That's a solid plug with an O-ring around the perimeter to seal.
I've removed them by lightly smacking the piston body against
a cavity (so the plug can move while the piston body is stopped
suddenly). Obviously, this is crude and you risk damaging
the piston body.
With age, the O-ring is probably glued to the piston body. Maybe
you can push it in a little to break the bond, then it'll pop out with
some gentle smacking against wood.
I'll try to think of a better way, but that's what I've done in the past.
If you want to drill a hole and tap it, you might be able to seal it
up with JB Weld. It's held in place by the triangular piece that
holds the vacuum canister to the piston body.
bs
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Bob Spidell San Jose, CA bspidell@comcast.net
'67 Austin-Healey 3000 '56 Austin-Healey 100M
***************************************************************
Subject: Servo Disassembly
> 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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