Re: FastTrack Tilt Trim Cylinder Cap Seal Replacement
Your cap looks a little different than mine off my 1993 40HP, but similar. I rebuilt mine last fall using an Evinrude seal kit. None of the parts were labeled, I compared them to the parts I removed to figure out what was what. There was one o-ring or two around a screw that was confusing but so far no leaks, and it works good.
The wiper on mine seemed to be held in with just the pressure around it. It was hard metal coated with a rubber type material and had to be pressed into the cap to fit. I use a small plastic hammer.
Here I'm removing the inner seal retainer. The inner seal, what your picture questions as an "o-ring" is the second part from the left in my parts pic below. The inner seal is a thick, square-edged flexible rubber seal. The seal is inserted by just bending it so it fits in the hole, sliding it down, and letting it re-expand in the groove. It was square shaped, so make sure it isn't kinked. I'm not sure if it had an bevel to the edges or not. The seal retainer is a split-ring design that you pull apart to fit in below the seal. When the retainer is in there, the seal will be snug enough to stay put.
The parts on top are new, bottom are what I removed. All came from the cap alone.
Left to right: cap o-ring, inner seal, inner seal retainer, upper seal (wiper)
Assembled
