Volvo Penta MD2040 gearbox problem.

Carmel2

Carmel2

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Hi,

Wondering if you have any tips on this? The bolt that acts as the fill cap and dipstick on my gearbox was threaded by the last person who serviced it. I have tried to get it out by pulling upwards with grips and that hasn't worked , and now it will not tighten or untighten. I am loathe to try and drill it out because I don't want to get any swarf in the box.

Any thoughts????
 
Its a MS 15L-A

Like this, and it's the bolt top left.

6fp8v8.jpg
 
Steel bolt on an aluminium box. I had similar problem with my MS-10L (could not tighten it properly and there was some oil coming out).
If you try really hard to untight it, it will eventually open but it will never tighten!
Unfortunately I didn't find a solution. Eventually I replaced it with a ZF10 because it was not working properly anyway (discs were slipping). If you ever decide to replace it have a look at the ZF15. Slightly different gear ratio but same box I believe (like the MS10L vs ZF10) and probably one third of the price.
 
Having got the dipstick bolt out, it transpires that the thread on the casing is gone so it's likely that there is swarf in the gear box. Someone has suggested that I flush it with petrol a few times, turning the shaft.............Is this a good idea? Will the mix of new oil and petrol residue cause any problems??
 
Is there a bottom drain plug? If so, flushing might help. Petrol is probably OK, but I think I'd choose a thin oil like ATF.
If no drain plug, the chances of removing all debris are less, and the suction pipe would have to go right to the bottom of the box. OTOH, there's probably not too much to worry about
How are you repairing? A helicoil is a good way, and that will introduce swarf unless great care is taken, esp if drilling is involved.
Ideal way is to remove the box, but a PITA.
 
Fortunately, aluminium swarf is not going to do a great deal of damage. Flushing through with a light solvent seems to me to be the way to go, petrol being close to ideal as it can be evaporated when the job is done. Paraffin might be as good and has the bonus that it is less flammable I suspect that anything more viscous might fail to penetrate into all possible areas. Once you have trapped whatever is washed through, blow warm air through the box. Whichever is used will mix with the new oil quite readily.
 
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