Ordinarily, I would have simply removed the compressed caps that retained each set of pins and spring, replaced the worn pin(s) that was causing the lock to not opperate properly, and replaced the caps with the Best cylinder reloading tool.
Well, I didn't have my reloading tool with me, but the customer had a second cylinder with a removeable retaining clip at the end of the plug. This core had the same keyway as the first, but pinned for a different user key with the same master key and grandmaster key and core removal control key. The first cylinder had a factory stamped collar at the end of the plug, which ment that the plug could never be removed.
I've reloaded plenty of cylinders through the plug hole before, but that was with just two pins and a spring in each chamber. I'm talking about four pins per chamber with some of them no thicker than a couple of pieces of paper.
I carefully removed the retaining caps with the tip of a small flat head screw driver of each chamber. I then inserted a paper clip through the opposite end, pushing each pin out of the core, carefully recording their oder as I took them out. I then used the master key to open the second cylinder and pulled the plug completely out, allowing the pins to explode everywhere. I was fortunate to identify the badly worn pins from the first cylinder and replace them from the second cylinder (it doesn't take much loss of allowable tollerances to make these locks not work), which had fairly new pins in it. Next, I was able to put the last two bottom pins pre-loaded in each corresponding chamber of the plug. Then, I put the first spring in, left with task of loading two top pins. At this point, I was using the partially loaded plug to retain everything without the aid of a plug follower. I memorized the order between the differrent sized top pins just in case I slipped and everything exploded. I loaded the first top pin with the aid of a large paperclip.
Finally, I positioned the second top pin close to end of the plug. I was able to backout the plug just enough to allow its edge to barely retain the existing loaded top pin, and at this point I forced the second top pin in place. I repeated the process for all remaining pin chambers. The dexterity that this required bordered near insanity. The first pin chamber was the hardest to get started. But, I was successful, and the newly reloaded second core worked beautifully.
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You're a saint. I would have found a way to weasel out of doing that. Partially repinned the first cylinder for the night and taken the other back to the shop or something.