Hi Tim - A rebuild is definitely a practical option, and not difficult at all. The key is removing any burrs in the valve holes so you don't cut the o-rings on the spring retaining plugs when you insert them. It only takes a hairline mark on the o-ring to cause them to fail. First - are you sure of your .944 measurement? I've done a number of them, and have only seen .91 and .98 pistons. My Vapormatic parts book shows your valve chamber numbers take .98 pistons. (This doesn't mean I have seen them all! Nearly every week somebody on the site here tells me something new about these critters. I've got a dozen of them, started my first overhauls in 1976, have been through them all now, but still learning. I thank my lucky stars for folks like Big Dean, John(UK) and David P!) There are two valve chambers shown in my 165 book (same pump as the 135). The difference is the top plug and retaining ring. One has a flat topped plug , conventional square section snap rings to hold in the plugs, and square grooves in the valve chamber for the ring. The other valve chamber has chamfered shoulders on the top of the plug, a wire retaining ring, and a round bottomed retaining groove. The parts book is not clear which is the later configuration, but I think it's the wire retaining rings. Either type fits the side plates and pistons, as long as the plugs and snap rings match the chambers. I mixed them once, (square section snap rings on chamfered plugs in the round bottom grooves), and two of the rings fractured and blew out. I tried refacing seats, and valve chamber ball valve replacement kits. Neither was satisfactory. The last valve chambers (new, aftermarket) cost me only $50 each - by far the best way to go. So 2 new valve chambers, a valve kit and an o-ring kit, maybe new pistons and rings, and you will be back in business - a lot cheaper than a complete pump.
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