Parts and equipment required.
Auto pedal box
Extra brake pedal pin from same style pedal box
A manual brake pedal rubber cover
A clutch pedal with plastic bushes (may be used from any E-series pedal box)
5mm roll pin and 5 washes to suit smaller diameter on spare brake pedal pin
Angle grinder
Welder and associated safety equipment
Oxy acetalyn set
Die grinder with carbide burr
Steel rule
Cutting down brake pedal.
As auto brake pedals are wider than manual ones the auto one will need to shortened. Put your manual brake pedal rubber cover on the pedal on the right hand side as if you where looking at it from in the car. Mark a line where the pedal starts to pet rude the cover on the left hand side of the pedal. Now cut down the line you have marked with an angle grinder and grind any burrs from your cut. Also be sure to grind a radius on both corners of your cut, this will stop your rubber cover from being destroyed but the edge of the metal it surrounds.
Bending spare brake pedal pin.
The way Ford put there clutch pedal pins onto their pedal boxes was a short pin welded on the side of the pedal box. There is a hole it goes through from the inside of the pedal box, and the pin has a hat on the end that rests on the edge of this hole. As a result the pins would over time break away from the weld and leave you stranded. The idea behind bending the spare brake pedal pin is as it is longer than the original clutch pedal pin, with the bend it can be welded in 2 places rather than one and significantly adding strength and guaranteeing you to have a trouble free pedal box.
Mark a line 60mm down the shaft.
Set the pin in a vice with the line you have marked level with the jaws. Add some heat and bend whilst the pin is glowing red using a large shifter.
Before you can weld the new clutch pedal pin in position you will need to notch out part of the pin to clear the brake pedal pin.
This is done with a carbide burr on a die grinder and by placing the new pin through the hole (the hole for the clutch pedal pin is there on auto pedal boxes) lining it up and marking the shaft where the shaft will interfere with the brake pedal pin, setting it up on a vice and burring it out. You may end up trial fitting the pin and taking it back to burr it out further.
Once it fits well with the original pin it’s time to weld it up.
You are now ready to install you clutch pedal. Remember to use the plastic bushes on the shaft. A few neat fitting washers go on before the pedal and 1 after it goes on. You will now need to drill a hole for the roll pin which will hold your clutch pedal on.
Make sure mark your hole for the roll pin in the right place, you don’t want any sideways movement.
And there you have it.
The reason why I modded a auto pedal box rather than buying a manual one is that it can be hard to find a manual one that has not already been repaired due to a faulty design by Ford.
Thanks for reading
Josh
