Hi All, found out the shaft that runs behind the PS headlight door is broken. Has anyone replaced this before and if so, what size Hex/Allen wrench did you use?
It's so small I'm not sure it is a Hex/Allen screw head. I have a good variety of tools, but nothing seems to fit.
As always, thanks for your help.

Shaft w/hinges

collar lock screw

 

I'd think this has to be a SAE hex screw as there was virtually no use of Metric at this time in the US automotive industry.
Try thoroughly cleaning out the entire cavity of the screw using a sharp "pick" and some solvent to flush out the debris. Then generously lubricate the threaded area with a penetrating oil and refresh over time. After sitting for 12-24 hours, play with Allen wrenches until you find the right one, push it in all the way, and give it a twist.
My best thoughts, and this is what I'd try for myself. If this fails, I guess a torch would be the next step, or find a replacement..
Good luck.

 

Thanks Toro. I have done just what you suggested. It would seem rust has gotten to the internal head of the screws making them super thin, thereby easy to strip. If I have the correct size I can insert it and put small vice grips on the outside and try to turn them. Heating the collar up at the same time is the last resort. BTW the (2) replacement driver's side assemblies I have are in the same condition. I just don't have the passengers side. The shafts are the same length, I just have to disassemble one to flip it. I would also get new screws if I can get them out.