Ok, here is the beast. Bit rough, it has been through many changes on the way to a working model.
Here is how it fits and sits on and around the rod and lever arm.
And here is it in action inside the tail housing/
The nut on the threaded pusher is 19mm, so had to make a custom bend on this 19mm open end wrench to allow access and at least 1/6 turn.
The nut is very close to the raised casting area around the reverse lockout assembly hole in the case. Had to get the length of this pusher bolt just right to allow you to put it on the wedge bolt tip and still get you enough room to push it off. The tail housing without this reverse lockout thingy would have much more room. You might even get a box end wrench on it.
Here is the SFT’s for the project
The bottom chunk is the part of an intermediate plate from a junked 4 speed. It has the hole for the end of the shift rod. Helps to keep the shift rod supported if you using the 1/4 socket extension whacking method to remove the wedge pin. I still needed a firm support behind the wedge pin area to the case to prevent the rod from just flexing when you hit with the sledge. That is what the 3/4” wide 1/8 thick angle iron piece does. Sits in there real nice.
Design wise, the biggest change I had to make to the original tie rod end puller was to cut the legs off close to the threaded end and shift the whole body down about 3/16” then re-weld. This is due to the fact that the wedge pin sit below the centerline of the shift rod by about that much. Your threaded pusher bolt has to be in-line with wedge bolt or you risk bending, well actually, snapping it off. You will be applying considerable compression on that little M6 threaded pin.The 1/4 hole in the end of the pusher bolt makes sure the pin end stays straight and engaged.
Now the real test is to try it on fresh untouched pin in another housing. This test pin was never re-inserted with the same pressure as it had from the factory. At least there was zero, and I mean zero signs of rust or pitting, or roughness on the pin. Being bathed in oil its whole lift kept this one clean. If you have a wet rusty one, you’re in for a fight. Heat, penetrating oil, time, the usual....
I still think the “best” approach is to use the pin punch (1/4” socket extension) from outside the case through a hole. Easy on a trans with the reverse lockout, but you’d have to make a hole in the same spot for the earlier ones. I don’t think this such a big deal. We have the exact location from any trans with the reverse lockout, and making NPT threads and plugging it is pretty benign. 1/4 or 3/8 NPT is a plenty big hole. Or you spend a day or two making a custom puller. Your choice.