In-situ flywheel timing pin replacement

[Alan Kramer]

I've got a need for a creative solution here...   Have a car with a timing
pin that's now only 5mm long.  It should be 12mm.  Problem is that it no
longer passes in front of the crank position sensor so the CPS no longer
picks it up.

I'd like to fix this w/o pulling the tranny.  I have decent access to it
through the starter hole.

Obviously it's a snug fit and a simple pull w/ vice grips ain't gonna work.

I don't think heat would help because it would make both the hole and pin
expand.  I guess liquid nitrogen or something might work, but that's an
unlikely solution.

And the pin's real hard, so breaking it will be easy.  But because it's hard
it'll probably be a pain to drill out in place.

I tried threading it with a 4mm die, but the metal seems to hard to start
threads on.

I also thought one of those nut extractors would work well, but I haven't
been able to find one as small as the pin.  The smallest I've found is
5/16ths (8mm), the pin is 4mm.

The other thought I have is to snap off the pin and weld a cut-to-length 16
penny nail (head against flywheel) over top the broken pin.  It looks like I
have plenty of room to fit my mig gun in there.  Admittedly a "rig" but it
will save me a day or two's worth of work pulling this tranny.

I'd also thought of moving the sensor slightly, maybe I could weld up the
upper sensor bracket hole and re-drill another one a few mm to the left of
the original one.

Any other thoughts?

-----------------------------------
Alan Kramer
http://www.geocities.com/audikramer

'83 CGT 20vt
'86 4kcsq
'90 v8q
-----------------------------------

_________________________________________________________________
Protect your PC - get McAfee.com VirusScan Online
http://clinic.mcafee.com/clinic/ibuy/campaign.asp?cid=3963