Clutch Pedal pivot rod repair

[Jack P.]

I had started out for NYC last week to join the Scandinavians in a send off of starting their Lincoln Highway Tour 2013.


As you recall, my pedal was heading left. Well about 3 miles away from home the pedal came off. Tow truck brought it back home and I was in my other car and off to NYC. I was fortunate not to have it break in the middle of CT or MA.


Once back home I took on the job of repairing the pedal. I ordered a new pivot rod and had it welded back on to pedal. The following pictures will give you an idea what it looks like to do the repair.


First you have to take out the seat and steering column 1/2 hour





You have to take off the clutch spring and cover along with the column hardware . You can see the column hole in firewall . Also notice the bolts that hold the master brake cylinder and two above hold the pedal assembly to firewall





Column out complete , do not take apart , just pull out after removing under cluster supports.










Parts laid out on table. column parts in order , pedal assembly





Broken pivot rod and replacement rod inserted in pedal










Original Capacitor for brake lights





Pedal installed into assembly


The bushings used are the plastic ones use also in the headlights and convertible top latch assembly. Just re grease and insert pedal pivot rod and re-clip









All done . Total time about 4 hours without rushing.

[Timothy B.]

Re: Clutch Pedal pivot rod repair

Jack,

Nice job, I was not aware the pivot rod could be purchased, I thought the complete pedal had to be bought. Is that rod spot welded to the pedal? I am surprised it came out so clean without damaging the fit between the rod and pedal.

[Jack P.]

Re: Clutch Pedal pivot rod repair

Jack,

Nice job, I was not aware the pivot rod could be purchased, I thought the complete pedal had to be bought. Is that rod spot welded to the pedal? I am surprised it came out so clean without damaging the fit between the rod and pedal.

Hi, yes you can buy just the rod. It is about $15 from Zip vs $70-85 for complete pedal, without pin plate for clutch rod. But back to your question. The rod as you can see has a machined end that is rectangular. Mine broke off after 150.000 miles , as I replaced the rod 35 years ago. They are only good for 150,000 miles. I ground off the weld spot down to pedal surface. Just popped out piece of rod still in pedal. The stamped slot in pedal was perfect with no distortion. If the pedal is bent or the slot is distorted, I would have gotten a new pedal. The rod is a press fit and I gentley hammered it in to butt up against pedal. Unfortunately , they machined the slot for the clip about 1/8 " to close to pedal. When you butt the rod against pedal for maximum strength and put the pedal back in the assembly, the clip slot can not be seen , not allowing the clip to be put back on.

So you have to back it out about until you can see the slot to clip. When you do this, the rod barrel is 1/16 " + away from flush with pedal, allowing the flexing of shaft over time , leading to breakage. Since I will be dead long before it breaks , I did not machine the clip slot out 1/8 ".

They must be using the same dimensions from 35 years ago, and they were wrong then and are now....

Jack

[Timothy B.]

Re: Clutch Pedal pivot rod repair

Jack,

If I understand you correctly the new rod and clutch pedal interface is not welded and just a press fit. Do you remember if it was that way originally.

Given what you stated about the clip groove, I think I would have welded the pin on both outside sides. I hate reproduction parts..

[Jack P.]

Re: Clutch Pedal pivot rod repair

No you still have to weld it in place. It is just a very tight fit, which is good, even if the slot was a little distorted, the weld will fill in the area from the end side.. You do not have the room to weld on the inside, it is better to just make the pin slot a little larger to the outside. Then you butt the rod against the pedal and weld on the piece of rod sticking through pedal. As I said, the rod from 35 years ago was not machined right as it had a gap because the rod had to be backed out to catch the clip in the end slot.

Jack

[Jim S.]

Re: Clutch Pedal pivot rod repair

Jack,

" Since I will be dead long before it breaks , I did not machine the clip slot out 1/8 ".

After reading all about your travels over the years , I would do the machining ! As I for one would not bet against 150,000 more miles before your death !

Jim

[Jack P.]

Re: Clutch Pedal pivot rod repair welding photos

I found the photos of the welding of the pivot rod to the Clutch pedal. Special thanks to Cottage Road Service Center, in South Portland , ME for the weld. Dan did the work. I take my regular cars to them and my corvette for special projects that require a lift or welding.


Parts on welding table











Dan ready to fire up the welder











Put back in pedal assembly





Dan with finished assembly