Pedal Box Refurbishment - Revision history

Mrrigma at 23:36, 21 November 2023

2023-11-21T23:36:30Z

← Older revision		Revision as of 23:36, 21 November 2023
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	[[Image:Pedal_Box_17.JPG\|Chocolate Hobnob time :)]]		[[Image:Pedal_Box_17.JPG\|Chocolate Hobnob time :)]]

			MrRigma’s tips:
			It’s not necessary to remove the stack or the drivers seat.
			Work from the passenger footwell, place a small cushion on the footrest at the end of the well. This gives you enough room to work on the drivers side by reaching across.

			The procedure above talks about removing the stack so that the steering column brackets are exposed to give room to remove them. There’s a short cut. Remove 3 pinch bolts, the lowest 2 on the universal joint that mates the steering rack to the lower part of the steering column. Then remove the next bolt that’s at the top of the steering column universal joint that’s easily accessed. Prize open the upper UJ a little with a screwdriver. Then take a pair of mole grips, some cloth around the column and grip the column so that the cloth is protecting the shaft. Lightly tap the edge of the mole grips so that column shaft moves upward into the highest UJ. Next loosen the 4 steering rack bolts, 2 per footwell 17mm and 13mm. This allows you to push the steering rack away a little such that there’s enough room to detach the column from the top of the lowest UJ. Hey presto it can be removed and you don’t have to reassemble all the stuff in early steps. :-).


	====Refurbishing the Pedal Box====		====Refurbishing the Pedal Box====

Flying banana at 13:59, 22 June 2011

2011-06-22T13:59:49Z

← Older revision		Revision as of 13:59, 22 June 2011
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	**You’ll need to undo three bolts from the cockpit. Two large bolts either side of the column immediately below where the stack was, one slightly shorter bolt in the bowels of the dash, on the bulkhead. Follow the column into the dash recess and it’ll be just above it, buried behind a nest of wiring.		**You’ll need to undo three bolts from the cockpit. Two large bolts either side of the column immediately below where the stack was, one slightly shorter bolt in the bowels of the dash, on the bulkhead. Follow the column into the dash recess and it’ll be just above it, buried behind a nest of wiring.
	[[Image:Pedal_Box_12_annotated.jpg\|Steering Column Mounting bolts]]		[[Image:Pedal_Box_12_annotated.jpg\|Steering Column Mounting bolts]]

	Once these are undone, assume the lotus position and undo and completely remove the pinch bolt on the steering column lower universal joint nearest the bulkhead. Use a large flat bladed screwdriver, or alternatively a crow bar to gently lever the forward face of the UJ away from the bulkhead. It will be tight. It will move eventually.		Once these are undone, assume the lotus position and undo and completely remove the pinch bolt on the steering column lower universal joint nearest the bulkhead. Use a large flat bladed screwdriver, or alternatively a crow bar to gently lever the forward face of the UJ away from the bulkhead. It will be tight. It will move eventually.
	[[Image:Pedal_Box_08_annotated.jpg\|Steering column UJ Pinch bolt]]		[[Image:Pedal_Box_08_annotated.jpg\|Steering column UJ Pinch bolt]]

	*Gently ease the entire column out through the dash into the cockpit.		*Gently ease the entire column out through the dash into the cockpit.
	**Do not put huge amounts of force axially through the steering column – the collapsible mechanism may collapse and then you’ll be spending time in a scrap yard looking for a mid-nineties vintage Vauxhall Corsa that doesn’t have a shagged steering column.		**Do not put huge amounts of force axially through the steering column – the collapsible mechanism may collapse and then you’ll be spending time in a scrap yard looking for a mid-nineties vintage Vauxhall Corsa that doesn’t have a shagged steering column.

Flying banana at 13:28, 22 June 2011

2011-06-22T13:28:06Z

← Older revision		Revision as of 13:28, 22 June 2011
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	[[Category: S1]]		[[Category: S1]]
	[[Category: Brakes]]		[[Category: Brakes]]
			[[Category: DIY]]

	== Elise S1 Pedal Box Refurbishment ==		== Elise S1 Pedal Box Refurbishment ==

Flying banana at 13:27, 22 June 2011

2011-06-22T13:27:12Z

← Older revision		Revision as of 13:27, 22 June 2011
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	[[Category: ~~Elise~~ S1]]		[[Category: S1]]
	[[Category: Brakes]]		[[Category: Brakes]]

Flying banana at 13:26, 22 June 2011

2011-06-22T13:26:26Z

← Older revision		Revision as of 13:26, 22 June 2011
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			[[Category: Elise S1]]
			[[Category: Brakes]]

	== Elise S1 Pedal Box Refurbishment ==		== Elise S1 Pedal Box Refurbishment ==

Flying banana at 13:15, 22 June 2011

2011-06-22T13:15:45Z

← Older revision		Revision as of 13:15, 22 June 2011
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	== ~~SELOC how-to:~~ Elise S1 Pedal Box Refurbishment ==		== Elise S1 Pedal Box Refurbishment ==

Flying banana at 13:15, 22 June 2011

2011-06-22T13:15:24Z

@@ Line 157: / Line 157: @@
 *Remove Brake Pedal pushrod
-**As per step 11a
+**As per clutch pedal above
 *Unclip brake light switch
@@ Line 227: / Line 227: @@
 =====If You’re modding the throttle pedal arrangement (Skip to section 1.3.2.2 if not)=====
 *Pedal box closure plate
@@ Line 267: / Line 268: @@
 [[Image:Pedal_Box_59.JPG|Shims in place]]

Flying banana at 12:57, 22 June 2011

2011-06-22T12:57:51Z

@@ Line 215: / Line 215: @@
 *Clean pedal shaft
 *Fit the trunnions
 **For the clutch pedal, using a small hammer tap the bushes into the pedal until they are flush on each side.  The Lotus trunnion kit allows you to do this because the trunnion itself is a loose running fit in the bushes and will slide in and out easily with the bushes in place.  If you are using the EliseParts trunnion kit, you’ll need to use a vice to press the bushes in and most likely the same again to get the trunnion in, which is a tight running fit.  There are plenty of guides on how to do this out there but it’s much easier when the pedal is off the car for obvious reasons.
 **For the brake pedal, lubricate the original trunnion with LM grease and replace.

Flying banana at 12:28, 22 June 2011

2011-06-22T12:28:23Z

← Older revision		Revision as of 12:28, 22 June 2011
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	*'''Have a cup of tea and a chocolate hobnob or two – you will have earned it at this point'''		*'''Have a cup of tea and a chocolate hobnob or two – you will have earned it at this point'''

			[[Image:Pedal_Box_17.JPG\|Chocolate Hobnob time :)]]

			====Refurbishing the Pedal Box====


			*Strip off Throttle pedal
			**Slide the pivot bearing spacer off the shaft and remove the throttle pedal itself.
			**Remove the thrust washer and discard
			**Tap the pivot bush fitted to the throttle pedal out using a small drift or flat bladed screwdriver and discard
			[[Image:Pedal_Box_20.JPG\|Removing the throttle pivot bearing]]
			*Clean throttle pedal and set to one side

			*Undo 2 x pedal shaft bolts
			**Using two 10mm combination spanners, undo the two shaft fixing bolts holding the shaft into the pedal box
			[[Image:Pedal_Box_23.JPG\|Removing the throttle shaft bolts]]
			*Remove the shaft
			**Slide the shaft out of the pedal box towards the throttle pedal end. Remove and discard thrust four thrust washers from the clutch and brake pedals as they fall out
			[[Image:Pedal_Box_24.JPG\|Removing the throttle shaft]]

			*Remove bushes and trunnions from brake and clutch pedals
			**Tap the pivot bushes fitted to the brake and clutch pedals out using a small drift or flat bladed screwdriver and discard
			**Remove trunnions from clutch and brake pedals. Discard clutch trunnion, inspect brake trunnion and clean for re-use. Clutch trunnion on the left, Brake on the right!
			**Clean brake and clutch pedals. Some light smoothing of the clutch trunnion hole with fine wet and dry may be required if excessive spalling has occurred. Take a look at mine!!!!
			[[Image:Pedal_Box_27.JPG\|Knackered trunnion...]]
			[[Image:Pedal_Box_28.JPG\|...what it does to the pedal...]]
			[[Image:Pedal_Box_29.JPG\|...and comapred to the brake trunnion]]
			*Clean pedal box extrusion

			*Clean pedal shaft

			*Fit the trunnions
			**For the clutch pedal, using a small hammer tap the bushes into the pedal until they are flush on each side. The Lotus trunnion kit allows you to do this because the trunnion itself is a loose running fit in the bushes and will slide in and out easily with the bushes in place. If you are using the EliseParts trunnion kit, you’ll need to use a vice to press the bushes in and most likely the same again to get the trunnion in, which is a tight running fit. There are plenty of guides on how to do this out there but it’s much easier when the pedal is off the car for obvious reasons.
			**For the brake pedal, lubricate the original trunnion with LM grease and replace.

Flying banana at 12:12, 22 June 2011

2011-06-22T12:12:14Z

← Older revision		Revision as of 12:12, 22 June 2011
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	*Loosen diverter flap housing screw		*Loosen diverter flap housing screw
	**There is a single machine screw with a big washer on the base of the diverter flap housing – undo and remove it. This will allow you to move the housing to the side slightly		**There is a single machine screw with a big washer on the base of the diverter flap housing – undo and remove it. This will allow you to move the housing to the side slightly

			[[Image:Pedal_Box_15_annotated.jpg\|Diverter Flap fixing Screw]]


			*Remove 6 x bolts holding the pedal box onto the scuttle bracket
			**I found this to be the fun part. You’ll need perseverance. In fact, accept that you’ll need the patience of Jobe. The three right-hand bolts are too long to come out with the diverter flap housing in the way. The three left hand bolts are hidden out of sight underneath part of the structure of the front of the car.

			*The left hand ones are not dreadful to remove provided you have the brake master cylinder eased up high enough to slide your left arm under the pipe work and around the scuttle bracket. Even so, you will be working blind. A straight 10mm ratchet spanner (£10.99 from Halfords) is invaluable here. Once you have the spanner on, should be simple, if intensely uncomfortable.
			**The right hand ones I could only get out be punching holes in the diverter flap housing and using a long socket from within the housing itself. Even so I needed a big lever to move it across to the right as far is it would go and the front lower bolt in particular was tough to get out.

			[[Image:Pedal_Box_16_annotated.jpg\|Overview of Pedal Box location]]


			*Remove pedal box
			**The pedal box will have glued itself (via the foam strips on the mating faces) to the scuttle. You’ll need to us a large flat bladed Screwdriver to lever up the front edge, and a drift and hammer to get the rear edge released from within the cockpit.
			**Once the box has been released from front and rear edges, push the rear edge up and rotate the front edge down and through the hole. You’ll then have to manipulate the pedal box further round (front edge down) until it’s been rotated around 90 degrees. The top front corner of the box will have to clear the steering rack pinion and the bracketry in the base of the foot well, but it will go through '''provided you took out the throttle stop bolt earlier'''. When the throttle shaft has cleared the lower edge of the hole it’ll get much easier and you will be able to pull the entire assembly down through the foot well and out of the car.

			*'''Have a cup of tea and a chocolate hobnob or two – you will have earned it at this point'''