How can you fix and reenforce bent pedal box ??

tickford6 · 27-09-2012, 03:17 PM

Hey guys just wondering how to fix and straighten up a bent clutch pedal box and reenforce it ? Any help will be appreciated thanks

Kieron · 27-09-2012, 04:03 PM

Would this be an E series Falcon by any chance?

If so, and going by memory there is a triangular plate that is spot welded onto the main pedal box assembly that breaks at the spot welds. I simply had holes drilled thru the two plates and sandwiched them back together with nuts and bolts.

**Sorted** · 27-09-2012, 04:47 PM

I had a Bent Pedal Box on ProEF

Welded some thick metal at the pivot point - not pretty but effective

But had to remove remove dash to get to it - have fun with that :(

mik · 27-09-2012, 08:54 PM

that`s looks to be a stout repair Sorted, no mucking around here, well done, you can repair my kenworth chassis rails any day ;).

**ebxr8240** · 27-09-2012, 08:57 PM

Quote:

Originally Posted by mik

that`s looks to be a stout repair Sorted, no mucking around here, well done, you can repair my kenworth chassis rails any day ;).

Repairing the Keny would be easier !!!

Coyote mk3 · 27-09-2012, 09:07 PM

I pretty much did the same as Sorted, although slightly smaller piece of metal welded on

But going strong so far. It's been there for over 6 months now.
Enjoy taking the dash out. And whatever you do don't crush any wires when bolting the pedal box back in...you may have difficulties starting the car if you crush the right ones hahaha

mik · 27-09-2012, 09:13 PM

Quote:

Originally Posted by ebxr8240

Repairing the Keny would be easier !!!

indeed it would

.

XR Martin · 27-09-2012, 09:20 PM

Dont know what's the big deal in pulling the dash, its all pretty straight forward. Just time consuming.

tickford6 · 27-09-2012, 09:45 PM

It's au xr6, is it the same pedal box as the e series ? I don't think I'll have to take the dash out will I?

mik · 27-09-2012, 10:20 PM

Quote:

Originally Posted by XR6 Martin

Dont know what's the big deal in pulling the dash, its all pretty straight forward. Just time consuming.

it`s a bit back breaking if your an old fart :(

au adam · 27-09-2012, 10:46 PM

Just get a new one and reinforce that.While you at it replace the clutch cable.

Kieron · 28-09-2012, 12:26 AM

Quote:

Originally Posted by tickford6

It's au xr6, is it the same pedal box as the e series ? I don't think I'll have to take the dash out will I?

Welding you will have to take the dash out, the bolt method I had done can be done with the dash in (this was on an EF) using a flexible drill shaft then large nut/bolt with locking washers, worked perfect and never had a problem with the HD clutch/pressure plate I had in it.

Nikked · 28-09-2012, 07:29 AM

Quote:

Originally Posted by Kieron

Welding you will have to take the dash out, the bolt method I had done can be done with the dash in (this was on an EF) using a flexible drill shaft then large nut/bolt with locking washers, worked perfect and never had a problem with the HD clutch/pressure plate I had in it.

Elaborate more....

tickford6 · 28-09-2012, 07:57 AM

Quote:

Originally Posted by Kieron

Welding you will have to take the dash out, the bolt method I had done can be done with the dash in (this was on an EF) using a flexible drill shaft then large nut/bolt with locking washers, worked perfect and never had a problem with the HD clutch/pressure plate I had in it.

I'm liking the bolt method haha, can you explain it a bit more ? Thanks

tickford6 · 28-09-2012, 08:06 AM

Are you sure have to take the dash out? It's an au, I got under it then and you can get to every bolt it's just going to need some skilled mongering to get around the sterring Collum but should be revatibly easy?

graham7773 · 28-09-2012, 11:13 AM

Quote:

Originally Posted by au adam

Just get a new one and reinforce that.While you at it replace the clutch cable.

I agree with AU Adam (has anybody priced a new pedal box from Ford?) but Ford aus simply did not learn. This problem went on for 10 years. All the E series had it and it can be a beartch to fix as sometimes the firewall tears as well as the pedal box bending and cracking. I have to say that in my EB I didn't remove the dash but I was a bit more flexible then. I plated the firewall, strengthened the pedal box and replaced the clutch cable....then sold the car. I will never trust another E series manual. Seen too many fail.

**Sorted** · 28-09-2012, 12:30 PM

If you look at the pedal box you will see that attaching a clutch pedal to the side of it seems like an after thought and not well nutted out.

The Brake Pedal and the Accel Pedal are supported on both sides by the pedal box's frame BUT the clutch pedal is just attached with what is basically a bolt on one side of the pedal box's frame - it has no support for the other side of the bolt - this is why it bends the pedal box frame

Mal Wood has the right idea with this Pedal Pin Kit - it has more than enough support for the pedal box to not bend - this can be fitted to an Auto Box and it's said you don't have to remove the dash to fit it

Quote:

Originally Posted by mik

that`s looks to be a stout repair Sorted, no mucking around here, well done, you can repair my kenworth chassis rails any day ;).

It was just a chunk of metal lying around - very dodgy repair but it does the job

Quote:

Originally Posted by ebxr8240

Repairing the Keny would be easier !!!

Quote:

Originally Posted by mik

indeed it would

.

lol

After you fix the Pedal Box you may want to reinforce your fire wall as well as they tend to fail as well - these also have no support

[QUOTE=Sorted]Cam.

Of coruse the pedal moves as the cable is still attached to the clutch pedal

BUT that cable is supposed to be fixed to the fire wall as per below pics

yours has broken - common issue with the fire walls

How to make a fire wall plate http://www.fordmods.com/post848422.html

Clutch cable with Fire Wall Plate - see no cable is showing

[QUOTE]

Kieron · 28-09-2012, 01:35 PM

Quote:

Originally Posted by tickford6

I'm liking the bolt method haha, can you explain it a bit more ? Thanks

It's been 10 years or so now, but from memory -

In Sorted's first pic, you can make out the additional clutch bracket that is spot welded in 3? positions to the main pedal box. In my case, one of these spot welds broke which, I believe is the usual problem.

As you can't get a full on drill up inside the dash, use a flexible drill shaft -

Drill the broken spot weld(s) out, you may have to drill a pilot hole then enlarge it with a bigger drill bit.

Get a large nut/bolt, some flat washers plus locking washers and bolt it all back up using a bit of muscle to clamp the bent bracket flush against the main pedal box.

In my case it was an EF and there was enough room to get the flexible drill up inside the dash, hopefully an AU has enough space to get it in too.