I have broken three starboard plungers recently. It appears that when the rudder cam over rotates the plunger squirts out between the cam and the lower casting and breaks the shaft of the plunger off at the head. This is the newer style casting. I have had no trouble with the assembly on the port side. Any recommendations?
Sounds like wear. Basically things have worn down and the holes have gotten bigger so the plunger can do something it was not intended to do.
1) Replace the Cam or if it's new swap side to side.
2) Look at the 2 rudders assemblies, something on the other side is keeping it from have having problems. Try and duplicate it.
Once you figure out what the problem is, post again and I will try to help.
Thanks Carl. The boat is parked on a the beach in SC. It will be a couple of weeks before I get some time with it.
The problem was too large of clearance between the plunger cylinder and the cam. I used tape to form up more of an edge with JB Weld and then filed the whole thing to perfection. Works like a charm now.