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Repairs and modifications to Pedal assembly and rat trap

LJ LC Clutch Brake Worn Broken

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#1 sibhs

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Posted 23 January 2013 - 10:42 PM

My pedal assembly is tired and worn. What modifications can be done to improve the operation of these units?
I don't want any cable or hydraulic systems just the Rat trap version.
Firstly where the pull rod bracket runs on this pin, it has worn a groove. (how to fix?) Can you get new pins or weld and file?
Attached File  IMG_1980.jpg   33.36K   10 downloads

Then the main shaft is worn where the clutch pedal runs. Can you get new shafts or weld and file, or grind off end weld, remove shaft, weld worn section then finish in lathe? Is that end weld factory? (doesn't look it) The holes through the clutch pedal are enlarged so there is slop on the shaft.
Attached File  IMG_1979.jpg   37.76K   9 downloads

Now those are just repairs, my modification is to fit a tube through the clutch pedal like the main bracket has a tube therefore spreading the load on the plastic bushs. Anyone see an issue with this?

I haven't checked the Rat trap yet but know they get sloppy too, so if you have some mods or fixes please let me know.

Also if there any other threads with other ideas please link them.

Cheers

Marty

#2 Ice

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Posted 23 January 2013 - 10:55 PM

If you need any spare parts for your rat trap marty i got a box of them not all parts but some left overs

#3 _hutch_

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Posted 24 January 2013 - 06:44 AM

I put up a thread on this subject a while ago,off to work at the moment,so if you can't find it I might still have the piccies

#4 76lxhatch

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Posted 24 January 2013 - 07:51 AM

If it were me I'd just attack it with the welder and tighten everything up

#5 _johns_lc_

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Posted 09 February 2013 - 11:47 AM

We had similar problems on our two LC's. We welded new ends on the various rattrap parts and replaced pins etc but for us the main problem was enlarged holes in the pedal where originally it's just a shaft going through a hole at the top of the pedal. Not a lot of thought there on the part of the designers. Not designed to last long. We wound up fashioning a small steel cylinder roughly 25mm diameter by 12 deep, which was a press fit for a small ball bearing which engaged the shaft. The small cylinder was welded to the top of the pedal and the bearing pushed in. Goes well.

#6 sibhs

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Posted 04 March 2013 - 10:58 PM

Almost finished my mod and very happy with results so far.

Machined up a bit of tube and drilled the hole in the clutch pedal larger.

Attached File  IMG_2327.jpg   50.79K   15 downloads

Checked for a nice firm fit.

Attached File  IMG_2326.jpg   43.19K   13 downloads

Weld tube into pedal.

Attached File  IMG_2382.jpg   43.48K   10 downloads

Won't know if this will work until two years time but i'm feeling confident.


Edited by sibhs, 04 March 2013 - 10:59 PM.


#7 sibhs

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Posted 30 April 2013 - 05:45 PM

I presume these holes should be round?
Right hand one looks made that way but other has wear.
Anyone know for sure?Attached File  ImageUploadedByTapatalk1367307877.085657.jpg   89.31K   9 downloads

#8 S pack

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Posted 30 April 2013 - 06:59 PM

Yes they do wear and No they are not round.


Edited by S pack, 30 April 2013 - 07:00 PM.


#9 sibhs

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Posted 30 April 2013 - 07:13 PM

They all seem oval so I'll make them look like the least worn one. Attached File  ImageUploadedByTapatalk1367313184.217470.jpg   90.14K   9 downloads
Thanks

#10 sibhs

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Posted 30 April 2013 - 07:27 PM

What are my options for these two bits?
Do they sell the rivet thingy or clutch adjusting nut?
Or do I have to make, sort of part that is neon impossible to find second hand without wear.
Cheer
Marty.

Attached File  ImageUploadedByTapatalk1367314031.202450.jpg   178.95K   11 downloads

#11 S pack

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Posted 30 April 2013 - 07:43 PM

The rivet thing was never sold separately. They only came as part of the relay lever assy.

I modified a bolt to replace the rivet thing then zapped it with a bit of weld to hold it in.

 

The clutch pushrod nut could either be built up with weld and machined or have a complete new part made.







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