Usually when the tunnel is cut open it's because
access was needed to weld the clutch cable conduit in
place (a loose tube is another cause and/or symptom of
clutch chatter). There's also a mounting tab near the
center of the tube - below the handbrake pivot, you
can see it with a good light - that often breaks.
Sounds like your first order of business should be to
fix the stripped threads for the pedal-cluster bolt.
You may need to use that hole in the tunnel to get in
there and weld a new nut inside...
When adjusting the pedal stop be sure that you keep a
slight amount of freeplay in the master cylinder
pushrod or you'll have problems with the brakes
binding up when driving. The pushrod length is
adjustable but unless someone has tampered with it
that shouldn't be necessary, you should be able to set
the stop to hold the pedals where they belong,
approximately 200mm from the firewall, while
maintaining 1mm of pushrod freeplay (that's about 6mm
at the brake pedal). Sometimes the stop is eroded and
needs to be tweaked straight and built back up with
weld, and sometimes the floorboard where the stop
anchors needs repair. I've done a few "quick fixes"
for this problem short of floorpan replacement by
drilling a hole in an old oil pump cover and welding a
nut to it for the pedal-stop bolt to screw into, after
the original nut has been cut off the floorboard.
--- asad ishaque <[EMAIL PROTECTED]> wrote:
> --Pedal cluster removal, inspection and probably
> swap. Have a very good
> complete set with me. The original on the car had
> its clutch cable hook
> broken many years ago. It was welded by a not so
> competent mechanic back
> then. Further that rascal butchered the centre
> tunnel to gain access to the
> hook and cable. This needs to be welded shut. Also
> the brake pedal is
> sitting too close to the driver. Probably the stop
> plate on the floor needs
> tweaking/repair. One of the bolts holding the assy
> to the tunnel has slipped
> threads. This needs to be drilled out and new bolts
> put in to make a
> headache free setup.
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