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Its done! The instructions are up, I need to get the photos approved some how...by the way this is so easy it can be done in the truck in under 30 minutes! This works on 03 -06 as far as I know right now. Still researching the exact years.
I need to fix my 05' expedition pedals. From yours and others' description, the gear will be the issue. So if your brass gear is compatible, I'll be in for one.
I considered pulling the gear out and drawing it on a CAD program and submitting it to an emachinceshop.com like place. They can print a plastic mockup for fitting, then make it out of whatever you order. But if you have one already, that's just too easy to pass up!
Looks like quite a bit of interest by the responses here. I hope it works out for you (and all of the other people with this problem).
ATTENTION MODERATORS: Please don't nuke this thread if I have violated any rules or need to become a vender please contact me. I have tried in the past and gotten no response. I am NOT trying to go around your rules, I just simple can't get a hold of any of you. I will be glad to do my part to support this site.