D6/DPH service cost

[Geoffs]

Ok, watch out with this one. The actuator-cable-selector assembly is a particularly bone-headed bit of design by Volvo, where the actuator is the (a) the weakest part of the overall mechanism and (b) is by some considerable margin the most expensive component of the three.

If the actuator works too hard moving in and out of gear, it'll burn out - and it's £700 for a new one. (Ask me why I know this...). My suggestion would be to disconnect the cable from the actuator, and try and move the unit in and out of gear by moving the cable by hand. If it works nicely, but occasionally completely sticks - then your selector mechanism is playing up. This isn't too expensive, but it is in the top of the leg and the boat needs to be lifted to change it. If (more likely) the cable is stiff to move, then you need a new (xact) cable. It should technically be possible to change the cable with the boat in the water, but it would be lot easier lifted.

From experience, I'd very strongly recommend trying this out before you kill the actuator. When mine failed, by the time I'd paid for an actuator, a lift, a couple of selectors and the labour I was backwards about £2k. This was the week before Christmas. Nice!

Thanks for all this useful info. I've disconnected cable both ends , my boat is dry berthed, and it is free and smooth. I've had the modified selector bracket fitted, it would seem sensible to investigate this xact cable you mention. I'd bite the bullet and change the actuator, but not totally convinced this would resolve things.

At the moment I get the alarm about 1 in 20 gear shifts, always when close quater handling of course.

 

[jimmy_the_builder]

Thanks for all this useful info. I've disconnected cable both ends , my boat is dry berthed, and it is free and smooth. I've had the modified selector bracket fitted, it would seem sensible to investigate this xact cable you mention. I'd bite the bullet and change the actuator, but not totally convinced this would resolve things.

At the moment I get the alarm about 1 in 20 gear shifts, always when close quater handling of course.

If the cable is free and smooth, then this doesn't sound like the problem. The selector mechanism that I replaced was the actual selector itself from the top of the leg, iirc it was assemby #1 off this diagram:

https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744790-44-6274.aspx

As I understand, this was a fault on early DPH drives, and doesn't happen with later ones. The fault was initially intermittent with mine as well...

 

[Bubblegtt]

If the cable is free and smooth, then this doesn't sound like the problem. The selector mechanism that I replaced was the actual selector itself from the top of the leg, iirc it was assemby #1 off this diagram:

https://www.marinepartseurope.com/en/volvo-penta-explodedview-7744790-44-6274.aspx

As I understand, this was a fault on early DPH drives, and doesn't happen with later ones. The fault was initially intermittent with mine as well...

A friend of my had the same problem with a dph leg on his Glastron, every now and again the selector would stick when trying to get into reverse. A new selector cured the problem.