xr4tic

Called up Stratmosphere, told them I had an old Forge BPV, and I needed the update kit. They said no problem, they'll send it out right away, FREE of charge (sent via USPS)

The kit contents:
<a href="http://johnbaas.dyndns.org/2point0/forge_rebuild1.jpg"><img src="http://pictureposter.audiworld.com/12130/forge_rebuild1_lo.jpg"></a>
Aluminum piston, two o-rings, and some Mobil 1 grease. You will need to supply the 3mm allen wrench to take it apart (simulated wood grain table also not included)
The BPV's are all the same on the inside, so one kit fits all.

Taking it apart:
<a href="http://johnbaas.dyndns.org/2point0/forge_rebuild2.jpg"><img src="http://pictureposter.audiworld.com/12130/forge_rebuild2_lo.jpg"></a>

Remove the six screws. Careful on the last screw, the housing top is spring loaded, and could send parts flying to dark recesses of your garage.
You can hold it shut with your hand, remove the last screw, then slowly let it open.
Please note the order of assembly.

Piston comparison:
<a href="http://johnbaas.dyndns.org/2point0/forge_rebuild3.jpg"><img src="http://pictureposter.audiworld.com/12130/forge_rebuild3_lo.jpg"></a>

Make sure you clean the housings out good, remove the two o-rings, then install the new ones.

Lubing it up:
<a href="http://johnbaas.dyndns.org/2point0/forge_rebuild4.jpg"><img src="http://pictureposter.audiworld.com/12130/forge_rebuild4_lo.jpg"></a>

There wasn't any instructions, so I applied lube everywhere, the sides of the piston, the sides of the housings, even the ends of the spring. I also put some where the housings meet, as there is no seal there.

Assembly is reverse of disassembly.


This can probably be done in the car, but it's much easier with the BPV out.

Lucas_Gchips

Aluminium Piston!!! That will get jammed when it gets hot.

Andy_FL

Thanks!

WJM

Lucas is right that thing is going to BIND!!!

xr4tic

It wouldn't be much of an upgrade if it was worse.

I think binding was a problem with the original piston, maybe this just binds less?

Who knows, I'm thinking of going with a BOV anyways - that is, if I go with an aftermarket EMS.

Toaster29

the friction AND sealing surface. Its just asking to leak/get stuck, etc....