still trying to find that manual, do you think you could spin the end caps off, pull the end caps and rod out, leaving the cylinder end attached to the boat?

Thats what I was thinking Spare. I've repacked alot of hydraulic cylinders on logging equiptment and other things and if you can leave the barrel in place it saves alot of time and work. I just look up into the barrel ta make sure its not scored up by the piston rubbing the sides. Good luck Lee.

The end of the rods (towards the outdrive) are square like a H they wont let the end caps slide off.

That pin has to slide out but I'm getting conflicting stories from 2 different "volvo marine repair shops". 1 says he's never seen removal of those pins by a grease fitting and the other says that's how it's done.

Without a good repair manual I think I'm fuked.

Lee, I found a parts break down today, it looks like the grease gun thing is the way its supposed to go, I'm getting a Volvo manual from a guy later this week, I'll let you know what it says. BTW, when I was looking atteh parts breakdown, it didn't list a rebuild or seal kit for the cylinders, didn't even have the cylinder broken down.

Ok on the grease fittings does it say approx how much grease pressure needs to be applied?

I think (hope) I can get parts to rebuild from a hyd shop. Maybe the guy on e bay can get them for me.
My local Volvo guy said he has rebuild parts but I'm betting he wont sell them to me, he probably will want to install the parts.

He is kinda a pain sometimes so he may not do either because I didn't bring the boat up there and let them do everything.

I still may have to carry it up there and let him press the pins out, but I'll give it a try first.

on the amount of pressure to the grease fittings, I'd guess a whole freaking lot, plus heat if needed,. it appears that there are plugs and screwws that close in the outward path of the pins. If you can come up with any part numbers let me know, I have a good line on Volvo parts

I have a customer that owns a Texaco Express Lube and he has grease guns where he can turn up the grease pressure so he's going to let me try.

If your manual has a parts breakdown on those pins: I can only see 1 bolt that holds these pins in. Can you scan or take a pic and send it to me?
If not just look at it and tell me if there is another screw or fastener that holds each pin in.

I don't see how I can use heat on the pins, the only way I could get direct heat on them would be on the exposed end (inside the boat) and there's not much room. If I put heat on them they will expand and I will have to let them cool again so that kinda defeats the purpose of heating it doesn't it?

try this
http://www.volvopentastore.com/Genui...view_id.343835


http://www.volvopentastore.com/Dp-Dp...view_id.312359

Spare
I got the hyd hoses off upper 1 in way of the plastic (yellow covers). Removed the yellow covers that keep water out where the grease fittings are. The grease fittings aren't there I guess volvo repair shops have them, they don't come installed behind the yellow plastic covers.

I looked at the schematics you linked but I don't see them for purchase. I was going to try to get the pins out myself but without the fittings I'm dead.

I talked to the local volvo guy and he wouldn't give me a estimate to push the pins out and rebuild the hyd cyls.

should be hard to thread some fittings in the holes, just pisk some up at teh local auto store, I even saw soem at Lowes. My buddy has the manual, just haven't gotten up with him yet. In the scematic, I saw there are plugs(screws) on the outboard side, have you removed them?