Pedal Cluster Rebuild Time.....
 

Ok, I did the usual BB search and have read the article in Wayne's "101 Projects" book. What I am looking for are any "Tips" that will make the job go easier! You know, the things that you find out after struggling for 2 hours doing it "the hard way". By the way, this is a 1980 SC coupe.

Thanks in advance for any and all replies!

Fred,
I have rebuilt a '78, an '88, and a '92 cluster and all were very straightforward. I think the only tricky thing you may get into is when there might be a lot of rust, and that of course will take extra time to deal with.
Good luck -

That pin cn be a b**ch to get out sometimes. It doesn't help that there isn't a good way to clamp the assembly in a vice.
-Chris

Pedal Cluster....
 

Thanks for the replies! Fortunately my car is virtually rust free so I don't expect that to be an issue. The roll pin however appears to have begun to shear off so I will probably have to drill it out.

One specific question that I have is what is the easiest way to remove the heavy clutch helper spring that runs from the firewall to the clutch pedal? That looks like it could be a real #@$%^#@ to get off!

Pedal Cluster is out!
 

I felt really energetic today so this afternoon I pulled the pedal cluster out of my SC.

http://forums.pelicanparts.com/uploa...1123368029.jpg

As you can see, the base is pretty nasty with all of the paint having been lifted and shrivled (brake fluid?). I got REALLY lucky and the clutch pedal roll pin came out with no problems! Once the roll pin was out the rest came apart easily. The original plastic bushings are shot, but the rest of the parts (brake spring, etc.) all look ok. I am going to get the base and pedals sandblasted and then powder coat painted. That along with the new bronze bushings should put the pedal cluster issue to bed for a long, long time.

Oh yeah, the old clutch cable had stretched almost 1/2" longer than the new cable!

I ospho'd mine and primed it. That brake fluid is a real ruster.

Here is mine after I plated and powdercoated everything.

-Britain

http://www.britainsmith.com/Porsche/...1_0010_JPG.jpg

I would suggest being careful taking it out. I broke one bolt off because it was really rusty. But looks like you're past that part.

After taking it out, I used a rust remover solution from pep boys to take off all the rust, had to sand/grind in some places a little though to get off all the rust. Do the floor too. After that, primer and you're done.

It's Done!....
 

Just finished the job tonight. New clutch cable, PP pedal cluster rebuild kit, new clutch cable clevis pin, brake pedal return spring and clutch helper spring! Everything went together as it should with little effort except..... the dreaded clutch helper spring. You know, the one that is installed between the pedal cluster base and the clutch pedal by Superman when the car is built. But, after much effort and sweat, it finally clicked into place.

The pedals now move more smoothly and the clutch effort is somewhat less than before. At least now I have some adjustment left on the clutch cable!

Price of new parts - $150
Cost of labor - $0.00
The satisfaction of a job well done - Priceless!

Fred, the helper spring is actually pretty easy to install. Although you already did it, an easier way is to rotate the clutch pedal in a circular pattern stretching it as the assembly spins. That way, you don't need to struggle manpowering it into place.

Oh well, congrats.

David

Re: It's Done!....
 

I remember a pelicanhead who looped some saftey wire thru the roll pin.. and then another pelicanhead chimed in that he had a pin come loose. That was the only instance where I've read that happening.. hope I'm not too late.

http://www.pelicanparts.com/support/smileys/wat6.gif