bilstein roll pin strength
 

I'm at it again, trying to get the [insert choice expletive here] roll pin out of my front right bilstein shock. I've so far gone through pretty much every punch available to mankind, and broken them all. I've applied heat, beat it with a sledge hammer, you name it, the bastard ain't coming out. I've now got two different chunks of punch stuck inside there, and that's after getting a broken awl tip out already.

I've come to the conclusion that it's time to pay a shop to do this. I've already been at it for 3 (very long) days. Question is, is it safe the drive the car with the roll pin beat to *****? I'd be going about 150km (car is in storage for the winter in the boonies) to the shop I always go to. I could take it someplace closer, but I'm not sure if I trust them. I could have it towed, but that's not cheap. My thoughts are that it *should* be safe, considering I can't get the f&^cker out to save my life, and there's extra chunks of steel in there, but I'd like a second (or more) opinion.

Thanks!
Chris

When I did mine I pounded the pin so much that it started to mushroom the end. I ended up drilling the pin.
I started with the smallest bit that would not fall thru the roll pin hole and went up in size. The thing is I just drilled about half the length of the pin and punched the thing right out. (I guess I loosened the grip of the pin)
I destroyed about 10 drill bits, but I got it out:)

The problem here is that there are pieces of broken punch inside the roll pin, which I can't drill. I used a cobalt bit on it (hardest, toughest bit I could find) and that barely made a dimple in the punch piece.

Any ideas?

just did this job on sat. your car should be okay to drive for the one-time 150km ride. all the roll pin does is keep the fixed end of the insert planted on the a-arm. worse case scenerio is that it moves up in the tube a bit when you hit a bump, then will expand back down to the seat on the rebound. try to avoid any potholes or running over any speed bumps or curbs.

here's how I finally got mine out: '7mm roll pin punch' from mcmaster-carr, bf hammer from home depot (4lb stanley) and a bunch of kroil applied over the last 4 weeks. new poll pins are available from Bilstein by phone in the west coast office, ask for 'small parts'

I removed mine the other weekend as well. I used a finish punch for finishing nails. I hit the pointed end. I used a short handled sledge, was probably 4-6 pounds. The pins were stubborn at first, but then broke free and slid halfway out. I was able to grab the exposed end with a vice grip and turned and pulled.

Dave

Thanks, guys. In searching on this board, I've noticed a lot of people talking about having to buy new roll pins directly from Bilstein, or other sources. The new inserts I bought from Pelican came with new roll pins in the box. Is this a new practice?

I bought my shocks back in November, but sat on them until the last two weekends. Mine came with pins as well. The wrong end of the finish punch was about the same diameter as the pin. Once the pin breaks free it'll slide out with much less force. Wail on it a bit more!

Dave

oh yeah, I also bought a Drill Doctor in case I ran into the problems you are going thru. (best thing since liquid Prell)
here's the thread I started when I was having problems

http://forums.pelicanparts.com/porsche-911-technical-forum/253231-roll-pin-wont-budge.html

Try hammering it out with an air chisel.