In an attempt to lessen the effort that it takes to push my clutch pedal, I elected to install the Mustang Steve pedal support repair kit. This kit is primarily utilized to repair a bad clutch/brake pedal support should the pot metal bushings be worn beyond use. I found the kit to fairly complete and the enclosed instructions to be adequate. I also believe that they would be better if it included a couple of diagrams or pictures.
First remove the Clutch/Brake pedal support from the car. That is not the subject of this tech article and it will be somewhat difficult if you are mechanically challenged. I do recommend having a shop manual on hand as it is very useful as a reference. This installation was specifically done on a 65/66' type Mustang support, although the modification is also applicable to Falcons, Comets, Fairlanes and other Fords, plus some GM, and Mopar cars.
Here is what the support and related parts looks like when assembled under the dash:
Note that the pedal stop is not shown. It would have been bolted to the square hole. Also note that there are nylon bushings found in the spring eyes. They are not included in the kit.
Here are the parts of a stripped pedal support:
Note that the nylon bushings on the right. Two of the large ones will be eliminated and replaced with ball bearings.\
Here is a closer look at the original type bushings:
Here are the components that came in the Mustang Steve kit:
It included 2 roller bearings, 2 sleeves to hold the bearings, 4 washers, 2 nylon bushings for the brake pedal, and a new bushing for the brake pedal to master cylinder rod.
First I cleaned all the parts and inspected them for damage. I found that the driver’s side pot metal bushing was egg shaped, which is a common problem:
Next I removed the pot metal bushings with a chisel and a hammer. I had to mess around a little with it to find the proper technique.
Next wire brush and sand the areas where the pot metal washers had been to prepare for welding. Then tack the big washers inside the clutch support. They do not need to be solidly welded as they are simply used as spacer washers:
It is best if the holes in the washers are centered inside the original holes in the support.
Now it was time to weld the supplied sleeves to the support. The alignment of these parts are crucial to properly support the bearings. I followed Steve's instructions and cleaned up the clutch pedal stud by sanding it and removing the raised worn spots until they could slide through the new bearings.
If the original pot metal parts were severely damaged, the stud may have wear marks cut into them. Normally there is not a problem in reusing it anyways since this kit locates the stud's contact points away from their original location.
Now do a test assembly for fitting. Place a bearing on the stud of the clutch pedal. Then put the sleeve on the bearing. Pass the stud through the clutch/brake pedal support and then put a sleeve plus the other bearing on the stud. I temporarily held it all together with a cotter key.
Try to center the stud between the washers that you have already tacked inside the clutch/brake pedal support. Then it is time to do some more welding.
I tacked the sleeves in place and then I removed the clutch pedal assembly and the bearings. You do not want to get the bearings hotter than is necessary. Then I welded on the sleeves a little bit at a time, periodically allowing them to cool before starting again:
Complete the weld and then test install the bearings in the sleeves:
Caution: If too much heat is applied to the sleeves, they will shrink and the bearings will not go in easily. In this case, you will need to be open up the sleeve slightly with a die grinder:
From the instruction sheet, I gathered that needing to grind is a common occurrence. The bearings should still fit snugly in the sleeves.
Next put a small washer on the clutch stud and slide it partially into the LH bearing that has already been installed in the support. Install the nylon washers in the brake pedal and put it into position inside the support. Then slide the clutch stud through it and fully through the RH bearing. Install the remaining small washer and either the original clip, or a cotter key.
Everything should fit smoothly and not bind. If it does bind (which is common due to the welding heat,) the support will need to be tweaked until the parts can be assembled freely.
Once satisfied with the fit, I removed the bearings, did some sanding, cleaning, taping, and followed that with a nice coat of semi-gloss paint:
Paint on the top of the pedals and the pedal support black is not an original treatment. I did it simply for appearance and for protection from rust.
Reinstalled the new support under the dash and test the pedals.
In summary, I believe that this kit is by far the best way to repair a worn pedal support and chances are you will never need to repair the support again. If you feel that you do not have the necessary welding or fabrication skills in order to do this modification, it might be best to send your support to Mustang Steve and have him modify it for you (at an additional cost.)