[orthodoct]

Aaron and Lynn are nice folks. Without their business, there would be a lot of crippled ZR1's out there. Did some homework today. Diameter of roll pin is 1.54mm according to my Starrett dial caliper which is very accurate. i notice that the Bilstein shocks are made in Germany so everything is bound to be metric. The pin size is 1.5 x 6mm and the hole size in the shaft of the shock appears to be 1.50 mm. I almost ruined the shaft. A 1/16" punch will push the pin up against the shock shaft and the hole in the gear will accommodate it, but a 1/16 punch will not go through that hard, tempered shaft but it WILL try to deform the metal. I burred it a little bit, but didn't ruin it. I ordered a 1.5mm punch made in Germany (from a company with a good reputation, Gedore, so it should be an accurate diameter) and some small metric drills to size that hole. Can't get to it with a dial caliper and it isn't accurate enough. I think that this hasn't come up before because we are used to replacing broken pot metal gears and the easiest way to get them off of the shaft is to break them up and then work out the pin. I am replacing two of the pot metal gears that haven't failed yet and tried to drive the pin all the way across. With those shocks being outrageously expensive if even available sure don't want to bend that shaft. Hope this information is beneficial to the forum. Will update this post when I can confirm that hole size is exactly 1.5mm.