Hi! My name is Chris Curless, I just signed on a few minutes ago and thought I'd let you know what I have. I do need to get a moderator to say its o.k. to sell on FTE first but I can at least give you some info!

I own a Merc Marauder and the pedals didn't work on it. I decided to look into it and found out that there is a plastic gear inside the brake pedal that cracks and stops the pedals. They move about a 1/4 to 1/2 inch and thats it. Well long story short I designed and built a brass gear that ends this issue. I was asked to look into the Expedition / Navigator by a member on CrownVic.net. Today I went to the local salvage yard and bought an assembly out of an 03...I still need to verify what the year interchanges are. Ford says that from July 02 till Dec 03 they are the same, then from Dec 03 till Aug 04 they are the same. Its the same supplier for each to Ford, I highly doubt they would change the internals of their assembly, its more than likely an added bracket or bolt location.
So if you are interested I will pursue being allowed to sell them on here. If you have any questions or if you own an 04 or newer and can get me some pics of the brake pedal assembly please PM me! Thanks, Chris.

Obviously with the rules of posting and pm's its going to be a few days until I can be reached that way so just post up here and I'll respond!

I edited this post, gear is NOT exactly the same as the first one I did. The acme thread on the inside is different. It can be made but we need a different tap that is custom to work on the Expy and Navs.

 

From what I have read online about this, the pedals are an issue for trucks as well. I am just surprised that no one has commented yet...any reasons?

 

No one has commented because it's not a big issue.

 

Gotcha, well thanks for letting me know. I was under the impression that it was more of an issue.

 

Most people, myself included, set the pedals the day they buy the vehicle and never touch the switch again. The exception would be when the vehicle is shared by 2 or more people that are of extreme varying heights. Most people will adjust the seat position rather than play with the pedal setting.

 

I would buy a gear from you to fix my pedals, my wife and I alternate driving the truck and it would be nice if it worked and didn't cost me a small fortune.

 

I'd say it is a big issue.
There is plenty on the net cursing Ford for the cheap gear.
I could have used one a month ago, but replaced the entire brake pedal assembly. I would say if you manufacture a replacement gear, and get on the forums with explicit repair instructions, you would have a small income for the thing. I know I would have paid ya 30 bucks at least for one.

 

I would say its a big deal as well due to the fact that the new pedals will fail in a matter of time again. They are plastic geared as well. I thought that the gear I created for the Crown Vics / Grand Marquis / and Maruaders would fit the Exps and Navs...but alas they are a different thread count. I can make this gear as well but we should really have about 35 or so sold to get group buy pricing. I would be glad to do a group buy for this site but I want to make sure the Moderators will allow me to offer this. I have sent messages but never heard back from anyone. I know we can make them, I can have them in about 2 weeks or so. The issue is price for one or two of them. The tap to make the acme thread is a one off and must be custom made. Its not terrible but it is not free. If we can get some more interest I would be glad to move forward. Let me know what you guys think. Thanks for your interest.

 

They can't be made for $30...its around $75 with shipping. I make them out of brass, they are nice pieces and work well. The main cost is the acme thread tap...its not a standard thread its custom.

 

I was able to get a brand new pedal assembly for about 125 IIRC. Still, the gear would fix it once and for all.

 

I discovered the cause for this failure a couple years ago.

I even contacted KSR International (maker of the pedal assys)... they referred my back to Ford.

It is such a common problem that that most of the time when you go searching for a replacement in the wrecking yards, the gear is already failed in those vehicles also.

I would be interested in purchasing a gear but $75 seems a bit high. Is that with a group buy of 50 or so? Hopefully with a lot of interest you can get the price down some....

 

The smallest run is 35...the shop I am using is local, American Made...they buy brass from American companies... I am in no way going to support off shore companies to save $20...

By the time we buy the custom tap, buy the brass, have it shipped, machined it into a gear, package it up, write the instructions, print them, buy the postage and ship them there is not that much margin left. I understand that cost is always issue, I am simply putting it out there. Many people have looked into this problem and left it on the drawing board.

 

If mine broke again, I would be all over this.

 

Ok, how do I place an order?

PM me with info of what to do.
Thx.

 

Here's the thing, I need about 35 orders to make it worth the time. I am pleased that you are interested, now if we can get others on board we can get it going. I can make one...you would not like the price though. Even if we can get 10 to order I can come up with pricing for that as well. But less than that would not be very nice!