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Also, I can't get the clutch shaft through the brake arm hole. It won't fit. It slides thought the big bracket with the bushing inserts no problem. But there is no way I can get that brake arm on the shaft without a sledgehammer.
again, what am I missing. Studying the assembly instructions carefully and can't figure it out.
Let's rewind. EDIT NO BRAKE OEDAL ISSUES. ITS JUST THE CLUTCH ASSEMBLY AND PEDAL
attached are pictures of everything I have and measurements. I assume the pork chop is what you highlighted in yellow. I have that. Here is the issue:
1. the CLUTCH pedal opening is .86" and the shaft is .87". I don't get it. I can't remember if I had to buy a new shaft from Chuck because mine was too badly worn. Maybe that is the issue and I need to machine out the LUTCH pedal a thousandth? I uploaded a video.
2. On the clutch shaft bushing that is 1.08" but the hole in the bracket is 1.15 or so. Is that bushing supposed to sit snug in that hole on the u bracket? I took pictures of the old bushing and how it is worn along with how it looks like it was seated in the bracket. If that hole is too big and out of round it looks like I need a new bracket...
in the diagram with the clutch detail what is the part # 356498-s? I can't find anything that looks like that and it is not shown in the other drawing with the brake and clutch assembly.
All the parts. Old busing inside of u bracket Bushing size Hole size.
What you are calling a bushing is in fact a spacer. It and the spring pass freely through the other part.
Are you calling this the "brake" arm? This is a clutch arm. Or are you just using "Brake" generically to mean the arm a pedal goes on?
Originally Posted by 8pack
Also, I can't get the clutch shaft through the brake arm hole. It won't fit. It slides thought the big bracket with the bushing inserts no problem. But there is no way I can get that brake arm on the shaft without a sledgehammer.
again, what am I missing. Studying the assembly instructions carefully and can't figure it out.
I'm not sure why the clutch arm won't fit. Mine was snug, but didn't need to be pounded into place. You could press it on and fit it from the out/under side, if you had to.
ETA: I checked my original clutch shaft, it measured .87".
Yes I was confusing the pedals. May brain had them correct my typing fingers got confused. It is just the clutch pedal that won't fit.
Now I see how that spacer works. I think my shaft was worn so badly that the spacer was pushing up against the bracket.
the clutch pedal hole seems badly galled inside FWIW.
if you have any more pics of that assembly it would be great. It's really hard to visualize off the diagram and it would be helpful to see the other clutch connections. If not no problem.
Sorry, I don't have many detailed pictures of the brake/clutch pedal assembly.
It looks like you're missing a washer. (356498-S) It holds the brake pedal against the main bracket (2467), while pulling the clutch pedal against the bushing through the frame. The drawing isn't very accurate. The washer is actually thinner than it looks in the drawing.
ETA: Mine does look a little different because of the dual master cylinder adaption, but it goes together the same.
Yes, I thought I was missing that part. Will look around for it. It's a BIG washer it looks like. That picture is very helpful. I am also doing a dual MC but with a brake booster as well. Hopefully my 223 makes enough vacuum for it.
What kind of grease do you all use when assembling the shaft and all? A high temp brake grease or something like red and tacky or just standard ball joint type grease?
I purchased a 1.00 grade 8 washer which seems to work. It is a slightly loose fit with the .87 shaft but I assume it should be fine.
I ground out the clutch lever hole in order to get the shaft through. I used Dykem scribing dye to keep testing and finding the high spots until I got it to fit in smoothly. Since it is help in place with a pin it doesn't seem like it needs to be a perfect cylinder.
Thanks for all the help on this one!! Problems solved so far. More to come I am sure....
What kind of grease do you all use when assembling the shaft and all? A high temp brake grease or something like red and tacky or just standard ball joint type grease?
High temp isn't necessary. It doesn't spin, just turns. I use the same as the ball joints, kingpins, leaf springs, shifter linkage, etc.
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