Restoration of 74 TCS - 044615R

[GavinT]

Yes. I've managed to drive it in pretty tightly. I can twist it with the vise grips but no pulling out. I went to HF and got a kit with a selection of punches that have a little tip. No luck moving it from below with the other punch still stuck.

Just a couple of thoughts.

Given you can twist it with the vise grips, that's pretty positive.
Any chance of twisting the vise grips while levering under the vise grips with say, a tyre lever?

Support the u-joint yoke with a block of wood. This allows the force of the hammer blows to go where it's needed without stressing the output shaft etc.

Other options if worst comes to worst:

1. Break off the punch and proceed from the other side. The punch remnant may be too jammed in there to push all the way through from this side. Punches are cheap enough.

2. Weld a nut on top of the punch and use a slide hammer . . if you've got one of course.

[dakazman]

I like where Galvin is going however can you drill down into punch?
If so thread the hole and put a machine screw in a dent puller and pull the punch out.
Dakazman

[jbcollier]

A punch is usually hardened steel and not easily drilled.  You would have to anneal it first which is not easily done in its current location.

[4129R]

When looking from the other side, how big is the hole in the pin?

Is there enough room to get an old drill, or the pin from a pop rivet, or something similar in the hole to bang the punch back out?

Getting the punch out should be easier than getting the pin out.

[racurley]

I'm going to try levering it with a short tire iron while twisting pulling. Will see how that works.

[dakazman]

Racurley,
I did ok some time to think about this and noticed that the hole you have the punch stuck in is slightly 
onboard of the case itself, with that said is the punch wedged next to the case? The picture does not have a top down picture.? If it is you may want to use a die grinder and cut off the punch just below that point. Then try to grab it with vice grips . You may also want to notch the punch and use a claw hammer to lift it out.
Dakazman

[dakazman]

Sorry, I hate spell check and need to read my posts before sending.

Let’s just say I thought about it,...is the punch hitting the case? Was supposed to be inboard not onboard.
Then please read on.
Dave

[GavinT]

Sorry, I hate spell check and need to read my posts before sending.

G'day dakazman,

You realise you can edit your posts, right?

[racurley]

Finally!  I turned the axle back about 45 degrees to get the punch off of the transmission, put some 3 in 1 oil on it and them twisted and pulled with the visegrips for about 5 minutes.  Yay!  I tried it Wednesday night with the crowbar and managed to smash my knuckles on the chassis.  This twist and pull method only caused minor back pain.   

Going to use the punch that's next to the one I just removed to hammer it out from below.  I have a 2.5 lbs hammer which will hopefully do the trick.  Will provide an update on success or failure (hopefully not) later.  Thanks for all of the advice.

Finally by acurley, on Flickr

Finally by acurley, on Flickr

Finally by acurley, on Flickr

[BDA]

 

[4129R]

I tried it Wednesday night with the crowbar and managed to smash my knuckles on the chassis. 


Spanner rash. Quite normal for Lotus repair work.

My arms and hands look like a battlefield after most weekends working on them. At times it looks like I am a heroin addict.

[racurley]

Ok, that was pretty easy to remove from below when you hit it from the end with the pin (smaller hole) using a 3/16" punch.  I used the HF punch since it has a pointy end to keep it in place but, about halfway through, it got a little stuck and the drift bent.  Finished it with the 3/16" punch I got from HD.  Here are some closeups of the roll pin.

Untitled by acurley, on Flickr
Untitled by acurley, on Flickr
Untitled by acurley, on Flickr
Untitled by acurley, on Flickr
Untitled by acurley, on Flickr
Untitled by acurley, on Flickr

[Grumblebuns]

Hard to tell but did the small pin break off? Hopefully the other side will be easier to remove.

I see that you have the entire rear suspension off. If you plan to remove the hubs, it may have been easier to remove the hub nut with the suspension still in place. 

[racurley]

So, I'm not sure what the roll pin is supposed to look like but it seems to be two pieces - one hollow piece that's full length with a slit so it compresses in the hole.  The other solid piece which is a bit longer than 50% the length of the hollow piece. 

The one on the left side was almost completely munged.  It came out in two pieces and was maybe a third the length of the other.

Any ideas on where to source replacements?

Regarding the hubs, I think you are right.  I may reinstall it to remove the big nuts.  I was having difficulty keeping the hub from turning.  I ended up putting a metal bar (used the original wheel lug bar from the kit) into the u-joint.  It would press against the outside of the hub assembly to stop it from turning.  I was a little concerned with the pressure on the u-joint.  Any thoughts on this?

[jbcollier]

An impact gun should take the axle but off.

All the usual Lotus parts suppliers would have the roll pins.  If you are in the NA you try RD Enterprizes.