Replace Lever on Brake Actuating Assembly

[Mike1291]

I'm attempting to remove the levers on both of my brake actuating assemblies and I am having trouble understanding the correct process. I tried grinding both sides of the pins down to chisel them out as a club member recommended but don't see where the pin fits into the lever after grinding it. I then tried drilling it out and was thinking that I should try hitting it out with a chisel but wanted to see if anyone had any advice before I damage something.

 

[JayJay]

I'm attempting to remove the levers on both of my brake actuating assemblies and I am having trouble understanding the correct process. I tried grinding both sides of the pins down to chisel them out as a club member recommended but don't see where the pin fits into the lever after grinding it. I then tried drilling it out and was thinking that I should try hitting it out with a chisel but wanted to see if anyone had any advice before I damage something.

They don’t get removed with a chisel, they get removed with a punch. Likely your grinding blended the pin and the lever so you can’t see it. You may need to poke around a bit with the hammer and punch until you get the pin to move. At that point you will see a circle around the center of the pin.

Be sure to support the arm when you whack it so you don’t bend the shaft below. I rest mine across the top of partially open vise jaws.

 

[mleder]

I f I understand right, once you ground the pin down you cannot see where to place the punch and hit the pin. If that is the problem, take a torch (small propane used for soldering plumbing) or another will work fine. Heat the area where you think the pin - is get it hot then drip a little motor oil on the spot you should see the out line of the pin circle. Then you know where to hit.

 

[Marshall V. Daut]

I have removed the stubborn arm this way: Once the pin has been drilled out of the arm itself on both sides of its base as you have already done, tighten the arm in a sturdy bench vise around its base. With a large punch and heavy hammer, drive the shaft out of the arm. This will shear the remains of the pin in the shaft. Once the arm is off, you will be able to either drive the pin out of the shaft or clearly see where to drill it out. Heating that area will also help separate the pin from the shaft. After almost 100 years mated to each other, this pin is a bear to drive out.
Marshall

 

[Marshall V. Daut]

I have also hung the assembly between the vise jaws with the arm on top. Drive the shaft out of the arm from the top using the vise's two jaws to keep the arm steady when hammering. Keep the jaws loose enough around the exterior assembly so that it can drop down as the shaft is struck.
Marshall