AU ute manual pedal box replacement

[eficoupe]

Hi there,

I just read the thread on here about a bent manual ute pedal box. I have the same problem with mine - where the clutch pedal pivot just pulls away at the spot welding.

Replacement pedal box from ford was quoted at $137 which I was quite happy with so my next question was "how much for you just to do it?". $700 and the dash out!

My question is - has anyone done this? I am not real keen to do it if it is a dash out job, but if not then I'm happy. So is it a dash out job? I didn't think it looked like when I was under there.

Can someone set me straight on this so I can sort my ute out!

Cheers.

[frd906]

im quite sure its not a dash out job, could be mistaken though

[bartsau]

Definately not a dash out job on the Au's unlike earlier models (E series), I have done this on my own car when doing the manual conversion i put the pedal box in myself. Took a bit of fiddling as there is not bucket loads of space to work with but you should be able to do it in about an hour comfortable if you have some idea on how to pull things apart.

Pretty much you need to disconect the brake light switch, cruise control switch (if it has cruise) and then i took the clutch pedal of the the side. Once this is done then you can undo the 2? nuts holding the box to the underside of the steering column, then the 4? holding it to the firewall/brake booster. Now you should be able to manouver it out. If you can't you can remove the shaft that the brake pedal operates off aswell if need be.

Hope this helps, Rhys

[eficoupe]

Thanks for the info guys. A great help. Between this and the fix for that annoying leak on my foot - guess what I'll be doing this weekend...

Cheers!

[loxxr6]

Mine was done in the last 2 weeks and I'm pretty sure it wasn't a dash out thing.

[XR Davo]

Have had mine done and you don't need to pull the dash out. Also my mechanic reckoned it was better to weld up original pedal box than put in a new one as it would break again over time. Replaced clutch cable at the same time. Clutch is sweet now and has transformed the driving experience totally. Think I spent around $400 on parts + labour. But I'm happy.

[Fuzzlet]

Curious as to whether my car is doing a similar thing (I should have a look under the dash with a torch)

My clutch pedal has bent around to the left a bit, and is no longer engaging the switch for it. I'm getting the clutch replaced tomorrow as its starting to slip, so I'm curious as to whether my pedal box may need replacing aswel...

[WannabeXP]

Originally Posted by XR Davo

Have had mine done and you don't need to pull the dash out. Also my mechanic reckoned it was better to weld up original pedal box than put in a new one as it would break again over time. Replaced clutch cable at the same time. Clutch is sweet now and has transformed the driving experience totally. Think I spent around $400 on parts + labour. But I'm happy.

Hey Davo,
Wondering if your clutch cable felt like the wire was burring inside the outer, My clutch is pretty solid to push in, with slight resistance(a bit notchy) which i believe is the cable.
What were your results with changing the clutch cable?
Cheers, Jason

[eficoupe]

My pedal was leaning to the passenger side which is what made me look in the first place. Also started making a weird squeaking kind of nice due to the cable not pulling straight like it should. Seems to be extremely common for these cars.

I think I will weld some reinforcement into the new one before I use it.

When looking under there it is quite obvious how it all splits off so some good tacks with the MIG on a new one should be heaps. I'd never trust the old one again after the metal has been fatigued like that.

[XR Davo]

Originally Posted by WannabeXP

Hey Davo,
Wondering if your clutch cable felt like the wire was burring inside the outer, My clutch is pretty solid to push in, with slight resistance(a bit notchy) which i believe is the cable.
What were your results with changing the clutch cable?
Cheers, Jason

Yeah you can try changing the cable as an initial cheap option. My cable used to feel like it was binding up and quite stiff especially when warm. You may have a cracked fire wall, (mine did) so have a look while you're at it... and because of this the pedal box could need sorting as well. Worth doing all 3 at the same time I reckon.

[superroo]

Drop the collum and that will make it very easy to get the box out.

As for the cable, I'm of the belief that it is a consumable part, replaced once the clutch peal starts to get hard.
I thinks it's to do with the grease drying up inside.
Replacing it makes the clutch a lot lighter. I think I’m up to my 4th or 5th cable in 2 years.

Also, once you reinforce the pedal box, keep a good eye on the firewall. My fire wall crack/split about 3 months after doing the pedal box.

Cheers

[xp_wannabe]

G'day guys, I know this is a bit of a thread mine, but I thought it would be better than starting a new one...

Does anyone have any good pics or links to other threads on reinforcing the pedal box so it doesnt bend again?

Also, the best price I can seem to find for a new on from Ford is around $250... Anyone got any contacts for a better price?