www.iFourWinns.com

Recently bit the bullet to replace the steering ram on my Sundowner 255. No problems until it came to the last cotter pin on the lower main retaining bolt, the one with the safety cotter pin inserted. The cotter pin is rusted in there and no easy way to remove it that I can figure apart from attempting to drill it out. Reaching out to the forum before I attempt anything further. This is the last item to be removed to get the ram out! Very frustrating - any suggestions please?

_________________
2006 Sundowner 255
Volvo Penta 5.7L GXi 320HP DuoProp

I have run into this problem in the past on other similar items. What
I have done is file the cotter pin smooth so the cylinder or whatever can be
removed, then you have more room to either drill out or drive out the cotter pin.
Choose a similar sized drift to drive it out. Make sure you use a ss cotter pin.
Good luck, John

I just went through this about two weeks ago -- when I REBUILT the piston seal in my Steering Ram. (total seal cost --$5.00)
I posted the complete story on iboats -- perhaps I should do the same here so people can search for it in the future.

The cotter pin was rusted on the lower retaining bolt on mine also. The ends just came free when I pulled on them.
I removed the riser on that side to get access.
I then used a small drift of similar size to the cotter pin. With a small ballpeen hammer I was able to tap the drift and force the corroded cotter pin out.
I have lots of those issues since I boat in salt water.

_________________
DaleG -- West Palm Beach FL
2003 240Horizon -- 5.7Gi -Duoprop

Thanks for the help! After removing the riser, the engine water hose, and the deck drain hose at the transom, we had enough room to drill out the cotter pin with a right angle chuck attachment - just could not budge it using a drift. What a saga, and a bad design if you ask me. BTW, this is the 2nd steering ram replaced in this boat in just under 3yrs - not happy that a VP part would fail again in a short space of time. From what I've read on other forums, there seems to be an inherent design flaw with this type of ram. Anyway, cotter pin replacements added to the regular maintenance schedule now!

thanks again for your replies.

_________________
2006 Sundowner 255
Volvo Penta 5.7L GXi 320HP DuoProp