Car prepping - pedals and clutch

Other than the obvious two vs. three pedals, the pedal box for manual transmission is different than that of a auto d:o. First of all, the auto pedal box does not have the thru hole for the clutch where the pedal connects to the master cylinder. This could be bored/drill fairly easily I would think, but the big difference is that the manual pedal box has additional bracketry to accomodate the additional pedal. For this reason the entire pedal box has to be switched out. This is no big deal either if you don't mind tearing down half the dash and removing the steering column etc, all the while contorting your body into an impossibly small space in a hot garage (Texas in early summer). Seriously, I'm not sure it would be even possible to re-configure the pedal box while still installed in the car given that there are snap-rings to access, shafts to remove/install and - as was the case for me - broken pedal return springs to replace.



Auto pedal box (steering shaft on the left)

Auto pedal box, instrument cluster, steering column etc.removed

This was also a good opportunity to clear up some dormant wiring for a car alarm from pre-2005. The trickiest part of the disassembly was probably to get the splined steering shaft to slide off of the steering U-joint assembly. You can't get in there with a hammer to tap on it but after some scrouging around in my attic I came across an L-shaped tool for installing hardwood flooring, which worked great as an adapter.


Manual pedal box in place

The manual pedal box was overhauled with a fresh coat of paint, as well as new linkages, clevises, springs and pedal rubbers installed; the shafts were also cleaned and greased. Wow - the pedals look and work like new! Finally, a new steering column bushing was purchased from PJ Grady and installed. (Hopefully that will alleviate the steering "moan" that's been plaguing #1283 all these years...)

On the other side of the firewall, I sealed the thru hole and installed the master clutch cylinder as well as the clutch reservoir (forgot to take pics!).

Finally, I reinstalled the steering column and then of course, the instrument cluster, knee bolsters, steering wheel, carpeting and driver's seat.