Pedal cluster game

[OldTee]

What do you use to put the spring on the left side of the pedal cluster back on. 78 SC. Here are the rules:

1: No special tools
2. Use only tools in your normal tool box.
3: Only one person
4: Can be done by someone between 15 and 20 or over 60 years old.

What do you win. The respect of everyone who has done it or will do it someday.

[vash]

i use my cheapo craftman drum brake tool. it takes seconds.

[PorschePilot]

I just used vise grips and gave it a pull.

[tyro]

Brake spring tools, vise grips - not sure how you guys do it, perhaps you have more muscle than me.

I struggled with mine for a bit, realized that taking out the cluster was the easiest way to get that spring on. Rotate the clutch pedal around and you'll see it is simple.

Are you replacing the bushings? That was the only reason mine was apart..

[RWebb]

motor-operated push-over

[boyt911sc]

Originally Posted by OldTee

What do you use to put the spring on the left side of the pedal cluster back on. 78 SC. Here are the rules:

1: No special tools
2. Use only tools in your normal tool box.
3: Only one person
4: Can be done by someone between 15 and 20 or over 60 years old.

What do you win. The respect of everyone who has done it or will do it someday.

The pictures show my procedure with no special tool except wire loop.

This is how I installed the spring. But with the pedal cluster unit installed in the car, do the opposite end (outer end). The wire loop helps hold the spring in place during installation.





Tony

[vash]

not bad...the drum brake tool is better. there is a divot on the end that lets you lever up the spring and simply drop it into place.

pulling with vice grips? crazy. i knocked myself out (out cold) pulling hard on something in my jeep (the shift lever). i learned a valuable lesson that day. brute strength mechanics is dangerous. anytime i can apply a mechanical advantage, i go for it.

[OldTee]

This cheats a little. That little allen cannot be put in the brace unless you take apart the heater in the trunk to get at the other end of that silly brace. This item needs to be in the Porsche maintainability hall of shame.

Ans to tyro. Yes, replacing the bushings AND the clutch arm at the other end is buggered up.

[tyro]

Originally Posted by OldTee

This cheats a little. That little allen cannot be put in the brace unless you take apart the heater in the trunk to get at the other end of that silly brace.

Heater removal wasn't required, at least on my 1980 model. There's a 17mm bolt on the aluminum brake booster housing that is easily removed, found out that I probably didn't have to mess with the allen screw on the cluster. Can't recall exactly, but it was much easier putting it all back together.

Originally Posted by OldTee

Ans to tyro. Yes, replacing the bushings AND the clutch arm at the other end is buggered up.

Mine was the same way. Had to get the cable clip from our host, but I had purchased the shaft ahead of time..oh well, all done now.

[SteveinTO]

Excuse me!

Is Oldtee actually using a piece of old coat hanger, to replace an official Porsche tool, to reassemble an official Porsche pedal cluster.

I have to go sit down.

[NY65912]

I did a seach a few years back and found a novel way of doing the deed. After an hour of scrapped knukles and cursing I figured "hey I must not be the only guy to do this" and searched the archives.

Form a oval from coat hanger wire, hook it to the spring J hook, Then get a small ratchet tie down and hook it to the wire ring, Secure it to the seat bracket and start cranking on the tie down,

After a few cranks on the ratchet, viola, the spring is pulled back far enough to gently hook the spting to the pin. Back it off and your done.

[OldTee]

Wish I could go out there in the garage and try one of these solutions but, I ordered a new shaft which is only available from Porsche and must come from the old country. That takes 5 or so days. Then I will try one of these.
Thanks

[VaSteve]

John.....I don't know if this is one of those riddles where you already know the answer, but you can just use a handful of washers. Just jam them between the rings of the spring and it will stretch it out enough to get over the post. That's what I did.

At Clarke's shop, he used the drum brake tool as someone suggested.