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  #1  
Old 11-30-2003, 10:20 PM
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Exclamation HELP!!! Stuck guide rail pins 603.9xx

Anyone who has changed a head on one of these, how do you get the guide rail pins out. I got that far in the removal process and have since slide hammered, beat, heated and beat, slide hammered until slide hammer broke and then gave up for the day. Can I drill a small hole behind them and drive them out from behind? Any help appreciated thanks.

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Old 11-30-2003, 10:33 PM
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I used the stacked washers method. Send a bolt into pin and keep adding washers so bolt pulls the pin out before it bottoms. I've never gotten homemade slide hammers to work.

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Old 11-30-2003, 10:51 PM
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The stacked washer and socket method has worked for me on my 601 on two separate occasions, and on one of my 617's on one occasion.

It works.
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Old 12-01-2003, 07:18 AM
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If you get to the point where the internal threads are no longer any good (and you can break off/get the guide rail out of the way) you can use a die to thread down on the outside of the pin. Use a couple few washers too. When the die gets tight against the washers and you keep turning it will work the pin out. This is a last resort type of method.
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Old 12-01-2003, 10:35 AM
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zbenz

As was mentioned above the stack of washers works best. I had one strip out and then had to cut it with a hack saw to remove it. It was an upper one but you might reach the lower ones with a sawzall.
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  #6  
Old 12-01-2003, 07:20 PM
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Thumbs up Thanks to All

Got the disassembly all done today. The top pin I drilled behind and drove out. The bottom I used the washer stack method and with some patients and tapping on the bolt and spraying with penatrating lube it came out quite well. Pulled the head and as predicted it's trashed two cylinders cracked between the intake valve and prechamber.

Anyway, thanks to all for your advice it was all well worth the price.

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