Date:         Sun, 12 Jul 2009 15:18:42 -0700
Reply-To:     Jim Arnott <jrasite@EONI.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jim Arnott <jrasite@EONI.COM>
Subject:      Wasserboxer piston pin removal
Content-Type: text/plain; charset=US-ASCII; format=flowed; delsp=yes

Another technique for the archives:

Fortunately it was number 4 so there was lots of room to work....
(should work the same on number 2 as well)

Searched the archives and found a couple good tricks.  Usually
requiring one the somehow get a nut started on a threaded rod between
the cylinders.  My fingers are too big. After messing with it for
twenty minutes I ran down to the hardware store and got the following:

6" long 3/8" x 16 bolt
3/8-16 nut
(2) 3/8" fender washers
2" 3/16" square key stock

Come home and apply the bench grinder to the head of the bolt.  Just
knock the corners off and it'll be close. You want it so it just fits
through the hole in the piston pin. (You DID remove the circlip, right?)

Slide bolt head first through pin. The head will drop down over the
far end edge of the pin. Slide key stock into pin next to the shank of
the bolt. That'll hold the head down. Add the fender washers and an an
appropriate length 3/8 drive socket (9/16 shallow was right for me.)
Add the nut and carefully tighten being aware of what the washers are
bearing against.

Getting the pin out took less time that the telling....

Jim