Pedal cluster puzzlement

[Jerome74911S]

First, let me introduce myself. I have been subscribed to this BBS for quite a while and I obsessively spend some hours reading and learning every day, but I have not posted much. Finally I feel that I know enough to ask a few questions, even though they are simple.

I bought a '74 911 (manufactured in November, '73) six months ago, but it has been in a heated warehouse over the winter. Before it comes out next month, a couple things on my to-do list have to get completed.

The floorboards were junk. After pulling them out I learned that a leaking windshield had been doing its thing for quite a while, so there is rust on the floor to be repaired. To repair the rust, or course the pedal cluster has to come out. I have questions about this process that have not been answered in my search of threads here, or elsewhere.

The first photo shows the clevis and opened snap-on retainer on the end of the clutch cable. In Wayne's 101 Projects book it says to use a small screwdriver to remove the pin from the clevis. It appears that I should pry on the left side of the retainer to move the pin out. Here is my question: The clutch cable is under substantial tension, so how is this possible? While driving the car a little over 1000 miles last fall I did not notice any clutch slippage. Neither did a local Porsche restorer who drove the car. Wouldn't the clutch slip if the cable was under too much tension? And yet it is under too much tension to remove the clevis pin.

Second question: 101 Projects says that starting in 1977, the clutch return spring was moved to the outside of the pedal cluster. In my second photo, don't we see the spring on the outside? Do I have a '77 pedal cluster? Or is it an uncommon variant on a '74?

Question three: When adjusting the clutch, 101 Projects says that clutch pedal free play is correct when you can pull the clutch pedal one inch back toward you. Both the clutch and brake pedals rest against the rubber stopper that we see, and cannot be pulled back at all. Therefore, what does the 101 Projects advice mean?

Jerome

[javadog]

Jerome,

1. I generally remove the clutch cable at the transmission end first.

2. Can't help you here. I don't have an early pedal cluster in front of me and my memory is not great.

3. That advice is for an earlier clutch release design and doesn't apply to your car.

JR

[911pcars]

As I recall, the clevis pin is part of the clip and you have to maneuver/swing it away from the cable end in order to remove the pin.

As javadog suggests, also try to introduce some slack from the clutch cable end (make note of exposed threads). After you rebuild the cluster, readjust the cable.

Sherwood

[VaSteve]

Disconnect at the transmission first, but also note that the clevis will probably have worn down into the bushing and will need to be replaced as well. When it wears down, it's hard to remove.

[ghost1001]

that little pin was very hard to remove...with no trany in the car!!

Here is a picture of a '76 cluster....maybe they had a few left over for '77 cars....yours looks like mine:

i am doing the rebuild now....the cluster came apart really easy with the proper sized punch, bench vise and a small hammer. I decided to replace the spings as well.....they are not cheap!!

[Jerome74911S]

An interesting note is that the gas pedal was bent into a curve from a PO really mashing it down hard. At least the car was not a garage queen. . .

Thanks for the advice - I needed a little boost and you guys provided it.

Jerome