Pedal Cluster Rebuild - Few Questions
 

I've refurbished a pedal cluster before but it's been about 10 years since (that was on my 914).

I'm just wondering if I need to loosen the clutch cable at the transmission. And, any other tips would be appreciated.

I just replaced the master cylinder and after installing, I noticed that the brake pedal does not full return (instantly) and so it leaves the brake lights on for a few seconds after releasing the brake. The original pedal cluster is in pretty good shape but still uses the nylon bushings so I figure a rebuild and brass bushings is in order. I'm hoping to get this done in a couple of days since I want to take the car on a trip this weekend. One day for painting and one day for reassembling.

no, you dont need to, but as you are likely going to have to readjust everything anyways, it might make it a little easier...

its pretty tight fit and not and easy place to move around. If you can get the clip off without any issues and the little pin out, then i wouldnt bother...if not then loosen it up and will make it a little easier to get out and reconnected.

I'd only recommend a fresh cable if you are not sure of the age of your current one. For certain you MUST get at that bushing holding the trunnion pin to the cable end @ the clutch pedal - critical.

Some discussion on nylon versus bronze. I used the bronze, overnight hot soak in a pan of 80/90 before I put them in. PeterZ however recommended the nylon bushings as I believe they are less likely to, over time, damage the cluster - the nylon bushings will not.

Yeah i put the bronze in as -is without saoking at all and have had zero issues over 8 years. I would recomend using the opportunity to check adjust your clutch cable anyway and back off the adjustment to give you some slack . pretty easy project overall.