Jono's gudgeon pin removal tool plans

steptoe · Post by **steptoe** » Tue Jul 24, 2007 11:40 pm

OK. I can only guess newer Subaru motors still use the gudgeon pin removal holes in front and rear of the block with circlips. I have found it an absolute P rick of a job to get them out. I have made a tool very cheaply.

Note: the circlips somehow wear a bit of the piston to reduce the diameter of the gudgeon pin hole jamming the pin in , as well as the carbon build up inside the fit

14mm dia mild steel rod cost $1.80
M10 1.25 intermediate tap $7.50 to suit the
old head bolt out of UFO
two big nuts (with some thread filed out) welded onto end of rod $1.20
bit of old steam pipe 150mm long
bit of pipe that just fits inside above 145mm long
2 big 30 cent washers to fit over 14mm bar, fit flush inside steam pipe and the smaller pipe just sits inside for extra weight.

The gripper bit:
The old head bolt was black like high tensile bolt. Ground the head round to fit along through gudgeon pin, then shaped half the head to clear the circlip prongs and it plops over edge of gudgeon pin.

The slide:
The 14mm rod, drill a hole in the end grain as if to hollow it out, tapped required thread to suit chosen modified head bolt.

The slide hammer:
Welded washers to each end of steam pipe and smash,smash,SMASH against the welded stopper nuts at the other end

YouTube · Post by **El_Freddo** » Wed Jul 25, 2007 1:58 pm

We made a hook to attach to the end of our slide hammer, its gotta be long enough to get to the other side of the gugeon pin and the hook short enough to fit inside the gugeon pin. Best tool we've made i reckon.

I dunno were the slide hammer came from, but then again, dad has a big shed...

Good luck, you'll love this tool mate!

steptoe · Post by **steptoe** » Wed Jul 25, 2007 7:23 pm

yeah , already thinking of MarkII, one to add to my top tools post !

Brumby Boy · Post by **Brumby Boy** » Thu Jul 26, 2007 9:17 am

Pics?
i just used a long flat blade screw driver with my ej22

steptoe · Post by **steptoe** » Fri Jul 27, 2007 12:23 am

not got time to learn how to get pics here but if you pm a email i can send low kB to you. You were lucky. Every EA81 I do gets harder....

redskin · Post by **redskin** » Fri Jul 27, 2007 9:53 pm

*rick of a job, l made a slide hammer to suit, got a length of rod and threaded 1 end for nuts, made up a slide, (read, drilled a lump of bigger rod), with an inner bore to slide over my rod length and flattened the other end of this rod into a hook then flame hardened it. Just push it down the gudgeon hole and slide away, it works a treat and took about 30 mins to make. Cost nothing to make as l utilised scrap from my lathe bin.

TiAgMY84 · Post by **TiAgMY84** » Fri Jul 27, 2007 10:19 pm

I'd have to agree it can be bloody difficult, I used a 12mm Diameter Dyna Bolt and attached my slide hammer. It just slides in the gudgeon pin expands as you tighten it up and out the pin comes. Cost was about $5.00 as you need one with at least 120mm of lenght.