Possibly stuck oil pressure relief valve. Help?

[TouringBubble]

I finished drilling and tapping my case the other day. I cleaned it out as best as I could with an air compressor and a rifle cleaning kit. I looked in every passage to make sure there were no slivers or anything and I verified clearance of all the new galley plugs. I tapped a little too deep on the one by the oil pressure switch, but otherwise everything was fine.

I reinstalled the oil pressure valves (I bought a kit with new parts). I noticed that the main valve by the pulley fit really snug. I noticed that there is a slight lip in that passage and thought maybe it was supposed to be a little snug. After installing the one by the flywheel it seems to move a little more freely, which worries me.

I'm concerned that there may have been a tiny sliver in there that's jammed around the valve. I tried to remove it but I'm not sure of the best way to grab it to remove it. I could remove the main galley plug or the full flow fitting to get access from the top, but I would like to try to get it out from the bottom to keep from having to reseal the plug or fitting. Considering trying to use air to push it down, but it's an empty case and I don't know if I could successfully block off all of the passages where the air would want to go.

Any help?

[Stray Catalyst]

The easy way is a magnet on a stick, but if that doesn't do it then you definitely have a problem. drilled and tapped cases get slivers of metal all over the inside - I'm not sure a bore brush and compressed air will get them all, and if even a few are left you have an engine that's going to need a rebuild before it should need an oil change. When I got my case back from the machine shop I pressure washed the oil galleys until I was head-to-toe soaked... then pressure washed it for a few more minutes for good measure. My mechanic keeps a few bearing halves to show the slivers of aluminum that have killed rebuilt engines of cars that get towed to his shop less than a week after their first drive.

In your situation I'd tear it down to case halves and clean the hell out of it. It's a lot of work, but there's nothing as discouraging as a postmortem on a brand new rebuilt boat anchor.

Stray

[FJCamper]

Hi Touring Bubble,

Try running a tap up inside the piston, one that will bite into the hollow (bottom side) of the piston.

It doesn't even hurt the piston, and it's always worked for me.

FJC

[TouringBubble]

I can take it apart and clean it better. That's not a big deal. I guess I'll just plan to do that and get the piston out at the same time.

Should the piston slide in and out somewhat freely?

[Leatherneck]

Should the piston slide in and out somewhat freely?

After a lot of miles it could be harder to get out but it should move but without slop or it's not doing it's job.