Removing Benelli G2 seized piston from jug

I have a piston on my Benelli G2 that I can't get out of the jug. I think there was moisture in it as the engine was stored away. I'm afraid I will have to cut the connecting rod in half to get the piston off and then replace the rod, piston, and jug assembly. Does anyone have a suggestion on how to remove the seized piston before I make a drastic move.

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Re: Removing Benelli G2 seized piston from jug

Don't cut the rod. Block any ports and let it soak for a while. Kroil, pb blaster, acetone-atf mix, marvel mystery oil, take your pick. Then put a block of wood between the cylinder base and crankcase (Since it's at bdc) and use a block of wood and hammer to knock the piston out. It really only needs to move another half inch or so and then you can take out the piston pin.

Re: Removing Benelli G2 seized piston from jug

haha.....i had the same thing all typed out. copied it to check, and see if anyone had commented before i could. sure enough he beat me to it...so yeah what saabsonettguy said...

Re: Removing Benelli G2 seized piston from jug

puller anchored to the studs, or a press - there is plenty of room to support the jug and press it out.

Re: Removing Benelli G2 seized piston from jug

Tri-ped Dave O.D.B. /

All of the above advice is great and I have done all. Rarely, as a last resort, I got out the torch and heated it to glowing and out she popped.

Re: Removing Benelli G2 seized piston from jug

Angry Hipster /

You don't even need to use a torch, soaking with oil and heating it up with a heat gun works and is less dangerous/damaging. I've even left the tip of the heat gun in the cylinder for a few minutes to heat the hell out of it.

Then you can hit and free it.

Re: Removing Benelli G2 seized piston from jug

Pushrod Fifty /

Most of the time the rings have indented and rust fused to the cyl wall. Heat gun and pb blaster many times over. I use large diameter dowel rod cut about 6 in. Long to hit the piston. Refasten the jug first, using copper pipe to take up the stud slack. If the engine moves around too much to get a good hit, two large angle braces with a bolt thru the motor mount, that will hold it screwed down to a bench.

Re: Removing Benelli G2 seized piston from jug

consider yourself lucky, that piston/rings are at bdc instead of tdc. not too far to go.

Re: Removing Benelli G2 seized piston from jug

solid block of wood and hammer

Re: Removing Benelli G2 seized piston from jug

Thanks for all the suggestions. One of them should work for me. I'll let you know how things turn out..........Sandy

Re: Removing Benelli G2 seized piston from jug

so did you ever get your piston out?

I'm in the same boat and tried all the suggestions with no luck?

I took the drastic route and now need a new cylinder and piston, been checking for 3 days and have come up short, need some help....

Re: Removing Benelli G2 seized piston from jug

> Robert Parr Wrote:

> -------------------------------------------------------

> so did you ever get your piston out?

>

> I'm in the same boat and tried all the suggestions with no luck?

>

> I took the drastic route and now need a new cylinder and piston, been

> checking for 3 days and have come up short, need some help....

Soak it in marvel mystery oil (or pb blaster if you don't have any, but mystery oil is way better)

Then take a piece of wood that will fit in the cylinder, put it against the piston, and hit the fuck out of it. That will free it up, guaranteed.

Re: Removing Benelli G2 seized piston from jug

♣Slew Foot♣ /

Aero kroil the aliens use it to clean the cattle mutolators...

You will never use pb blaster again or wd40.

Re: Removing Benelli G2 seized piston from jug

I did get my piston removed finally. I had to take it to my local machine shop and he was able to press it out of the jug for me. The rings were seized to the piston which had a crack on the top so they can't be used again. But I saved the wrist pin, connecting rod, and crankshaft to use later.......Sandy

Re: Removing Benelli G2 seized piston from jug

> ♣Slew Foot♣ Wrote:

> -------------------------------------------------------

> Aero kroil the aliens use it to clean the cattle mutolators...

>

> You will never use pb blaster again or wd40.

Just so you all know, all kroil is the same. aero kroil just comes in a aerosol spray can. And yes its the best ive ever used. One can mix up a generic form of it with 50-50% acetone and automatic transmission fluid.

Re: Removing Benelli G2 seized piston from jug

Or take a grinder and cut the jug and pry open with a chisel. Just did this the other day with a vw engine.

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Re: Removing Benelli G2 seized piston from jug

fuck

Re: Removing Benelli G2 seized piston from jug

> Born to be WillD Wrote:

> -------------------------------------------------------

> fuck

Right? Shit everywhere.

Re: Removing Benelli G2 seized piston from jug

Maybe that was the wrong way around that bush ?

Re: Removing Benelli G2 seized piston from jug

Haha I know it is drastic but got the job done. Gonna take everything apart and rebuild so no biggie. I'm sure the OP could have done the same and packed the case with rags and duct tape and no debris would have entered the cases. Would have only cost them a cutting disc instead of a trip to the machinist. No damage would have been done to the crank.

Re: Removing Benelli G2 seized piston from jug

♣Slew Foot♣ /

I've used a slide hammer on a stuck Sachs jug got the wrist out. Another used a frame straightener and seat belts bent crank tho.

Re: Removing Benelli G2 seized piston from jug

im pretty sure the press crushed the piston, which leads me to ask? with all this good advice here, did the op even try? annoying.

Re: Removing Benelli G2 seized piston from jug

I have done the block of wood thing but never feel great about bashing on the thing if you want to make sure the crank is not damaged. I usually do the croil soak for a few weeks and if that don't work out comes the grinder, muahaha!

Re: Removing Benelli G2 seized piston from jug

♣Slew Foot♣ /

I tried the water in the jug and freezing split jug.

Re: Removing Benelli G2 seized piston from jug

> Steve Dolan Wrote:

> -------------------------------------------------------

> I have done the block of wood thing but never feel great about bashing

> on the thing if you want to make sure the crank is not damaged. I

> usually do the croil soak for a few weeks and if that don't work out

> comes the grinder, muahaha!

When you block up and pound on an otherwise junk seized piston be sure you're doing so above bottom dead center, otherwise yes you will fuck up a crank or rod. Once the piston breaks free and starts to move you will need more blocks.

Re: Removing Benelli G2 seized piston from jug

> Steve Dolan Wrote:

> -------------------------------------------------------

> Or take a grinder and cut the jug and pry open with a chisel. Just did

> this the other day with a vw engine.

Please tell me your just trolling.

Re: Removing Benelli G2 seized piston from jug

> Brandon Love Wrote:

> -------------------------------------------------------

> > Steve Dolan Wrote:

>

> > -------------------------------------------------------

>

> > Or take a grinder and cut the jug and pry open with a chisel. Just did

>

> > this the other day with a vw engine.

>

> Please tell me youre just trolling.

Re: Removing Benelli G2 seized piston from jug

> pat splat Wrote:

> -------------------------------------------------------

> im pretty sure the press crushed the piston, which leads me to ask? with

> all this good advice here, did the op even try? annoying.

perhaps sandy does not feel comfortable beating that engine with a sledge. nothing wrong with paying to use a press. how much could it cost? (I own a press)

Re: Removing Benelli G2 seized piston from jug

> Brandon Love Wrote:

> -------------------------------------------------------

> > Steve Dolan Wrote:

>

> > -------------------------------------------------------

>

> > Or take a grinder and cut the jug and pry open with a chisel. Just did

>

> > this the other day with a vw engine.

>

> Please tell me your just trolling.

No this is a pic I took the other day when I sliced off the cylinder.

Re: Removing Benelli G2 seized piston from jug

> el pollo Wrote:

> -------------------------------------------------------

> > pat splat Wrote:

>

> > -------------------------------------------------------

>

> > im pretty sure the press crushed the piston, which leads me to ask?

> with

>

> > all this good advice here, did the op even try? annoying.

>

> perhaps sandy does not feel comfortable beating that engine with a

> sledge. nothing wrong with paying to use a press. how much could it

> cost? (I own a press)

the point is money, if we all could pay someone why freekin buy a press, dont need it just pay someone that has it to tear your project up, why have any tools or any tools or experience, throw the stupid hammer out and pay someone elese...why even ask here for help, totally annoying.

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