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Yesterday, I got back to the point that I'd been when I was last working on it in the spring, which was putting the pedal cluster back together after having checked the clutch hook. I wanted to get the brake pedal set up again so that I could stop the car when pushing it ina nd out of the garage. To do that properly, I needed to create a retaining clip that holds the brake push rod on the pin that comes out of the brake pedal shaft.
The parts of the brake pushrod, cleaned and ready to assemble and install.
The metal piece in the lower left of the corner is the brake pedal
itself. In the lower middle of the photo is the pin that the pushrod
goes on. The pushrod extendes forward into the rubber dust boot at
the top of the photo and contacts the brake master cylinder. Three
parts of the pin are marked with colors. The green part on the left
is where the pushrod sits. The blue line shows where the pushrod
retaining clip is supposed to go. The part of the pine indicate by
the red line is where the brake pedal returning spring attaches.
Here I'm holding the brake pushrod in place to show you where it sits
on the pin.
To make the clip, I cut a small square of aluminum and bent over one
edge to make a spine.
I made this slot a bit narrower than the diameter of the pin where the
clip goes. I beveled the end of the slot to aid in slipping it on.
I filed out the end of the slot so that it will sit properly on the
brake pedal pin. I also trimmed the bottom down some so that it
didn't interfere with the movement of the pedal.
Push rode in place, the clip is ready to install.
Pushed down onto the pin.
Now the brake pedal is fully assembled and fully functional. The end
of the brake pushrod is marked with green dots. The retaining clip
that I manufactured is marked with blue dots. The end of the return
spring is marked by red dots.