I long ago faced this problem, and did the simple solution: remove the
broken taper pin head, use a big wrench to be able to remove the remaining
piece of pin, and remove the whole assembly. Once out of the trans case,
I assembled with a new pin, then cross-drilled a 1/4" hole through the
fork and shaft and used a 1/4" shouldered bolt. I then disassembled the
shaft/fork, replaced it in the trans case, and reassembled. The nut on
the 1/4" bolt was retained with locktite. Never had another problem, and
I have done the same with each of my TR's.
Cheers.
[This message delayed, as it needed manual intervention by the list
administrator. mjb.]
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