Need help with pedal cluster rebuild/assembly
 

I am in the process of rebuilding the pedal cluster for my 1976 911S Targa. I believe that I have all of the necessary parts for the assembly. I was doing a test/dry fit and its looks like I might have a fitment issue. I'm hoping its a simple fix that one of the members will be able to easily diagnose. I have posted a few pictures.

It looks to me that the plastic bushing on the right might be thicker/wider than it should be which is causing the misalignment for the pin hole on the left.

Anyone have any thoughts or suggestions? My first thought was to shave down the plastic bushing/spacer until the holes align but figured I would check here before I make any modifications to the new parts.

Obviously the springs are not attached in the photo: again just a test fit.

http://i942.photobucket.com/albums/a...SizeRender.jpg

http://i942.photobucket.com/albums/a...zeRender_1.jpg

http://i942.photobucket.com/albums/a...zeRender_2.jpg

Give Whit a shout. Be rebuilds the PC and I am sure he could give you a hand. He is a really good dude.

Cheers and good luck.

http://forums.pelicanparts.com/porsche-911-used-parts-sale-wanted/852191-fully-rebuilt-pedal-cluster-assembly-68-73-a.html

Nice and clean :)

I'll be doing the same thing soon, having just bought the bronze bushings from our host. Good luck getting the last details sorted.

Shave down the plastic spacer???

Morning Bolson.
Man nice cluster!
What Draco said. The spacer currently being supplied by Porsche is too long. After having this issue myself I sourced a bushing from another supplier and had the same problem. The correct bushing may be out there somewhere but not at Pelican or Stoddard.
Just shave a little at a time, let it cool and pop the melted plastic out of the center where it will accumulate.
Be cautious not to shave too much as you will end up with unwanted slop in the assembly.
FYI I have tried both ways and find it simpler to put on the spring before I press in the roll pin. Just keep the clutch arm hallway off the shaft until you spin it into place and clear the rubber bump stop.
Good luck!
Whit

You guys know that there were two bushings used and one is narrower than the other... right?

JR

^^^ Well that would make it easier :-)

I do not recall having to shave my bronze upgrade either. Hmmm?

There are lots of different parts used over the years. I know of three or 4 clutch release shafts and at least 2 plastic bushings. Some combinations of these parts work better than others...

I don't have a part number handy for the narrower plastic bushing, so you'll have to do a little research on your own. Or, just trim the one you have in a lathe.

JR

You are correct JR. Pedal clusters for the early cars are 65-67, 68-72, 73-76, 77-78. With a couple funny crossovers thrown in transition years just to foul us up 50 years later ;)
But as I stated the one being supplied by Porsche for the 73-76 clusters is too long. It is the bushing for a later production set. If you can find the shorter bushing I would love to know where.

Whit is the man!
 

Special thanks to 'bugstrider' for recommending Whit.

BIG thanks to Whit for getting me set up. First of all, Whit was more than willing to talk me through the reassembly and after several emails it was obvious that Whit knows his stuff (especially the pedal cluster). Do I think I could have assembled it myself with the help of Whit? Most likely. Would I have damaged the powder coating, busted my knuckles, and swore like a sailor? Probably. Would it have turned out as nice? I think not.

I have attached a few 'before' pictures from when the cluster came out of the car. The last two pictures were after Whit's handy work. Its just a shame that the floor boards will be covering it up. Turned out perfect.

Can't recommend Whit enough. Price was extremely fair, shipping was fast, and Whit was always quick to respond to my questions before, during, and even after the work was done. A+

http://forums.pelicanparts.com/uploa...1432787499.jpg

http://forums.pelicanparts.com/uploa...1432787537.jpg

http://forums.pelicanparts.com/uploa...1432787569.jpg

http://forums.pelicanparts.com/uploa...1432787597.jpg

Sorry if this is piling on, but I had another post-purchase experience with Whit and I can't say enough about his willingness to help and prompt response. I won't go into great detail, but I will say that I was attempting the install after a long day at work. The solution to my problem was simple (and most likely a non-issue had I not been tired) but nonetheless, Whit got right back to me and got me on the right track.

Before removal...
http://forums.pelicanparts.com/uploa...1433304404.jpg

After restoration/installation...
http://forums.pelicanparts.com/uploa...1433304445.jpg

Cluster looks awesome. Which pedals are those and how do you like that gas pedal?

Looks like the black variant of the Rennline pedals.

Yes, they are the black Rennline with rubber grip: they are also sold perforated (without the grips).

I'm very happy with the install, although it was a little difficult to install the clutch and brake pedal since the actual pedal is textured it was hard to get a precise hole since the drill bit wanted to "walk".

I'm pretty happy with the gas pedal. There were plenty of reviews against the pedal extensions (red piece). I had the top and bottom installed and just on looks, unless you have freakishly narrow feet, it would be nearly impossible to push the brake pedal...and only the brake pedal. That being said, I really enjoy the pedal and it's nice to have the lower extension. Makes for much better heel-toe, if you're in to that type of driving.

One other little note, there is a small spring tensioner on the gas pedal that keep a little pressure on the pedal toward the driver, feels a little loose when initially pressing the pedal since you are pressing against the tension before you are actually pressing the acceleration linkage. Not a problem, just a bit surprised by the initial feel.