Ok guys, I've spent the last year working on my truck on and off, and I got the insurance back on it yesterday and was taking a load of bricks to the dump. It was my first drive with it since changing the transmission, rear end gears, and putting a 4bbl intake and carburator on my 300 I-6. The engine was running great, and I'd made it halfway to the dump and all of a sudden the clutch pedal felt funny, and then the next time I pushed it, it stayed on the floor. Turns out the weld holding the pedal to the shaft broke! It looks like it had really poor penetration in the first place. So, is the clutch pedal just supposed to be welded on? Would one of you guys be able to run out to your truck and have a look to confirm this for me? If so, that is one crappy welding job from the ford factory or PO, that it didn't penetrate.

On a positive note, the engine ran great, and I haven't even tuned the carb yet!

 

Are you sure it's not a result of a previous owner?

Weld it back together... this time with proper weld penetration.

 

No, Im not sure. That's a good point. So, welding it back together, I should just drill out the existing weld and clean up the outside face of the pedal where the weld currently is, and then should I grind a fillet into the pedal and fill the fillet with weld?

 

Yep. Chamfer the shaft to get a good bite.

 

Kinda looks like that shaft may be some kind of hardened tool steel. It is brittle and does not respond well to being welded.

 

Pic: With a M/T .. the brake pedal (2455) rides on the shaft of the clutch pedal (7519).

 

Turn up the heat.

.

 

If it were me I would probably find another clutch pedal box and install a factory welded pedal.


looks like the shaft should protrude beyond the pedal for good penetration and strength.

 

Try pre-heating the shaft with an oxy-acetylene or propane torch. Don't go crazy with the heat, but if you warm it right before you weld it you will get better penetration.