How to remove roll pin from 4wd lever - B6200D

[Mot]

The 4wd engagement lever on my B6200 has been twisted since I bought it. The cast part that holds the ball for the detent is distorted and the lever will not stay in position. I bought a new lever but I am unsure how to remove the roll pin. It is painted in. I tried tapping on it a little with a rod but Im afraid to really whail on it or the shaft might get damaged. Heat may damage the seal behind it if there is one.

Anyone have any idea or experience in removing these?

 

[DustyRusty]

The only thing that I can think of is for you to make a jig that will have a hollow tube at one end and a small diameter pin at the other end so as you tighten it will push the pin while the tube at the other end presses against the shaft. If you wanted to sacrifice a C clamp, weld a 1/4" deep socket to one end, and on the other end weld a small 1/4" Allen wrench to the threaded part of the C clamp. In a sense, you are making a miniature hand press to push on the roll pin. There is a special tool for hammering out roll pins but most people are not aware of them and just use a punch. Many years ago I worked in a shop where we needed to make specialty tools for just these types of jobs. Sometimes making the tool took longer than the time it took to make it.

 

[North Idaho Wolfman]

You have to get pretty aggressive with the roll pin to get it out.
I try and support the back side while driving the pin out if I can.
use the right size punch with a flat face.

You could try something like this if you have enough room.

Chain Breaker

Amazing deals on this Chain Breaker at Harbor Freight. Quality tools & low prices.

www.harborfreight.com

 

[MapleLeafFarmer]

I use a punch that I put into a metabo palm nailer and punches them out fairly easily. Air palm nailer cheap about $50

A a battery palm nailer like dewalt or milwaukee probably closer to $200.

 

[Mot]

I use a punch that I put into a metabo palm nailer and punches them out fairly easily. Air palm nailer cheap about $50

A a battery palm nailer like dewalt or milwaukee probably closer to $200.

Thanks to all for all replies. The ideas have me thinking.

 

[Vince1230]

There eas a tool i got to remove my roll pin on a polaris atv. https://www.harborfreight.com/pin-a...IuWZPkEGd2uOvnf0zlrLczyXzTlV4HaxoCWgUQAvD_BwE