Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Click when pressing clutch pedal

Appears the click was coming from the pushrod where it enters the piston cup.
Rotated the pushrod 180 degrees and readjusted
Click gone!
Thanks for your help all
Simon

No click from my pedal but whilst ferreting in drivers footwell found a fair amount of play with clutch pedal despite regular lubrication and less than 19,000 miles. Pulled out clevis pin and found it worn as below right.



Note the wear is tapered to one side suggesting pedal is twisting in operation. Also no washers found which there should be, against the split pin at least Replacement stainless pin with washers and fresh split pin left, ready for re-assembly.

Clevis pins 3/8" x 7/8" long ordered from here. Note parts manual lists clevis pins as 7/16" diam so ordered a pair of those as well. Whilst too big to fit they may be useful in the future if holes in pedal become too worn.

As told I (or better my MOG) had trouble with the clutch mastercylinder.

I renew it and after the work I also notice such a noise. So it‘s caused in my repair. Now I‘ m happy to read it could be the pushrod.

The MOG is in hibernation so there is a good time for a little work.

Greets René

Replacing the pivot pin with stainless will accelerate wear to the pedal and actuautor keep it lubed...

I think in the same way. But I remember that at my Harley are some nylonbushes in the the handlevers. And it looks they would fit.
If this would work no more worn pins.

Have a look here:

https://www.wwag.com/cgi-bin/WebObjects/WebSite.woa/wa/DirectAction?page=%21WW2671


There is the original Harley partnumber (OEM 45036-82) listed, so with this number you can get it worldwide from a Harley-Dealer or aftermarket dealer.

Greets René

Hi Richard, mine was worn exactly the same after 9K miles on our Roadster.. I pulled the pedal box assy when looking for a brake pedal issue and corrected the wear in the clutch arm/clevis pin at the same time by making a new pin. I re assembled with hi pressure grease, but due to the small bearing area between the arm/pin I suspect it will wear again. I believe some of the one sided pin wear is due to the angle your leg/foot pushes the clutch pedal together with inbuilt loose tolerance between pin and clutch pedal arm. Also as per your car, the flat washer was missing between the clevis and split pin and I agree having a washer fitted will help reduce the side twist on the pin.. When I stripped the pedal box I noted that the clevis pin dia used on the brake is larger than the clutch pin dia.. The larger dia pin gives a greater surface area to transmit the force and should reduce wear due to this.
In the future if the pedal arm pin hole wears oval it should be relatively straight forward to bore it larger and tig weld in a top hat type insert to bring it back to spec, or alternatively fill the area with tig weld and rebore.

I agree with all your thoughts and findings Dave and will keep fingers crossed regarding future wear. One hope is that stainless will wear slower.

I did look at a suitable rose joint solution but couldn't find anything that transmitted the force to master cylinder square on.