Abstract:
A tool facilitates removal of a caliper pin from a brake caliper. The pin removal tool includes a tool head, an opening, and a shaft. The opening is defined in the tool head by a first and a second portion of the tool head, and the opening extending inwardly from a side of the tool head and between a proximal surface and a distal surface. The opening is sized to receive a shaft portion of a caliper pin therein while allowing the distal surface to abut a head of the caliper pin. The shaft has a longitudinal axis which is not parallel to the distal surface, and the shaft includes a first end portion rigidly connected to the tool head and a second end portion having a striking interface. The striking is interface configured to receive an impact force and transmit the impact force along the longitudinal axis.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims the benefit of priority to co-pending provisional application No. 61/889,560, filed on Oct. 11, 2013, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates generally to hand tools and, more particularly, automotive hand tools. 
       BACKGROUND 
       [0003]    A typical disc brake assembly includes a rotor secured to the wheel of the vehicle for rotation therewith. A caliper assembly is slidably supported by pins secured to an anchor plate, which is attached to a non-rotatable component of the vehicle, such as the steering knuckle or axle flange. The caliper assembly includes a pair of brake pads disposed on opposite sides of the rotor. The brake pads are operatively connected to one or more hydraulically actuated pistons for movement between a non-braking position, in which the brake pads are spaced apart from opposed braking surfaces of the rotor, and a braking position, in which the brake pads are moved into frictional engagement with opposed braking surfaces of the rotor. When the operator of the vehicle depresses the brake pedal, the piston urges the brake pads from the non-braking position to the braking position so as to frictionally engage the opposed braking surfaces of the rotor and thereby slow or stop the rotation of the associated wheel of the vehicle. 
         [0004]    As mentioned above, the caliper assembly is slidably supported on pins secured to the anchor plate. A typical pin includes a non-threaded main body and threaded end. The main body of the pin extends into a non-threaded opening formed in the inboard leg of the caliper, and the threaded end of the pin is received in a threaded opening provided in the anchor plate. 
         [0005]    In performing maintenance on the brake caliper, it is often necessary to remove the pin from the opening in which the pin is mounted. However, during operation, the pin may oxidize due to exposure to moisture during normal use and become seized in the associated opening. Removal of the pin can be difficult, and improper removal can result in damage to the caliper. Furthermore, the pin is typically located on a side of the caliper facing inwardly toward the vehicle when the caliper is mounted on the vehicle. As a result, generating sufficient force to remove the pin is difficult without removing the caliper from the vehicle. What is needed, therefore, is a tool for removing brake caliper pins from the brake caliper. 
       SUMMARY 
       [0006]    In one embodiment, a pin removal tool includes a tool head, an opening defined in the tool head by a first and a second portion of the tool head. The opening extends inwardly from a side of the tool head and between a proximal surface and a distal surface and the opening is sized to receive a shaft portion of a caliper pin therein while allowing the distal surface to abut a head of the caliper pin. The pin removal tool further includes a shaft having a longitudinal axis which is not parallel to the distal surface. The shaft has a first end portion rigidly connected to the tool head and a second end portion having a striking interface. The striking interface is configured to receive an impact force and transmit the impact force along the longitudinal axis. 
         [0007]    In a further embodiment, the tool head includes a base portion, a first prong, and a second prong. The first prong and the second prong each extend from the base portion. The first prong and the second prong define at least a portion of the opening therebetween and define at least a portion of the distal surface. 
         [0008]    In yet another embodiment, the first prong has a first end attached to the base portion and a second end opposite to the first end, and the second prong has a third end attached to the base portion and a fourth end opposite to the first end. A width of the opening decreases from a location proximate the second and fourth ends to a location proximate the first and third ends. 
         [0009]    In another embodiment, the distal surface of the tool head is generally planar and is positioned in a plane that is at an angle of between 80 and 100 degrees to the longitudinal axis. 
         [0010]    In a further embodiment, the distal surface of the tool head is orthogonal to the longitudinal axis. 
         [0011]    In another embodiment of the pin removal tool, a height of the first prong along the longitudinal axis increases from a location proximate the second end to a location proximate the first end, and a height of the second prong along the longitudinal axis increases from a location proximate the fourth end to a location proximate the third end. 
         [0012]    In some embodiments of the pin removal tool, the shaft includes a textured portion adjacent to the second end portion of the shaft. 
         [0013]    In a further embodiment of the pin removal tool, the striking interface includes a striking surface generally orthogonal to the longitudinal axis. 
         [0014]    In yet another embodiment, the striking interface includes a pneumatic hammer interface configured to receive the impact force from a pneumatic hammer. 
         [0015]    In some embodiments, the distal surface of the tool head is arcuately shaped about a first axis of curvature that is generally orthogonal to the longitudinal axis, and the proximal surface of the tool head is arcuately shaped about a second axis of curvature that is generally orthogonal to the longitudinal axis. 
         [0016]    A method of removing a brake caliper pin includes inserting a tool head between a head of a caliper pin and a body of a caliper such that a shaft portion of the caliper pin is received in an opening defined in the tool head by a first and a second portion of the tool head and between a proximal surface and a distal surface and abutting the head of the caliper pin with the distal surface. The method further includes transmitting an axial force to a striking interface located at a first end portion of a shaft, transferring the axial force along a longitudinal axis of the shaft from the first end portion to a second end portion of the shaft, diverting the axial force from the second end portion to the tool head, which is rigidly connected to the second end portion, and transmitting the axial force from the tool head to the head of the caliper pin through the abutment of the distal surface and the head of the caliper pin. 
         [0017]    In one embodiment, the transmitting of the axial force to the striking interface includes impacting a planar surface that is generally orthogonal to the longitudinal axis of the shaft. 
         [0018]    In another embodiment, the transmitting of the axial force to the striking interface includes attaching a pneumatic hammer to a pneumatic hammer interface of the striking interface and activating the pneumatic hammer. 
         [0019]    In a further embodiment of the method, the inserting of the tool head includes inserting a first prong and a second prong, which define at least of a portion of the distal surface and of the opening, between the head of the caliper pin and the body of the caliper such that the first and second prongs engage opposite sides of the shaft portion of the caliper pin, and the transmitting of the axial force from the tool head to the head of the caliper pin includes transmitting the axial force to the head of the caliper pin through the first prong and the second prong. 
         [0020]    In some embodiments, the inserting of the tool head includes inserting the first prong from a first end toward a second opposite end attached to a base portion of the tool head and inserting the second prong from a third end to a fourth opposite end attached to the base portion of the tool head, and the abutting of the head includes moving the first and second prongs such that the prongs move from a first portion of the opening proximate the first and third ends to a second portion of the opening proximate the second and fourth ends, the second portion of the opening having a width that is reduced from the first portion of the opening. 
         [0021]    In yet another embodiment of the method, the inserting of the tool head includes inserting a first end of the first prong, which has a reduced height compared to a second end of the prong, between the head of the caliper pin and the body of the caliper, and inserting a third end of the second prong, which has a reduced height compared to a fourth end of the second prong, between the head of the caliper pin and the body of the caliper. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a top perspective view of a pin removal tool for use with a manual hammer. 
           [0023]      FIG. 2  is a side perspective view of the pin removal tool of  FIG. 1 . 
           [0024]      FIG. 3  is a side view of another pin removal tool for use with a manual hammer, illustrating the tool engaged with a caliper pin. 
           [0025]      FIG. 4  is a top perspective view of a pin removal tool for use with a pneumatic hammer. 
           [0026]      FIG. 5  is a side perspective view of the pin removal tool of  FIG. 4 . 
           [0027]      FIG. 6  is a side view of another pin removal tool for use with a pneumatic hammer, illustrating the tool engaged with a caliper pin. 
           [0028]      FIG. 7  is a side view of another embodiment of a pin removal tool having an arcuate head. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains. 
         [0030]      FIGS. 1 and 2  illustrate perspective views of a pin removal tool  100  having a head  104  and a shaft  108 . In the illustrated embodiment, the head  104  extends in a plane orthogonal to a longitudinal axis of the shaft  108 . In other embodiments, the head is angled relative to the plane orthogonal to the longitudinal axis of the shaft, for example at an angle of between 80 and 100 degrees with respect to the longitudinal axis of the shaft, or the head has a nonplanar shape. In the embodiment of  FIG. 2 , the head  104  and the shaft  108  are separate pieces joined together by, for example, a weld. In another embodiment illustrated in  FIG. 3 , the head  104  and shaft  108  are integrally formed from a single piece of material. The tool  100  is formed from a suitable hardened material, for example a tool steel or other steel alloy. 
         [0031]    The tool head  104  includes a distal surface in the form of a generally flat engagement face  112  defined at least in part by a first prong  116  and a second prong  120 , both of which extend away from the intersection of the tool head  104  and shaft  108 . In the illustrated embodiment, outer surfaces of the first prong  116  and second prong  120  are substantially parallel to one another, though in other embodiments the prongs are angled relative to one another. The prongs  116 ,  120  are tapered at end regions  128 ,  132  remote from the shaft  108 , such that a height of the prongs  116 ,  120 , defined parallel to the longitudinal axis of the shaft  108 , is less at the ends  128 ,  132  of the prongs  116 ,  120 . Additionally, the prongs  116 ,  120  have a tapered width, such that the width of the prongs  116 ,  120  is greater at the end nearest the intersection of the tool head  104  and shaft  108 , and less at the opposite ends  128 ,  132  of the prongs  116 ,  120 . As a result, an opening  124  defined between the prongs is narrower at the end near the intersection of the tool head  104  and shaft  108  than at the opposite end of the tool head  104 . 
         [0032]    The tool shaft  108  is substantially cylindrical in the embodiments of  FIGS. 1 and 2 , and includes a textured portion  136  (best seen in  FIG. 2 ) for enhanced grip of the tool  100 . In the embodiment of  FIG. 3 , the tool shaft has a hexagonal cross section, while in other embodiments the tool shaft has another shape or a non-uniform cross section. The end of the shaft  108  opposite the tool head  104  has a substantially flat striking face  140  oriented in a plane generally orthogonal to the shaft  108  of the tool  100 . 
         [0033]      FIG. 3  illustrates the tool  100  in use. The tool  100  is positioned such that the ends  128 ,  132  of the prongs  116 ,  120  are wedged between the head of a caliper pin (not visible in  FIG. 3 ) and the body of the caliper  160 . In this configuration, the distal surface of the prongs  116 ,  120  abut the head of the caliper pin while the shaft of the caliper pin is received within the opening  124 . The tool head  104  is then pressed downwardly in the view of  FIG. 3  until the distal engagement face  112  is securely engaged with the head of the caliper pin. The tapered end regions  128 ,  132  facilitate wedging the prongs  116 ,  120  under the head of the caliper pin. If the tool cannot be wedged between the pin head and the caliper  160  with manual force, the tool head  104  is hammered at the end near the shaft  108  to force the tool  100  between the pin head and caliper body  160 . In some instances, the tool  100  is wedged between the head  172  of a caliper mounting bolt  176  and the head of the caliper pin, for example if the caliper pin is damaged, to remove the mounting bolt  176  from the caliper pin. Since the opening  124  in the tool head  104  is tapered, the tool  100  is suitable for use with pins and bolts having various head diameters and shapes. 
         [0034]    The tool head  104  is wedged between the pin head and caliper body  160  until the height of the tool head or prongs immediately adjacent to the shaft of the pin is of sufficient height to preclude breaking the tool head when the tool is impacted. Once the engagement face  112  is thus securely engaged with the pin head, the user strikes the striking face  140  with a hammer or other object suitable for striking the face  140 . The force from hitting the striking face  140  urges the caliper pin out of its mounting opening and out of the caliper body  160 . Since the tool shaft  108  extends along an axis substantially parallel and only slightly offset from an axis of the caliper pin, the force exerted by hammering the striking face  140  runs close to the axis of the caliper pin. Consequently, the caliper pin is not subjected to a substantial torque, and the risk of damaging the caliper pin or the mounting opening in which the pin is situated is low during removal of the caliper pin. Additionally, the tool head  104  is configured such that a user can engage the pin with the tool head  104  from behind the caliper. As a result, the tool  100  can be easily engaged with a pin located on the back of a caliper while the caliper is mounted to the vehicle. 
         [0035]      FIGS. 4 and 5  illustrate perspective views of another embodiment of a caliper pin removal tool  200 . The pin removal tool  200  includes a head  204  and a shaft  208 , the head  204  extending along a plane approximately orthogonal to a longitudinal axis of the shaft  208 . In the embodiment of  FIG. 5 , the head  204  and the shaft  208  are separate pieces joined together by, for example, welding, though in the embodiment illustrated in  FIG. 6 , the head  204  and shaft  208  are integrally formed from a single piece of material. 
         [0036]    The tool head  204  includes a generally flat engagement face  212 , a first prong  216 , and a second prong  220 , both of which extend away from the intersection of the tool head  204  and shaft  208 . The first prong  216  and second prong  220  extend substantially parallel to one another, and define an opening  224  therebetween. The prongs  216 ,  220  are tapered at end regions  228 ,  232  remote from the shaft  208  such that a height, defined parallel to the longitudinal axis of the shaft  208 , is less at the ends  228 ,  232  of the prongs  216 ,  220 . The prongs  216 ,  220  also have a tapered width, such that the width of the prongs  216 ,  220  is greater at the end nearest the intersection of the tool head  204  and shaft  208  than at the opposite ends  228 ,  232  of the prongs  216 ,  220 . As a result, the opening  224  is narrower at the end near the intersection of the tool head  204  and shaft  208  than at the opposite end of the tool head  204 . 
         [0037]    The tool shaft  208  is substantially cylindrical in the embodiments of  FIGS. 4 and 5 , and includes a striking region configured as a pneumatic hammer interface  236  at an end remote from the intersection of the tool head  204  and shaft  208 . The hammer interface  236  is shaped to enable a pneumatic hammer to engage the interface  236  and be securely attached to the shaft  208 . In one embodiment, the pneumatic hammer interface  236  is a separate piece and is joined to the shaft  208  by any form of attachments. In another embodiment, the pneumatic hammer interface  236  and the shaft  208  are integrally formed. In other embodiments, the pneumatic hammer interface is replaced with an interface for another power tool, such as an electric hammer or a hammer drill. In some embodiments, the shaft includes a gripping portion similar to the one described above with regard to the embodiment of  FIGS. 1-3 . The optional gripping portion includes a surface that is altered or modified from the surface of the shaft  208  for enhanced grip of the tool  200 . 
         [0038]      FIG. 6  illustrates the tool  200  in use. The tool  200  is positioned such that the ends  228 ,  232  of the prongs  216 ,  220  are wedged between the head  148  of a caliper pin  152  and the body of the caliper  160 . The tool head  204  is then pushed downwardly in the view of  FIG. 6  until the engagement face  212  is securely engaged with the head  148  of the caliper pin  152 . If the tool  200  cannot be wedged between the pin head  148  and the caliper  160  with manual force, the tool head  204  can be struck at the end near the shaft  208  to force the tool between the pin head  148  and caliper body  160 . In this configuration, the prongs  216 ,  220  abut the head of the caliper pin while the shaft of the caliper pin is received within the opening  224 . 
         [0039]    Once the engagement face  212  is securely engaged with the pin head, the user attaches a pneumatic hammer (not shown) to the pneumatic hammer interface  236  of the shaft  208 . The pneumatic hammer is activated, providing a repetitive striking force running along the axis of the tool shaft  208 . The force from the pneumatic hammer urges the caliper pin  152  out of its mounting opening and out of the caliper body  160 . Since the tool shaft  208  extends along an axis substantially parallel to and only slightly offset from an axis of the caliper pin, the force exerted by the pneumatic hammer runs close to the axis of the caliper pin  152 . As a result, the caliper pin  152  is not subjected to a substantial torque, and there is little risk of damaging the caliper pin  152  or the mounting opening in which the pin  152  is situated during removal of the caliper pin  152 . 
         [0040]      FIG. 7  illustrates another embodiment of a caliper pin removal tool  300 . The embodiment of  FIG. 7  is generally identical to the embodiments of  FIGS. 1-2  and  FIGS. 4-5 , except that the tool head  304  and the prongs  316 ,  320  are arcuately shaped. The arcuate shape of the prongs  316 ,  320  enables the tool  300  to be wedged between the caliper pin  152  and the caliper  160  by pivoting the tool  300  about the intersection of the tool head  304  and shaft  308 . 
         [0041]    While the above embodiments have been described with reference to removal of caliper pins and mounting bolts, the reader should appreciate that the above-described tool is not limited to use on caliper pins and mounting bolts. The tool is suitable for removal of other bolts on a vehicle, for example suspension bolts, or removal of bolts and pins in other settings, such as industry or manufacturing. 
         [0042]    It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the foregoing disclosure.