Rebuilt Pedal Box - Amazing Improvement

I picked up my car last night from having my local Porsche mech do a few bits and pieces. My 911 needed a new brake master cylinder, but had been leaking prodigious amounts of brake fluid all over the pedal box and floor. I had to really scrub the carpets before they disintergrated!

It must have been leaking for some time as the pedal shafts had rusted and had started to bind/stick. NOT very safe!

He's totally rebuilt the box, machining the shafts down a few thou' on his lathe and fitting new bushes. The end result is an amazing improvement. The car is now much smoother to drive!

I can highly suggest that you check out your pedal arrangement, as this can breath life into dull, heavy and lifeless pedals.

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Adam Chaplin
1976 911S Coupe

Adam,

I recently just dissassembled, cleaned, and lubricated my pedal assembly, as well as adjusted the accelerator linkage (which had 1cm of play!!). I can also attest, what a difference!! My clutch is now 2x easier to push, and no annoying creak noises!.

I recommend this to all with older 911's. It does not take long and the results (assuming yours is gummed up) are great!
Nick.

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Nick Shumaker
1982 911SC Coupe

[This message has been edited by Nickshu (edited 01-11-2001).]

explain the process more. I've been down there to change cables and so forth, but what did you do to really get in there and clean it? I surely hope I don't have to remove the cluster, as that looks very unfun.
Can I just pull up the board and get a good working feel for the area and do a good cleaning?

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Kurt B
1984 911 Carrera Cabriolet
75 914 1.8

Kurt,

I assure you, it is not fun. It took my back about a week to stop hurting from hanging upside down under the dash. If you dont want to take it all apart, you could clean it by removing the carpet and then the accelterator pedal (2 bottom bolts, the "pull" the ball type joint out of the back), then the floorboard. Vacuum it out and soak it with WD-40. Let it sit/drive it a couple of days, then follow it with a spray teflon or silicone lubricant (WD-40 doesnt last long). Use the straw on the cans to avoid getting it all over. Avoid the area in the center tunnel with the cruise control switch when you lubricate. Dont ask me how I know.
Best of Luck,
Nick.

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Nick Shumaker
1982 911SC Coupe

Actually, lubricating the pedal cluster is not such a great idea ... it attracts dirt and creates a worse problem, ultimately! The pedals use Nylon/Delrin bushings that are considered 'self-lubricating' and installed dry at the factory! WD-40 can cause some plastic bushings to swell and bind!

There should not be a problem with bushings swelling, or pedal pivot rust on SC's or later models, as the brake master cylinder is in the trunk. Leaking windshield seal or Targa seals allowing water to collect in the pedal area are about the only source of rust on brake booster models!

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Warren Hall
1973 911S Targa

Oops,

Oh well. At least it will be good for awhile.

Nick.

I just completed this job. You must do this job IF, when poking around where the clutch cable meets the clutch pedal shaft lever, you see that the round brass bushing is eaten away and that the clutch cable trunnion pin has started to eat through the shaft lever metal. Much more of this means you are buying a new pedal shaft, which can't be very cheap. Also you will find that the part breaks when you least want it to. You'll have to tow the car to get it fixed.

John