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It can be difficult to remove the old post without damaging the plate.

The back portion of the post is often expanded/distorted in the assembly process. If you just pry it out, the hole will be damaged, and the plate might crack.

 

I unsolder all the wires so the plate can be removed from the transformer, and carefully drill out the old post.

I am looking forward to reading about other solutions.

Once they're loose, I've simply removed them by prying up the loose petals inside, I've never damaged a KW or ZW taking them out this way.  I've never had to remove the wires, I've probably replaced one or more posts on at least a dozen transformers.

 

If you can get in there with a Dremel grinding wheel, you could probably grind down the inside of the post, I've never tried that, it's just an idea.

 

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