Trim Cylinder Rebuild Kit - Brace yourself this explanation is long but narrows down the info onto this one page.

For Volvo Penta Cylinder 3860881 (Metric/Imperial Variants)

Compatibility

Fits the following drive models:

• DP290 (all types), DP-B, DP-C, DP-D, DP-E, DP-G, DPX

Suitable for repairing all 280 and 290 trim rams, including the later 3860881 cylinders.

Kit Contents

• New anodised aluminium end cap

• Pre-installed dust and pressure seal

• Upgraded bidirectional seal (improved material for easier installation and durability)

• O-rings and full seal set

(Cylinder assembly shown in images is for reference only)

Fitment Guidance

• Early end caps DO NOT have a machined groove as they DO NOT have the return spring inside of the cylinder and the rams mostly use imperial threads.

• Early rams have Forked end Square rams (872612, 270–early 290 drives):  imperial threads.

• Later metric caps  have the machined spring groove and measure 39.80 mm over the outer diameter of the thread.

• Singular Round end rams for the pin  (DP-B, DP-C, DP-D, DP-E): Mostly metric threads, but some imperial-thread exceptions on later models.

• DP-G (late 1990s/early 2000s with KAD300): Often are imperial threads, with 3/8” piston securing bolts instead of M10. Also have singular round end rams for the pin

• DPX: Generally metric some later models have imperial thread cross over production caps

Important Notes

• Volvo Penta never listed these cylinders as repairable parts, so the metric/imperial variations were undocumented. Around ≈90% of 3860881 cylinders are metric; the remaining ≈10% are imperial due to crossover production on later rams manufactured in the late 90's to early 2000's. As there is no definitive point that these rams changed from metric to imperial, they will require measuring.

• • The biggest clue is the piston securing bolt,
    If this is an imperial 3/8" bolt the end cap will likely be Imperial,
    If the Bolt is a metric M10 bolt then the end cap will likely be Metric.

    The End Cap measurements
    Imperial: ~1.57" (1 9/16"), groove for spring, 3/8" piston bolt.
    1 9/16" 18g - 18tpi (threads per inch) thread has a basic major diameter of 1.5625 inches (39.688 mm)
    The hole for the piston securing bolt will allow a 3/8 bolt to pass through, the hole is too small for the M10 shouldered bolt that comes with a metric assembly

  • Metric: M40 x 1.5mm overall diameter (39.80 mm), , M10 piston securing bolt. 

• Some aftermarket kits have incorrect threading and only engage partially. Our End Cap kits are made to OEM specification for a correct fit.