I'm stuck on my 603 head-pulling job. Used the bolt and washer trick to pull the upper chain guide pin--worked just fine.

The bottom one is a bear. On the first try, I stripped the threads on a bolt, so threaded in a much longer and I think stronger bolt, which snapped with about 10mm protruding. Backed out the remains of the bolt.

Now I see that I should chase the threads before proceeding further--they weren't helped by these escapades--but I think my options are diminishing. The pin seems to be seated so firmly that low-strength bolts may fail if I use the same method again. So, what to do?

1. Chase the threads with a tap, find a high-strength bolt/nut combo and try again.
2. Find an impact puller as specified by Mercedes. (where to get one of those?)
3. Another option I've not considered?

I'd appreciate any ideas before I really make a mess of things.

The good news:

• No apparent cracks, based on a careful look with a mirror.
• Evidence of head gasket degradation--the likely cause of oil in the coolant.
• An undetected leak from #6 exhaust at the back end of the exhaust manifold. The car should be quieter when I'm done.

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Rob

The proper tool is always the best bet! But when you can't get that you need the next best thing which would be carefully using a tap to clean the pin's threads and then the best quality bolt you can find, last when you get to the actual pulling try to make certain that you're getting the straightest pull on it possible to avoid breaking the bolt off. If that does not get it done this thread shows one last ditch strategy that might get things done.

http://www.peachparts.com//shopforum/showthread.php?t=240678&highlight=pin

Good Luck!

I had exact same problem - re-tapped but used a high tensile bolt (allen key type) tighten bolt hard then tapped around area with small hammer, nipped it up a bit harder the did the same -

Took hours but came out eventually

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David


1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)

This is going to sound weird, but it worked for me - put the tool or home-made tool - whichever you are using - in the freezer overnight. When you get ready to try again, get a heat gun and gently warm up the area around the pin - it will take some time to do this without damage. then go get the tool out of the freezer and try working the pin - you may have better results.

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327K on 1986 W201, 602.911, 722.414 2.5 190D ("The Red Baron")
139K on 1993 W124, 104.942, 722.433 2.8 300E ("Queen")

http://farm5.static.flickr.com/4081/...0bb92d3c_m.jpg http://i370.photobucket.com/albums/o...g?t=1325284354

Do not worry about your difficulties in Mathematics. I can assure you mine are still greater.
- Albert Einstein

take a walk down memory lane...

I'll have to find the correct tap tomorrow, and then locate some high-strength bolts. I need a heat gun anyway, and that might just do the trick...

Thanks for all of the ideas!

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Rob

When I pulled my head a few years ago I borrowed a slide hammer from a plumber; it was too big to use so I had to remove the radiator and the ac condenser. The weight of the slide hammer is what moves the pin. Unfortunately I twisted off the union on the condenser at the same time fortunately I live in Vermont where A/C is not so much of an issue.

Persistence is key; I fought mine for a LONG time, but the bolt and washer eventually did the trick. You'll get it; good luck!

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

Got a 6x1.0 tap, which cleaned out the threads nicely. Screwed in a high-strength 30mm-long Allen-head bolt and nut, and added a few washers. Came right out! Just need to make room for the engine hoist and get the head out now.

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Rob