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Topic: Tips for breaking loose six pack plungers? (Read 567 times) previous topic - next topic

Tips for breaking loose six pack plungers?

I've got my rear six pack out and the solenoids off but can't get the damn brass rings to break loose. I've tried two different size band wrenches to no avail.

Time for some pb blaster?

1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: Tips for breaking loose six pack plungers?

Reply #1 –
Maybe the other Chuck will chime in. The 2 small holes in the center part with the shaft looks like it takes a small spanner wrench to take them off.
1999 40 ft. U-320 wtfe build 5563 Chuck & Lynda's "Rollin' Inn"  2030 watts solar
prev. mh's 71 GMC 5 yrs. 73 Pace Setter 1 yr. 78 Vogue 5 yrs 81 FTX 40ft all electric 18 yrs. 1996 Monaco Signature 3 yrs.
2014 Grand Cherokee Overland
Dream as if you will live forever. Live as if you will die today.  James Dean

Re: Tips for breaking loose six pack plungers?

Reply #2 –
If you purchase the kits from Tom McCloud, wrench is in kit.
Rudy Legett
2003 U320 4010 ISM 450 hp
2001 U320 4220 ISM 450 hp
1995 U320 M11 400 hp
1990 Granvilla 300 hp 3208T
Aqua Hot Service Houston and Southeast Texas

Re: Tips for breaking loose six pack plungers?

Reply #3 –
Quote from: Rudy –
If you purchase the kits from Tom McCloud, wrench is in kit.
That was the golden ticket! I hadn't even open the kit yet so thanks for putting 2 and 2 together for me.

Per the instructions that Tom included in the kit (banging head against wall), he recommends using channel locks on the brass rings if you can't separate them from the stems. I'm now making quick work of them with the wrench and channel locks
1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: Tips for breaking loose six pack plungers?

Reply #4 –
Are you doing the front or the rear first? I've done the front couple of years ago, when the kit was distributed. I did not do the rear yet, got side tracked :-(
Former 2003 GV U295 (6230) (2015 - 2025)
Former 94 GV U225 (2013-2016)

Re: Tips for breaking loose six pack plungers?

Reply #5 –
Quote from: propman –
Are you doing the front or the rear first? I've done the front couple of years ago, when the kit was distributed. I did not do the rear yet, got side tracked :-(
Ultimately both but i've started with the rear as practice because It's easier to get to
1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: Tips for breaking loose six pack plungers?

Reply #6 –
Yeah twig told me channel locks would do it. We were going to do my front one in Mexico and didn't have time one of these days I need to do it cuz I have a leak on one of them. Also twig does them under the coach without taking the entire six pack off. Seems like an easier way to do it to me and that's the way I'm going to try to do it if I ever get around to it.
Bob
'99 U320 40 WTFE
Build #5462,
1500 Watts Solar 600 amp Victron lithium
2012 Jeep Grand Cherokee Overland Hemi
Instagram bobfnbw
Retired

Re: Tips for breaking loose six pack plungers?

Reply #7 –
One of the key parts of the kit is the plunger.  It can only be replaced if body is removed from manifold.
Rudy Legett
2003 U320 4010 ISM 450 hp
2001 U320 4220 ISM 450 hp
1995 U320 M11 400 hp
1990 Granvilla 300 hp 3208T
Aqua Hot Service Houston and Southeast Texas

Re: Tips for breaking loose six pack plungers?

Reply #8 –
I can tell these had been rebuilt before. The stems are marred where they used channel locks en lieu of the wrench.

1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: Tips for breaking loose six pack plungers?

Reply #9 –
FWIW.  Too late now, but I found the best sequence for disassembly was:

1.  In Elliot's photo (first post):  While all the brass valve bodies are still firmly screwed into the aluminum manifold, use the little spanner wrench from Tom's kit to break loose the inner stainless shaft assemblies.

2.  After all the inner pieces are loose, THEN unscrew the brass valve bodies from the manifold.  I was able to get them all off using a rubber strap wrench, but if that doesn't work you can resort to the channel locks.

1993 U280 SE 40' WTBI, Build: 4359
C8.3 300hp, 6-Speed, Exhaust Brake
960 watts on the roof (6 x 160)
Sorento (or BOLT) on a Kar Kaddy SS
"Nature abhors a vacuum"

Re: Tips for breaking loose six pack plungers?

Reply #10 –
I did it by disconnecting the ground and plug, then using channel locks on the knurled body removed the whole assembly and rebuilt it on a table. Then screwed the complete rebuilt unit back onto the manifold with channel locks. The hardest part was all the blasted cable ties.
1994 U280, Build 4490
Deming, NM.

Re: Tips for breaking loose six pack plungers?

Reply #11 –
I checked all the solenoid's for continuity but before putting them back I still wanted to make sure that they were all working. So without further ado, I present to you my solenoid test station:

1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: Tips for breaking loose six pack plungers?

Reply #12 –
Quote from: Elliott –
I checked all the solenoid's for continuity but before putting them back, I still wanted to make sure that they were all working. So without further ado, I present to you my solenoid test station:


Kinda a expensive power supply looking good

Re: Tips for breaking loose six pack plungers?

Reply #13 –
Quote from: Elliott –
I can tell these had been rebuilt before. The stems are marred where they used channel locks en lieu of the wrench.

That could just be if 2 of the o-rings were replaced before.  That's a pretty common air leak repair.  The kits from Tom are a more comprehensive project.

Prior to some work by members of the forum and Tom's kits, I don't believe anyone "tore into" the valves themselves.  Certainly not FT.  O-ring replacement was fairly common (HWH sells a kit of 12 per six pack - RAP6554) and there's an entire thread on what the common sizes are), and if that didn't fix the leak, the entire valve/solenoid assembly was replaced.  Just 1 assembly costs more than an entire six-pack kit from Tom, one major reason for the enthusiasm about his kits.
Learn every day, but especially from the experiences of others. It's cheaper!  - John C. Bogle

2000 U320 36' non-slide / WildEBeest Rescue
2003 U320

Re: Tips for breaking loose six pack plungers?

Reply #14 –
I did my rear 6 pack yesterday in same fashion as Chuck mentioned in reply #9.  His tutorial on rebuilding them is the best.

jk
Jack and Cathy
1992 U280 Unihome 36' Build #4034
Cummins 8.3 /  Allison MT647/ PacBrake
Apopka, FL / Barre Center, NY