This is from Deve's TechNet (for next time - if there is a next time)
To reinstall the gear, get the proper length and size of roll pin. I use high strength stainless steel ones from McMaster-Carr. The 3/16" pin will be tight in the shaft, but I do not rely on that single roll pin. Put another M2.5 (x30) pin inside the first one making sure the openings are opposite each other. This almost guarantees that gear isn't going anywhere. Test it to make sure there is no slop introduced by the pin combination and then cut off the pins flush same as the one that was there in the first place. If by some chance there is any slop in the gear to shaft connection, drill both the gear and the shaft out to the next size roll pin combination which is 7/32" and 1/8".
This is timely for me, I am in the middle of an engine (235) assembly now. Have a nos gear I'm using.
I wonder though how a non rated 2.5mm spring pin that is only 1/2mm thick inside the 3/16" pin is really going to make a difference in the overall picture. Any others want to offer up an opinion?
