Impossible to get the roll pin in the pedal cluster to move....
 

I am in the process of rebuilding my pedal cluster with bronze bushings. However, I can't get the roll pin that holds the clutch pedal in place out. I have tried drilling, but I have not succeeded in drilling all of it out. I have tried heating it up and then smashing at it with a punch and a big hammer. I have tried the mechanical press I have in my garage, but it is impossible to get the pedal cluster orientated properly for it to work.

So, can I just use a grinder and cut a slot in the pedal, and just weld it back afterwards when I am done? Or will this not work? I am really sick and tired of this now, have spent two days on the damn thing...

I have never had a problem with it. You may need a work buddy to relieve you when you are tired of it.

Did you try anything like PB blaster?

I would not cut it. Let one of your buddies take a fresh look at it. You may be spinning your wheels. I did this same job in my garage and again at the track. The track was tough as we had no vise to lock it into but we made do. We've all been there on these smaller type jobs. Take a step back and regroup. Hold off on the radical measures!

Hang in there!!

I dealt with the exact same problem a couple of weeks ago. I could not punch/press the pin out no matter what I did. Tried to drill it out - broke 2 bits, with the last one firmly stuck in the pin, further wedging the pin in!

I sprayed the pin with more WD40, went away for a few hours, came back, took the punch tapped on one end (with broken bit), then a few good whacks on the other end and poof, out the f**ker comes!

Patience! It'll come out with gentle persuasion.....

Drill out the pin. Make sure you drill from the right direction so that the edge of the roll pin does not grab your drill bit and break it. Start small and progressively get larger.

Then clamp the clutch cable end in a vice. heat the clutch arm lever at the base where it meets the shaft until it is cherry red. You will need a MAP or Oxy/acetylene torch to do this. Then use a drift to cool the center rod section. Repeat the heat/cool cycle 2-3X and then simply twist off the clutch arm. This has always worked for me on even the most stubborn parts.

Thanks for all the advice! :) I have drilled from each end so far that the part of the pin remaining is only on the axle, not on the pedal. So I will try with WD40, let it soak over night, and tomorrow try heating/cooling as jpnovak suggested. Hopefully it will come off tomorrow. ;)

I have never had to drill one of the pins out...maybe I'm just lucky. My trick is to soak it with PB Blaster and then with a flap sander or a dremmel grind off one end of the pin flush with the clutch arm. Then when you apply the drift and the hammer to it, it will not mushroom out and bind in the arm.

BTW make sure that you use a correct roll pin when reassembling it. I have seen more than one kit which did not have the right pin in it. The correct roll pin looks like a rolled up newspaper from the end view perspective. An incorrect pin is an open "C" shape. These can fail over a period of time with some very, very unfortunate results.

that's why shops have air hammers. you just need them sometimes.

use very HIGH quality drill bits (Milwaukie is what I used) and drill just a tad out of the center with each pass - use a lube on the bit

the freaking pins are hardened & a mess

then beat or press it out - using a jig to hold the thing where yo can get at it

most importantly, you have to have a stubborn mentality -- if you lack the genetic defect of Scottish Stubborness you will have to cultivate a "I WILL pull thes #$%^&* badger out of its hole" attitude.

Good Luck

Maybe a stupid question, but do you removed the cluster? Because I cannot understand the problem of orientation at a press...

Yes, you have to remove the cluster from the car. The awkward shape of the assembly along with the position of the pin makes it difficult to use a press on the piece.