Quick Pedal Cluster Rebuild Question

[Glasgow 911SC]

I was going to rebuild my pedal cluster this weekend. i've removed the floorboards following Wayne's book. I'm now at the disconnect clutch cable part.

Now I have to remove the retainer pin. That's the pin to the left of the green dot below, yes? Does it just hammer out? Wont budge at the moment.

Next I'll have to unscrew the clevis from the cable. Thats' at the red dot, yes? I can only access this with the clutch pedal pressed. Is this correct or am I gonna launch something when the thing unscrews?

Thanks for any info.

[john walker's workshop]

disconnect the clutch cable at the trans first. then unclip the front clip and maybe it comes out with a bit of screwdriver twisting, and maybe it's stuck. they get notched by rubbing on the lever, or rusted, and occasionally i just have to pry the clevis apart, ie: break it, in order to separate it from the lever. i keep a supply of clevises for that reason.

[Glasgow 911SC]

Thanks JW. I was thinking that removal at the tranny end would be the case but quietly hoping I wouldn't have to crawl under my car in the freezing cold. Maybe I should leave this and replace the cable and clevis etc at the same time.

[Schrup]

I had to bust my clevis fork to get the retainer pin out because of what John described. I used a long skinny punch to get it started, then pryed on it with a screwdriver till it broke. The retainer pin had worn a 1/8 inch groove in the clutch shaft arm. I used a dremel to clean up the hole in the arm & pressed in the new brass bushing.

[Thomas Owen]

Glas - you see the clip to the left of the red dot? You have to pivot that down...that is the retainer for the pin. Now with the cable loose to pin will come out.
Good luck-

[911pcars]

Thomas,
Here's a pic of that type of retaining clip:



Sherwood

[vash]

yes, look at the pic of the part. you unclip it at the back and rotate it abit. then grab it with some needle nose pliers and pull towards you. i would disconnect at the tranny first.

[911pcars]

BTW, no need to remove the clevis. It's part of the clutch cable. It'll just fall away from the pedal assy. clutch arm after you remove the retaining clip. You also have to remove the ball socket for the throttle cable (above the clutch clevis).

Sherwood

[Glasgow 911SC]

That makes more sense seeing that pic Sherwood. I had it pivoted down but didn't want to force it too much. Maybe I'll just go ahead with the removal afterall. I got the accelerator linkage disconnected easily enough. hopefully I shall have squeak free pedals soon.

[Glasgow 911SC]

I take it in Wayne's book when it says

'The pedal cluster and the master cylider are bolted together on the early cars, so you need to disconnect the master cylinder in order to remove the pedal cluster.......after removing the belly pan'

it includes my car as an early car??? It really is too cold to be under my car at the moment.

[Jim Sims]

Yep, the two bolts on other side of the push rod into the brake master cylinder must be loosened and removed. It gets worse though: not only do you have to remove the splash guard under the front axle assembly you also need a second person to hold the wrench on the other side; some people get around this by welding the bolt head to the pedal cluster bracket. Cheers, Jim

[Glasgow 911SC]

Doh. Thanks Jim. I really do think I'm going to leave this for the better weather then.

[Early_S_Man]

No, Chris ... your car has power-assisted brakes, so the master cylinder is in the front 'boot' ...

No need to remove anything but the pushrod up to booster ... assuming that you DO want to remove pedal cluster!

[Glasgow 911SC]

hehe. am going round in circles on this one. Thanks Warren.

[Jim Sims]

Warren is right about the MC for your car being in the luggage compartment. However, looking at the parts diagrams for the power assisted brake system I cannot tell if one still has to get underneath to remove the nuts that secure the pedal cluster bracket or if these are now welded to the floor pan and one can simply loosen the screws from above. You'll know soon enough if the screws do not loosen from above. Cheers, Jim

[ohecht]

I just did this on my 82, and there are two bols under the steering rack guard that you need to take off from underneath the car. Mine were on studs welded to the cluster, so there was no need to have anyone hold them on the other side.

The clutch pin slide out easily for me, I had more problems with the brake actuating rod and the zinc plated bracket.

Olivier