Cotterpin trick
Thread Starter
Melting Slicks
Joined: Jan 2006
Posts: 3,028
Likes: 2
From: North NJ
Cotterpin trick
Anyone have a trick to get old cotterpins out of those dang castlenut holes?
I'm tearing down my front suspension to make way for the vb&p performance plus system but these ORIGINAL cotterpins don't want to come out.
If I put an airsocket gun to them will the cotterpins just sheer off without damaging the nut or bolt?
I'm tearing down my front suspension to make way for the vb&p performance plus system but these ORIGINAL cotterpins don't want to come out.
If I put an airsocket gun to them will the cotterpins just sheer off without damaging the nut or bolt?
Racer
Joined: Oct 2004
Posts: 379
Likes: 0
From: Thief River Falls Minnesota
We either torqued the nuts off, which shears the pin, or we drove them out with a small punch, I wouldn't recommend shearing them off with the nut if you are going to reuse the pieces, we had all new pieces so we just sheared them, I think that you may get metal shavings in the bolt or you may mess up the threads just torquing them off, depending on how hard they are to get off. We did not notice the bolts getting messed up, but then again we were not looking to reuse them.
76custompaint
P.S. one good tip, use a scredriver or a pliers to grab onto the loop part of the cotter pins, and then either pry or pull on it to try to remove the pins, if it breaks, try to pull each individual piece out with the pliers. It did work for most of the pins we had, we did shear off a couple with the nut, but did mainly because we had new parts and were in a hurry.
76custompaint
P.S. one good tip, use a scredriver or a pliers to grab onto the loop part of the cotter pins, and then either pry or pull on it to try to remove the pins, if it breaks, try to pull each individual piece out with the pliers. It did work for most of the pins we had, we did shear off a couple with the nut, but did mainly because we had new parts and were in a hurry.
Racer
Joined: Jan 2006
Posts: 458
Likes: 0
Originally Posted by Gordonm
I use a pair of heavy wire cutters or dikes to remove them. Straighten it out as much as possible and grab the loop part with the cutters and pry it out. Never had a problem this way.
Le Mans Master
Joined: Jun 2002
Posts: 8,339
Likes: 24
From: I can walk to MA
I usually get them out Ok - but I have resorted to shearing them with
the nut and punching out after. I have never mucked up any threads
this way. The pins are usually a very mild steel and the nuts/pins are
quite hard. Still, there is a chance to mess them up (always is).
the nut and punching out after. I have never mucked up any threads
this way. The pins are usually a very mild steel and the nuts/pins are
quite hard. Still, there is a chance to mess them up (always is).
Instructor
Joined: Oct 2004
Posts: 159
Likes: 1
From: North of Boston Massachusetts
Originally Posted by Gordonm
I use a pair of heavy wire cutters or dikes to remove them. Straighten it out as much as possible and grab the loop part with the cutters and pry it out. Never had a problem this way.
This method has always worked for me. 
Race Director
Joined: May 2006
Posts: 16,528
Likes: 53
From: Dayton, Ohio
Originally Posted by SIXFOOTER
Use the heavy dykes to cut the loop and pull it out in 2 pieces
This is your best chance! Try a little heat also.(make sure your not near any fuel leaks)Next a small punch.If you use a drill remember if you break "that"off its hardened. 
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Drifting
Joined: Jun 2005
Posts: 1,950
Likes: 498
From: Chino Hills CA
Once in a while I encounter one of those cotter pins that seem to be totally inaccesible for a pair of dykes, or needlenose. I just put a good box wrench on the nut and shear it off. Haven't damaged any threads yet.
Melting Slicks
Joined: Jan 2004
Posts: 2,672
Likes: 1
From: New Cumberland PA
Originally Posted by Gordonm
I use a pair of heavy wire cutters or dikes to remove them. Straighten it out as much as possible and grab the loop part with the cutters and pry it out. Never had a problem this way.
If that doesn't work, then !!! I never had a problem doing it that way. I could cut a 1/4" bolt with a good set of dykes. Grip the cotter pin close to the nut and pry it out, it will come so far and then regrip it.
Team Owner
Joined: Oct 2004
Posts: 23,831
Likes: 10
From: Springfield MO
St. Jude Donor '07
Don't forget to put them back in...I've found a scary number of them missing from my front end, all from "professional" mechanics in the past. Professional, my shiny metal azz... 
Thread Starter
Melting Slicks
Joined: Jan 2006
Posts: 3,028
Likes: 2
From: North NJ
My cotterpins are a special breed called Permanent!
They have solidified over the years within the bolt itself. I yanked, gripped, snipped, regripped, cut in half, yanked somemore, cursed and no luck. Finally I used the air gun and let the castle nut sheer the ends off. I even smacked it with a punch to get the pin out from the bolt with no luck. Tonight I will try my luck with dynamite.
They have solidified over the years within the bolt itself. I yanked, gripped, snipped, regripped, cut in half, yanked somemore, cursed and no luck. Finally I used the air gun and let the castle nut sheer the ends off. I even smacked it with a punch to get the pin out from the bolt with no luck. Tonight I will try my luck with dynamite.
Racer
Joined: Dec 2005
Posts: 344
Likes: 0
From: Washington DC
Seems like I have pulled a few by driving a nail, awl, or small screwdriver through the eye. Once you have something in there to grab onto, you can usually pull them out with pliers or pry it out with a claw hammer or some big screwdrivers. 
Team Owner
Joined: Jul 2001
Posts: 61,416
Likes: 478
From: Here to make friends
St. Jude Donor '11, '16-'17
Originally Posted by Gordonm
I use a pair of heavy wire cutters or dikes to remove them. Straighten it out as much as possible and grab the loop part with the cutters and pry it out. Never had a problem this way.
Drifting
Joined: Oct 2003
Posts: 1,486
Likes: 10
From: Big Pine Key FL
Just did mine last weekend....
I cleaned the whole area with a scotchbrite wheel on a die grinder....
PB Blaster
Straighten out...
Us a pair of HD needle nose pliers through the loop and use a screw driver for a fulcrum... Mechanical advantage is your friend.
For the really tough ones use a pair of end nippers like you would use to pull a nail...
And for the impossible ones... The Hot Wrench, and drive out the remnents with a punch
I cleaned the whole area with a scotchbrite wheel on a die grinder....
PB Blaster
Straighten out...
Us a pair of HD needle nose pliers through the loop and use a screw driver for a fulcrum... Mechanical advantage is your friend.
For the really tough ones use a pair of end nippers like you would use to pull a nail...
And for the impossible ones... The Hot Wrench, and drive out the remnents with a punch
