Started to rebuild my BJ8 servo today. Now I know why they cost so much
to have one rebuilt. Spent all day (50% looking for what ever
infrequently used tool I needed) getting it almost apart. The casting
broke where the screw that holds the little air cleaner goes, but J-B
weld should hold that guy on OK. Everything else is apart and I've
coated the chamber with the dry lube spray. Only one more problem, how
the heck do I get the plug out that holds the piston in the top part of
the cylinder. The lower three sided one broke apart and came out under
protest, but a new one comes in the kit. That metal plug is supposed to
be pushed inward to release the T thingy that moves the little plastic
valves up and down. It pressed in, but with a brute amount of pressure.
The instructions say bend a piece of 1/8 wire and push the plug and
piston out. NOT! Maybe when the unit was brand new and they wrote the
instructions, but not now. I was thinking of drilling a couple small
dimples in the plug and using needle nose pliers to try to turn it in
the bore. I have it soaking overnight and will try compressed air
tomorrow first. If worse comes to worse, could I drill a hole in it and
use a tapping screw to pull it out? How would I seal the hole? J-B weld,
but will it be against any brake fluid? or does that part stay dry as
long as the piston seals are good?
Any suggestions welcome.
Dave
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