volvo outdrive

[lyt]

Re: Service of DP-A Volvo outdrive

Hi Don, lol

the top nut.... yes i figured out that i dont really need to get in there.....it just dawned on me.....

Yes I know, I understand how it works. In the manual it says punch the pin thru. well, I punched with a small punch I did lightly at first.... and kept trying to punch it thru. did not work.... I punched harder but the pin does not go "thru" so then I guessed it might be corroded. So I punched harder....

the bottom line ....why does the manual say the pin will go thru when it clearly does not. as I look in the hole I see solid piston only and there is nothing that appears to be holding it. But....that pin will simply not go thru.

Maybe I do not understand what "thru" means

In my mind, thru means there should be a hole inside the piston I should see when I have punched the pin "thru"...am I not thinking of this correctly?

 

[Don S]

Re: Service of DP-A Volvo outdrive

the bottom line ....why does the manual say the pin will go thru when it clearly does not.

Got me, never had problems with one.
Did you look on the sides for another hole the pin might be in, like the other pictures in the manual? You may just have a previous owner problem.

 

[lyt]

Re: Service of DP-A Volvo outdrive

great.... yeah I know you probably thought I was the "just get a bigger hammer" type.... actually quite the opposite.

no other holes I can see..... this is the only one.

here is the issue I have as I think about it.

there was a "pin" supposedly a roll pin in there. I began tapping it and after a few taps i no longer noticed a roll pin. maybe it broke apart or maybe it got smashed down in the hole. either way nothing went "thru" as the manual says.

so literally all I see is a hole and the top of the piston.....so I am thinking to myself well the piston should just slide out...... there is nothing holding it.... but i cannot even hammer it out after applying heat and on the side of a pair of vice grips.

this leads me to believe either a wrong part was jammed in there.... or there is some sort of thread sealer (odd since there are no threads).

one thing is for sure.... what I thought would take literally 30 seconds, has turned into one of those wonderful mechanics moments where you literally have to count to 10 slowly just to remain calm.

what I did notice.....is that the hole that the piston sits in seems a bit oval and the pin seems more circular....

it seems to bind on the sides but there is a tiny gap at the top and bottom....maybe the pin or the housing has just has worn badly and warped out of shape.

I am coming up to the point where I will just cut the piston, grind it smooth so I can remove it ....and just replace the part. or at least then i can hammer it out "easily" at least. famous last words.

 

[lyt]

Re: Service of DP-A Volvo outdrive

ok

here's a nice tidbit -- something to annoy you till you die.

it seems there was ALREADY a broken off roll pin in the bottom hole, so perhaps that is why the top ring it would not punch thru.

I can only guess the drive was serviced before and no one wanted to remove the old ring.

Maybe I am mistaken but this was the issue of me not being able to pull out the pin, because the one I "punched" NOT "thru" just started getting jammed in there.

so do I just drill out that old one? I cant seem to pull it out with a awl....... maybe I can thread it somehow and pull it out.....

 

[Don S]

Re: Service of DP-A Volvo outdrive

Interesting, those things are designed and drilled deep enough to hold 3 roll pins when you knock them through. That would mean this is the 4th time it was apart ?????????
I suppose it could be a factory defect, maybe a broken drill bit under the roll pin ????

 

[lyt]

Re: Service of DP-A Volvo outdrive

maybe.....

what would you do? try to punch thru?

....just tried to.....it wont budge......

i guess drilling is the only option.........

or maybe I can find a small screw and thread it and pull?

 

[Don S]

Re: Service of DP-A Volvo outdrive

You aren't going to "Punch them through", you either remove them, or replace the part.
With all the hammering that's been done, I would replace it.

 

[lyt]

Re: Service of DP-A Volvo outdrive

right... wallet says $123 -- ouch....

the part is fine....just need to deal with this....

 

[lyt]

Re: Service of DP-A Volvo outdrive

actually now that i think of it.... I wont need to do much just a quick drill and short depth..... since the new one does not need to go in much right?

 

[Nickypoo]

Re: Service of DP-A Volvo outdrive

Good thing Don's here. It didn't even occur to me to think about why you were trying to take that nut off.

I drilled my roll pin out even though I could have just punched it out. I didn't see how it would come through the other side when everything was assembled.

 

[lyt]

Re: Service of DP-A Volvo outdrive

Good thing Don's here. It didn't even occur to me to think about why you were trying to take that nut off.

I drilled my roll pin out even though I could have just punched it out. I didn't see how it would come through the other side when everything was assembled.

Yeah I agree....I don't care what they say about him.... he's alright :laugh:

I think what he was trying to say is that the pins will NOT "punch" out because there is no way for them to come out.... they have to be drilled out or removed somehow....

Waiting for the kit to arrive......

Anyway.... I've been meaning to buy a nice torx bit set for a while now, I have a small junky set....but don't have a large enough bit to take off the u-joint.

Can anyone confirm the size torx bit I will need on the other side of the u-joint...so I make sure I have it when I buy the set..... Im thinking it is a TT45 but I could be wrong....?

 

[Don S]

Re: Service of DP-A Volvo outdrive

Been a while since I did one, but I'm positive it was a T50 bit. Take it with you and make sure.

 

[lyt]

Re: Service of DP-A Volvo outdrive

ok ....

FINALLY

All seals kits/parts are in..... if I had known it would take this long.... well... you know....

OK...

I started disassembling U joint housing and the Input gear.

It says "press out" the input gear

well .... it doesn't press out. once again it says I need a special tool. I had to MAKE a special set of snap ring pliers to get that monstrous snap ring out....

I thought someone told me you needed no special tools for this job of doing the upper seals. Well...sure you dont NEED them....but you will spend HOURS looking for and fabricating special tools to do it.

how do I get the input gear off? I am following the manual, but since I do not have the special tool, I need help because one could easily damage the splines. I tried a wood dowel so far and all it did was cut into the splines

 

[Don S]

Re: Service of DP-A Volvo outdrive

You don't need any special tools to press out that gear. A piece of pipe smaller than the gear shaft would do the job, or an extention with a socket on it. :facepalm:

 

[lyt]

Re: Service of DP-A Volvo outdrive

yeah but wont that damage the splines? the gear does not press out easily I need to hit it....

 

[lyt]

Re: Service of DP-A Volvo outdrive

are you saying not to hit it?

what use my drill press?

I am not set up with a hydraulic press, ya know

 

[Don S]

Re: Service of DP-A Volvo outdrive

First thing you need to do is get the sealing washer out of it. Then you can see the gear shaft itself.

A drill press is not a press, it's a drill. Have never tried to beat one out with a hammer, you better have a brass drift if you try.

 

[lyt]

Re: Service of DP-A Volvo outdrive

Let's just cut thru all the "possibilities" and get down to how to do this.....

how does Don S. remove them? literally step by step. why is this shrouded in mystery?

do you use a press? do you use your vice? do you build a wood frame to press against?

a 3/4" socket fits perfectly in the shaft but rests against the splines....from what you are telling me its ok to just press against the splines.... correct?

I know how to press.... I just dont want to spend hours making a jig (once again since i do not have the correct special tool) if there is an easier way

 

[lyt]

Re: Service of DP-A Volvo outdrive

First thing you need to do is get the sealing washer out of it. Then you can see the gear shaft itself.

A drill press is not a press, it's a drill. Have never tried to beat one out with a hammer, you better have a brass drift if you try.

and yes.... the manual says press....not hit... so I do not plan to tap it out. I want to press it out....

 

[lyt]

Re: Service of DP-A Volvo outdrive

ok... boy dont I feel dumb...... i see it now....

you were right as usual....the shoulder washer..... .... hard to see....i thought it was all one part........


ok so....

the shaft appears to be raised slightly, still not sure how to press this one out....

how do you press them out?