I never had that much of a problem on the 700s on the relief valve plunger,more problems on the 500s but basically the same thing.Seems he shouldn't have to pull the engine with all the tools out there.https://www.lowes.com/pl/Screw-extra...ols/4294607735 along with angle head drills and specialty pullers that the tool trucks carry,but he's the one doing it,not me.

 

OPT, my guy got the plunger out. But, I'm now being told that the bore is out of round, causing the new plunger to catch and cause issues. No fixing this, only buy a new case. Does this sound right?

 

Possible,but I'd still get a new relive valve plunger and see how it does. A new case and labor if you let them do is a high dollar job.

 

New plunger and spring didn't fix it. It is back in my garage now. I replaced the plunger with two 8mm ball bearings -- seems to have fixed it for now. Still playing around with this though.

 

Granted bearings have been used in other brands for years,but I'd check that it's holding oil pressure that the manual calls for. At 5500 rpm should be an average of 39 psi with a minimum of 35 psi.

 

OPT, oil pressure above idle is good. I'm at 40-45 PSI at 5500 RPM when the motor is hot (fan running).

Now, what should my hot idle pressure be? I can't find that in my service manual. Seems I'm at about 4-5 PSI.

 

Manuals don't show idle pressure on the 700/800, just 35-39psi at operating temperature.