Pedal Box rebuild, roll pin question revisited.
 

A month ago I posted about having a replacement roll pin that would not even start let alone fully insert. I tried all the normal tricks, compressing with vide grips, grinding a more extreme beveled edge (thanks for the tip John Walker), and even freezing the pin. No luck.

I had to walk away to the project due to the same life altering circumstances many others are dealing with during this crisis. It looks like I will be able to get back to the 911 this weekend but before I try again, or break something, does anyone know the correct diameter for the roll pin? I'd like to make sure I am not trying to force the pin if it won't work or fit anyway.

The pin I have was sourced as part of a pedal box rebuild kit and at least one other part in that kit was not correct so I am wondering if this roll pin is simply too large.

Thanks in advance for all responses.

I remember reusing the old pin once or twice. JW suggested grinding off the tip of the new pin and using an air hammer to drive it in.

The pin is tapered I believe, so its not like you can just go get another one of smaller diameter. Also, its not supposed to just drop in so some force will be required.


You know its possible you got a totally screwed up pin! Maybe order a 2nd one and compare?

The pin is made of a flat strip of spring steel rolled up.

Soak it in light oil to reduce friction between the turns.

Line it up and press it in.

Bevel is good, hammering is not.

Years ago I quit using the roll pins and opted for a capscrew with a nylock nut on the back side after my own car sheared a roll pin on the track. Not having a spare, I rummaged through one of the track boxes and found a bolt that fit, then backed it up with a nylock nut. Since then I quit using the roll pins, even on customer cars. I've NEVER seen the bolt fail.

Did you find that the bolt has a small amount of play which gives the pedal a dead zone?

None, zero. I don't remember offhand what size the bolt was (6mm?), but I used a bolt with the unthreaded part long enough to fit correctly through the holes, then installed the nut and trimmed the rest of the bolt.

Mind you, this was the second roll pin that sheared on my own ride. Something else needed to be done besides putting in a softer clutch. ;)

Brian, if this is for the clutch pedal of your 71 T, it requires a Spiral Pin (Spiralstift), not a common roll pin.
A spiral pin is rolled beyond 360°, and is much stronger than a roll pin.

Have you tried to order the genuine pin from Porsche? The part number is 999.095.003.00.

Heads up, host shows that superseded to 900.309.002.00:

https://www.pelicanparts.com/More_Info/90030900200OEM.htm?pn=900-309-002-00-OEM&bt=Y&fs=0&SVSVSI=0817