I am rebuilding the flipper assemblies on a 1976 Gottlieb Buccaneer. I am having a lot of difficulty removing the set screws which hold the flipper shaft in place. Even if I decided to not replace the plunger (which I do want to do) I cannot get to the upper bushing without being able to disconnect the flipper shaft.

What is the best tool and method to get on these square shaped set screws to loosen them? I tried an ignition combination wrench but can get enough leverage on them.

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What should be there instead of the square head set screws? This game is not supposed to even have this style of flipper assembly according to PBR’s dating information. It is a Sample game.

The other side is the same.

It’ll get the Aero Kroil treatment tonight.
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Certainly looks like the right set screws in this exploded view.

http://www.pbresource.com/rebuildk/kt-gflip-03amfa.jpg

They’re getting the Kroil treatment now in the hopes that they’ll budge. If they do snap off, any suggestions on the plan of attack? There is not much room to do much of anything and as you know, you can’t remove the assembly from the playfield to get more access without having removed the flipper shaft.

I can’t believe how tight they are.

Well, I gave the set screws the old Kroil and time treatment and was able to coax them loose with a small ignition wrench. Thanks for all of the help and encouragement. I replaced them with Allen head set screws.

Everyone has their own go-to for penetrating lubricants, but Aero Kroil truly is amazing stuff.

http://www.kanolabs.com/

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I do have one additional question. After reassembling the flipper assembly with all new bushings, I was surprised to find that the flipper itself is still very close to the playfield. It does not appear to be touching but it’s also not gapped off the playfield like I’m used to seeing on my 2” flipper games. Those are gapped off the playfield by a good 1/8”.

Should the flipper shaft be set right down onto the top bushing? That’s how it’s shown on this exploded view. There’s also a groove in the shaft where the set screws go which make it appear that there’s about 1/4” of play up and down.

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JB Weld an extension onto the broken screw? Desperate times call for desperate measures.