Rebuilding Pedal Cluster Questions

[s_wilwerding]

I was told that I should rebuild my pedal cluster because the clutch and brake pedals squeak. I have Wayne's 101 Projects book - does anyone have any tips above and beyond the book? Is it necessary to reset the clutch or throttle linkages when reinstalling the pedals?

Thanks.

[Jdub]

A Search will reveal much.

First and foremost, check how your clutch pedal "ear," in the tunnel, appears. That is, is there a notch now since the old bushing is probably toast. This notch will affect the trunnion pin that hooks to it: do yourself a favor and order one right now so you have it at hand when you find it is dead. You may also have to dot some weld to the now-notched secton of this clutch pedal. Don't scrimp here: have it done and put in the brass bush provided with PP's kit.

For my '78, much like your '81, I found that the small hex bolt at the leftside of the 'rack was a bear to reinstall since it sits right in the way of rehooking the clutch spring. You've got to decide to put the spring in first and then get at the hex as best you can ( was most successful following this procedure). To reinstall the clutch assistance spring at the 'rack you simply rotate the pedal all the way 'round, hook the spring, then use the clutch pedal as a lever to rotate back to normal position.

Really, the sequence of reassembly can ease reinstallation. If memory serves, I put the flat support bar to the rack first, then eased the rack pan back to the floor, and, with clutch assistance spring in place, gently got the hex bolt to engage using a specially-sawed short hex wrench. The sawed-off hex wrench will assist here in incrementally moving that hex in. Patience here!

Be sure to replace the helper spring back at the trans. I would highly recommend a new clutch cable as well. It is not usually clear that these parts wear, but the difference with new parts is INCREDIBLE! Do youself a favor, gather all of the parts and do the whole procedure, you will not be sorry you did.

John

[BoogieOnSkis]

The 101 book does not describe how to reinstall the clutch return spring without putting a screw driver or prybar through it.

There is a much easier way -

You need to remove all four nuts that hold down the cluster, detach the master cylinder linkage, then remove the allen head bolt from the brace that attaches to the cluster. Lift the cluster about a half inch off the floor then pull the clutch pedal towards you; the spring pin on the clutch pedal rotates to the floor. Now, just slip on the spring. When you push the clutch pedal back, it will pop into position. Now bolt it all back down. Done!