Cody 283 #1 Posted December 29, 2025 I'm currently in the process of rebuilding the pump on my 702. Of course both ends of the spring were broke off and stuck in the holes. The edge of one hole was enlarged a little from the broken spring constantly rotating over it. The second hole really didn't suffer any damage. The one with the enlarged hole I was able to get the rest of the spring out with a little compressed air, the second one I wasn't so lucky. I fought with it pretty much all day, finally decided to take the beginning of the hole out one size bigger and lucky enough was able to get the spring out. My question to everyone is what's your thoughts of the importance in hole diameter? The first 3/16" of the hole is approximately .0030 larger in diameter. Do you guys think that will be an issue? The holes are quite deep and I assume it would be ok but if everyone thinks it'll be an issue I will make a bushing for the top of each hole. I saw on another post where they used brake line to do that and looked like it worked well. 2 Share this post Link to post Share on other sites
Achto 30,322 #2 Posted December 29, 2025 I don't think that it will be a big issue. I would put a new spring in and carry on. 1 Share this post Link to post Share on other sites
Cody 283 #3 Posted December 29, 2025 I appreciate your input, I think that's the route I'm going to take. If it turns into an issue In the future I'll address it then. The more I thought about it the less crucial it seemed, ultimately it just holds a spring. Sometimes I overthink the simple things 2 Share this post Link to post Share on other sites
sqrlgtr 1,573 #4 Posted December 29, 2025 How do we know you're really rebuilding HY2 unit without pictures? Share this post Link to post Share on other sites
adsm08 3,921 #5 Posted December 29, 2025 (edited) My experience with this issue is as follows: A little drag damage, and a slight increase in the size of the hole is no big deal. A lot of drag damage, or a large increase in the size of the hole is a problem. Too much enlarging of the hole can allow a new spring to escape. The pump head that was on my 855 when I got it had this issue, and even with a new spring it would not stay in properly. I tried several things to fix it, mostly various forms of building a bushing out of tubing, but was never able to make anything stay correctly. I may revisit the issue again this year, but I have since acquired a couple other pumps that haven't been damaged by broken springs. Edited December 29, 2025 by adsm08 Share this post Link to post Share on other sites
Cody 283 #6 Posted December 31, 2025 (edited) I have few pictures I look along the way I'll get posted soon, but I ran into an issue, I can't get the spool valve back in the bore. When I took it apart I was able to get it out without an issue. I oiled everything up before reassembling but cannot get it to go in nicely without tapping it in with a mallet. When is fully instilled you can barely move the lever. The bore looks perfect and so does the spool valve. No signs of anything rubbing it's like the tolerances are just that tight. Am I missing something here? It was free and smooth working before, nothing's changed but the o ring and I even put the old one back on with the same results Edited December 31, 2025 by Cody Share this post Link to post Share on other sites
adsm08 3,921 #7 Posted 10 hours ago 3 hours ago, Cody said: I have few pictures I look along the way I'll get posted soon, but I ran into an issue, I can't get the spool valve back in the bore. When I took it apart I was able to get it out without an issue. I oiled everything up before reassembling but cannot get it to go in nicely without tapping it in with a mallet. When is fully instilled you can barely move the lever. The bore looks perfect and so does the spool valve. No signs of anything rubbing it's like the tolerances are just that tight. Am I missing something here? It was free and smooth working before, nothing's changed but the o ring and I even put the old one back on with the same results IIRC that bore is tapered and installing the valve from the wrong direction can cause all sorts of issues. Take it out the way you originally removed it and then put it back in moving in the same direction. Share this post Link to post Share on other sites
Cody 283 #8 Posted 10 hours ago I read every post I could find on here before I rebuilt this and I did see where people said it was tapered so I took note of that on disassembly. I made sure it went in the same way I took it out. I was able to take it out by just pushing on it with my fingers, I didn't have to tap on it or anything like that. I even measured the spool before installing it. The one end is roughly .003-.004 larger the the other. Like I said there's not even a whiteness mark of it hitting somewhere. It has me stumped Share this post Link to post Share on other sites
sqrlgtr 1,573 #9 Posted 9 hours ago Just thinking out loud here but is there any way it be caused by hydraulic or air pressure? Share this post Link to post Share on other sites
