huntingman2706217

Apparently im not the first this has happened to so figured i would take some pics and make a short How To to make this thing a bit more beefy...

Today i went to leave the gas station less than a mile from my house and the pedal went to the floor... looked everywhere and found nothing wrong till i realized when i pushed the pedal my engine linkage twisted then twisted back when i let go... took it out and this is what i found...





This is not a major thing to do and took me less than a hour... i wanted to do this because some people would freak out and think they need to go buy a whole new pedal now and WHERE would you ever find one... Also some would just weld the cracks and call it good... may as well go above and beyond while its out!

As you can see even from the factory they didnt weld all the way around and with so much force the two thin pieces laid side by side actually ripped...


First things first i removed my pedal... pretty self explanitory so i didnt take a pics but heres the steps...

Remove the spring

Remove the pin holding on your clutch and be careful not loose any of the parts... (mine are long gone from a 94+ AX15 bellhousing swap)

Loosen the large bolt running from the other side of you brake pedal to the far side by the left kick panel... this nut is a smashed style lock nut... and is 18mm... i used a 19 but a 18 on the head so i think it was suppose to be a 18 nut also...

i found a large washer i already had... you may need to go buy one... take you pedal with you if so and match one up best you can... mines hole was slightly larger but didnt matter to me... if your going to buy one buy one thats a tight fit...

make sure your pedal is bent back as good as possible so the crack is hardly visible and slide your washer over the hollow tube... i used a large bolt and nut to run through the tube and finger tightened... this was to keep slag out since it is a "bearing" like surface in there...

Then i just began welding all three layers (the two factory layers plus the washer) together to make one strong unit... as well as welding the washer on the flat spot that runs down and connects to your reservoir



I also welded along the inside where mine was only half way welded around... this was not a break point for mine but it could become one in the future...



I also welded the other side that goes to the pedal all the way around since it was only tack welded as well...



kinda ugly welds but...


then of course a quick scrub with the wire brush and some paint just for kicks... and install as you took it out... told you it was easy!!!

BlueXJ

Travis I thought of one other thing that may enhance to function. I thought of drilling a hole and adding a zerk fitting and give it a yearly squirt with the grease gun. I welcome your thoughts on that.

huntingman2706217

it wouldnt be a bad idea but even mine being as old as it was still had grease in it and the plastic bearings were still like new... wouldnt hurt though!

huntingman2706217

Heres is another mods (Dan) who had the same problem... he added flat plate to his... not a bad idea either!