Clutch Pedal Cotter Pin

[MJ Journey]

OK, I got the defective clutch master cylinder out, despite the extremely rusty clutch pedal mounting hardware. The cotter pin at the pedal attach/master cylinder point snapped off both ends, so I started to drill it out. I've done a few, so I thought no biggie. Not this one - I stopped at 4 broken drill bit. This includes 3 titanium-coated and a cobalt split-point bit. Pin punch won't clear the hole either. Front bench seat is out, so I can get under the dash and see I'm aligned correcty. It's currently soaking in a container of Liquid Wrench PB. Just an idea . . .

 

Anyone else have this problem? Any ideas? Please, no wise-guy answers.

[Keyav8r]

Can you get to it with a file? File the ends of the cotter pin off flush with the body of the connection and see if you can get apart then. Can you post a picture of it?

[MJ Journey]

Keyav8r,

 

Thanks for the reply.

Yes, I was able to "Dremel" the front/head of the broken cotter pin, to get an idea of where the hole was, then I started drilling.

Part number ID is: (PIN, Cotter. .09375 x 1.250 Long)=3/32". Correct?. That's the size bits I used.

 

I'll get some pics ASAP.

[Keyav8r]

Yes, use a 3/32" drill. It may try to hang as you're drilling because of the parting line between the two halves of the cotter pin. Small bits like that are easy to break when you're working with an electric drill in close quarters. Go easy on the pressure and try not to flex the bit.