Need Advice on Pedal Box Removal

[Sapper]

G'day all,

Unfortunately I've been struck by the dreaded bent manual pedal box and need to remove it to make repairs. Unfortunately, after about 2 hours, I can't get the damn thing out! I've done a search and read all I can from previously discussed threads on this issue but I need some tips on what I can do to help.

So far I've:
-Disconnected ALL parts from the pedal box
-Loosened the brake master cylinder from the firewall
-Pulled away some of the sound deadening material from the firewall
-Got a headache from lying on my back for several hours

I can't quite squeeze the brake master cylinder shaft out of the pedal box and I can't rotate the pedal box far enough to slide it out under the steering column. I'm getting tempted to try and take out the steering column but I'd like to avoid doing so.

Any advice would be awesome.

[philstoj]

Best advice, take the column out!! Made life so much easier when i did mine!!

[Sapper]

Thanks dude. I assume taking the column means unbolting it from just inside the firewall. Before I remove it I want to be sure that it's not too difficult to get back in...

[philstoj]

Theres a little bolt that holds the shaft together with the shaft in the engine bay to the rack, also a clip, so you must remove clip aswell, all you do is slide it out of its position along the steering shaft, not removing it completely (you will see what i mean when you see it) and then theres 2 bolts that hold it to the dash, you can see them if you look to the side of the column adjuster, make sure all the plugs are undone, and remove the 3 screws and clip and its out, fairly straight forward, and will make the job so much easier to do.

Make sure it isnt just the pedal thats bent, i was surprised by mine when i pulled it out that it wasnt the pedal box, just the pedal.

For extra insurance, bought a new pedal box and got it braced, 5mm steel plates welded on the inside, and outside of the clutch pedal mount, stiff as now, but ive found my clutch pedal is bent... the original pedal box had a bit of flex, but it seemed to me after all that, that it was the cluch pedal that was the issue, that will get sorted next time.

[Sapper]

Thanks dude. Its out now. Pedal is fine, there's a nice tear in the box itself. New pedal box ordered from Ford. Progress is good!!!!

[Jokular]

Got a price on the pedal box?

[DoreSlamR]

Originally Posted by VenomST

Thanks dude. Its out now. Pedal is fine, there's a nice tear in the box itself. New pedal box ordered from Ford. Progress is good!!!!

You'd be better off welding and reinforcing the one you have, will be cheaper and stronger than the standard ford part.

[philstoj]

They are around $100 from ford.
You can weld it, but you must also reinforce it as it wont last...

Reinforcing a new one would be ideal.

[Sapper]

G'day all. New pedal box is in and working fine, cost me $120. Decided not to use the old one as it was simply too munted to fix. I also decided not to reinforce it as I wasn't confident that I could control the heat treating of the metal that occurs when welding. Instead, I'm chainging the way I change gears and will eventually install a lighter clutch.