Flipper rebuild step 6: pawl, plunger, link and bushing

Steps

• Or simply fit a new complete pawl/plunger/link assembly.
• Remove the Allen bolt joining the plunger/link to the pawl (spread the pawl slightly with a screwdriver if needed).
• If the pawl's bolt hole has gone oval, replace the pawl. Replace the bolt if its middle is worn.
• Measure the link spacer bushing: new is .310 inch outside and .090 inch inside. Replace it if it is even .003 inch under, or if in doubt.
• Fit a new plunger/link. If you must rebuild one, grind and bevel the mushroomed tip, drive out the roll pin with a 1/8 inch punch, fit a new link, refit the pin and check the link moves freely.
• Reassemble with the bolt through the pawl and the nut on the pawl side.

Systems

• WPC Alpha-Numeric
• WPC Dot Matrix
• WPC Fliptronics
• WPC DCS
• WPC-Security (WPC-S)
• WPC-95

Related tips

• WPC-style conversion: plunger, springs, bats and coil
• Converting to the newer outside return spring
• Coil sleeves and flipper rebuild spares
• Converting older flippers to the later return spring
• Flipper link spacer bushing wear limits
• Flipper rebuild part numbers for System 11
• Sloppy zipper flippers: worn base plate slots and bushings
• Flipper rebuild steps 14-15: tighten pawl and set the EOS

Source: Repairing Williams/Bally WPC Pinball Games from 1990 to 1999, Part Three, Clay Harrell (pinrepair.com)