[Rick Parker]

Mike:

The pin is made of hardened material it is intended to be a PRESS FIT in the cam and a very close slip fit in the cam gear. HOWEVER some of the pins have a reduced diameter in the length used to register the cam gear to allow for various bushings to be inserted in the large hole/small pin. I have seen these sold by Mr Gasket on a card they are Ford specific, about 1/2"- 3/4", long not the thinner Chevrolet version. Since Ford's engineering uses only 1 large center bolt to secure the cam gear the bolt must be of high quality and torqued properly as the clamping force created is the crucial. If you do not use the bushings to adjust the cam timing but rather the muti grooved crank sprocket it is vital that the pin fit in the cam gear without ANY slop. The pin for this application will not have a reduced diameter. The installed height of the pin and or bushing must be below the surface of the cam gear or the washer will not be able to clamp the cam gear securely to the cam.
It is not unusual to see 2 dowels used, (high spring loads & RPM) 180 degrees apart. The dowel (s) do share in the torque loading to some degree but the gear mut be clamped tightly (use 262 Locktite) to prevent any movement in this critical area.
From what you are describing there is no easy way out, a new pin will have to be installed and it will be best, as difficult as it is to accept to have full access to the front of the engine outside of the car. If you do othewise be sure you do not dislodge the cam plug on the back of the engine.

Sorry

Rick