Well, over the weekend I pulled out the clutch/brake pedal box on our 3.7 Roadster, to check out the brake and clutch pedal position adjustments at the pedal arms to master cylinder rods and also to make a new clevis pin for the clutch pedal arm, as it was fairly worn ( at only 9K miles).
What was found is as follows:
Brakes..
The brake master cylinder actuating rod is adjusted at the pedal arm by means of a threaded section of rod through the clevis that connects the brake pedal arm to the master cylinder rod. The rod was found to have been adjusted so that the rods threaded section was through the clevis to the extent that it touched the pedal arm, this meant that as the brake pedal arm went through its arc of travel when depressing the pedal, the rod locked up the clevis and stopped it swivelling on the pedal arm at approx 3/4 through its operational arc, when this happened the pedal arm pushed the master cylinder rod downward at the same time the rod was trying to move forward and actuate the m/cylinder, this produced a semi binding of its movement. The fix was to remove approx 4mm off the end of the threaded section of the rod using a dremmel cutting disk... This allowed further adjustment of the pedal position and allowed working clearance between rod and the brake pedal arm.
Note:- Operation of the brakes must be checked after any adjustment of the brake pedal arm.
Brake return spring.. The brake pedal spring as used appears coil bound.. i.e. As the brake pedal arm is operated it gives tension to the brake pedal return spring, but its coils are already touching each other and bind into each other as the brake pedal goes through its travel and the spring rotates. By pulling the spring coils gently apart ( using a fair amount of leverage ) slightly beyond their elastic limit, the spring coils can be set 2mm apart, this means that as the pedal spring is wound by operating the brake pedal the coils have clearance to move towards each other.
The result of the above two adjustments have made a big improvement of the brake pedal feel.
The next job is to clean the front brake pads in hot soapy water or replace the pads, most likely I will try to clean first..
Clutch.
While the pedal box was out I made a new clevis pin on the lathe for the clutch pedal arm, the original clevis pin had worn so that it had about 15mm of slop in the clutch pedal arm. All moving parts for the clevis are now greased with high pressure grease.. Interestingly the brake pedal clevis pin is larger than the clutch clevis pin, this gives a much larger surface area to transmit the force.. The Brake clevis pin was not worn at all!.
I had previously fitted the Wolf Performance Roadster 3.7 adjustable throttle pedal, the end result with an adjustable throttle pedal and tweaked positions of brake and clutch pedals has transformed what was a poor driving position.
