2nd Gen Non-Engine/Transmission Brake&clutch pedals fell down

[GSchroeder]

Has anyone had the shaft that the pedals hinge on come partly out causing almost no braking? Not a good feeling because there was no warning. The circlip on the right side must have come off a long time ago cause I couldn't find it. It is a hard place to work in also. I got the shaft almost all the way back in but need a new circlip and maybe new bushings. It's hard to see the condition of them. I thought this was a unique failure to occur so I posted it.

 

[Woodenhead]

I've never had mine apart so I'd don't know much about the assembly. I have noticed my peddles are a little sloppy. Is there bushings on shaft/peddals that can be replaced to tighten things up?



I'll be checking the circlip next time I get in the truck.



Thanks for the heads up.



Mike

 

[Berrigan]

There are 6 white plastic bushings in there. My DC service manual showed only 4, but it has 6. Mine was squeeky and sloppy so I changed all 6. The squeak went away but the slop is still noticable. ( Like if you have your right foot lightly pushing the brake pedal, then push in the clutch you can feel a slight movement of the brake pedal. ) Yes it is tight and cramped to work on.

 

[DEP5]

The brake and clutch pedals on my 2001 suffered the same fate. The C-Clip appeared to be stressed by sideloads and was distorted. I put it all back together only to have it happen again two months later.



Remove the dash access panel underneath the steering, pull the 3/4" dia shaft out, chuck the cross shaft up in a lathe, drill and tap each end for 5/16-18 thread. Found some wierd heavy duty combination hex nut/thickwasher in the bolt and nut bin, amazingly they were countersunk 3/8" deep and 3/4" dia, made perfect stop to fit over the ends. Switch the nylon bushings around to even out the wear pattern, reassemble the pedals and push the cross shaft through (with one end pre-assembled. . bolt . . lock washer . . the stop) and put the other end together. Don't forget to readjust your stoplight switch.

 

[BudW]

The Dodge part number for the bushings is 4294639 and they run $2. 35 each.

The clip (retainer) is # 4103262 and runs $1. 85 each.



The part numbers are from my 1997 to 1999 truck book.



I hope this helps,

Bud

 

[Partyat33]

Mine has done it several times. Its a bad design. I tried replacing the bushings but it just does it again. You can take the shaft out. For now, I just stuck a spare pair of vice-grips on the end. Not elegant, but its better than having 'no' breaks.



Dennis