FX3 actuator rebuild/roll pins - ZR-1 Net Registry Forums

orthodoct · 11-05-2016

Got another broken actuator. Had one rebuilt by Captain Z CNC; great folks. I am going to have the remainder rebuilt; just a matter of time before the other two break. Getting the roll pins out of old gears. They use a metric punch smaller than a 1/16! Does anyone know the size of the roll pin punch? I slightly bogeyed up the hole in the top of the shock but didn't go all gorilla and destroy it. Slight burr on one side of the hole that I was able to clean up. Have ordered three new gems from Captain Z as well. Any pearls about installing the new gears? These should be easier since these are the rear shocks and I have them off of the car. I managed to replace the gear on the right front after actuator rebuild with shock on the car, but reluctant to replace left front gear unless it fails. If I don't replace it until it fails, will it ruin my new rebuilt actuator? It is very delicate getting that roll pin out without damaging the shaft and reinstalling the roll pin in the new gear is very delicate. I used a hemostat to guide it and started it with a 1/16" roll pin starter punch.
Thanks!
Ty
Crossville, TN

orthodoct · 11-05-2016

Should say "gears", not "gems"! Spell check strikes again!!
Thanks!

BigJohn · 11-05-2016

But I like Captain Z Gems!

orthodoct · 11-05-2016

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.

orthodoct · 11-05-2016

If you do the math, 1.5mm=0.0591 inches (1.5mm/25.4mm per inch) whereas 1/16"=0.0625 inches; just enough to interfere.

GOLDCYLON · 11-05-2016

Quote:

Originally Posted by orthodoct

Hope this information is beneficial to the forum. Will update this post when I can confirm that hole size is exactly 1.5mm.

Please do and thanks

orthodoct · 11-06-2016

I most certainly will. An honor to be able to contribute to and be a part of this forum.

orthodoct · 11-13-2016

Final update. Hole in shock IS metric. 1.5 mm roll punch fits perfectly; 1/16 inch punch too big. Trying to knock out pin to replace gear with 1/16 punch will bend the shaft and ruin the shock. 1.5 mm punch is hard to find, but I found one made by Gedore made in Germany on eBay. Correct replacement roll pin is 1.5mm by 6 mm. Also hard to find, but I did but literally coming from a slow boat from China. Got 100 for four bucks. Other option was 1.5 mm by 20mm. Was able to find them from a US source and can cut to length with a Dremel cutoff wheel and chamfer the edge. Hope this helps add to our knowledge database.
Regards to all.
Ty

GOLDCYLON · 11-13-2016

Quote:

Originally Posted by orthodoct

Final update. Hole in shock IS metric. 1.5 mm roll punch fits perfectly; 1/16 inch punch too big. Trying to knock out pin to replace gear with 1/16 punch will bend the shaft and ruin the shock. 1.5 mm punch is hard to find, but I found one made by Gedore made in Germany on eBay. Correct replacement roll pin is 1.5mm by 6 mm. Also hard to find, but I did but literally coming from a slow boat from China. Got 100 for four bucks. Other option was 1.5 mm by 20mm. Was able to find them from a US source and can cut to length with a Dremel cutoff wheel and chamfer the edge. Hope this helps add to our knowledge database.
Regards to all.
Ty

If you want to part with a few of those pins lmk. Also can you pm me or email me that auction number.?I will like to pick on of those up for the tool box. Thanks for closing out your post to help the next guy. You will never be able to count how many folks leave it hanging with no followup. Goldcylon@cox.net is my email address. Thanks again GC

orthodoct · 11-13-2016

Hi Goldcyclon.
Will be happy to send you some, but they won't be here (no kidding, from CHINA!) until between 11/23 and 12/30! The 20mm ones will be here next week and I'll be happy to send you some of them as well. Will send you an email with the eBay info that you wanted.
Ty

11-05-2016	#1
orthodoct Join Date: Aug 2014 Location: Crossville, TN Posts: 88	FX3 actuator rebuild/roll pins Got another broken actuator. Had one rebuilt by Captain Z CNC; great folks. I am going to have the remainder rebuilt; just a matter of time before the other two break. Getting the roll pins out of old gears. They use a metric punch smaller than a 1/16! Does anyone know the size of the roll pin punch? I slightly bogeyed up the hole in the top of the shock but didn't go all gorilla and destroy it. Slight burr on one side of the hole that I was able to clean up. Have ordered three new gems from Captain Z as well. Any pearls about installing the new gears? These should be easier since these are the rear shocks and I have them off of the car. I managed to replace the gear on the right front after actuator rebuild with shock on the car, but reluctant to replace left front gear unless it fails. If I don't replace it until it fails, will it ruin my new rebuilt actuator? It is very delicate getting that roll pin out without damaging the shaft and reinstalling the roll pin in the new gear is very delicate. I used a hemostat to guide it and started it with a 1/16" roll pin starter punch. Thanks! Ty Crossville, TN

11-05-2016	#2
orthodoct Join Date: Aug 2014 Location: Crossville, TN Posts: 88	Re: FX3 actuator rebuild/roll pins Should say "gears", not "gems"! Spell check strikes again!! Thanks!

11-05-2016	#3
BigJohn Join Date: Feb 2012 Location: Ledyard,CT Posts: 8,227	Re: FX3 actuator rebuild/roll pins But I like Captain Z Gems!

11-05-2016	#4
orthodoct Join Date: Aug 2014 Location: Crossville, TN Posts: 88	Re: FX3 actuator rebuild/roll pins 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.

11-05-2016	#5
orthodoct Join Date: Aug 2014 Location: Crossville, TN Posts: 88	Re: FX3 actuator rebuild/roll pins If you do the math, 1.5mm=0.0591 inches (1.5mm/25.4mm per inch) whereas 1/16"=0.0625 inches; just enough to interfere.

11-06-2016	#7
orthodoct Join Date: Aug 2014 Location: Crossville, TN Posts: 88	Re: FX3 actuator rebuild/roll pins I most certainly will. An honor to be able to contribute to and be a part of this forum.

11-13-2016	#8
orthodoct Join Date: Aug 2014 Location: Crossville, TN Posts: 88	Re: FX3 actuator rebuild/roll pins Final update. Hole in shock IS metric. 1.5 mm roll punch fits perfectly; 1/16 inch punch too big. Trying to knock out pin to replace gear with 1/16 punch will bend the shaft and ruin the shock. 1.5 mm punch is hard to find, but I found one made by Gedore made in Germany on eBay. Correct replacement roll pin is 1.5mm by 6 mm. Also hard to find, but I did but literally coming from a slow boat from China. Got 100 for four bucks. Other option was 1.5 mm by 20mm. Was able to find them from a US source and can cut to length with a Dremel cutoff wheel and chamfer the edge. Hope this helps add to our knowledge database. Regards to all. Ty