With the previous post covering stripping and painting the pedal and clutch towers, its time to put them back together… with lots of shiny new parts 🙂

With the arrival of the DHL guy this afternoon with the final few parts, rebuilding the brake and clutch towers can begin.

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Everything laid out
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Original label on the replacement pedal shaft…. British Leyland. Made in England. Made to British Standards xyz There was also a date stamp… 1985. I was 11 years old when this was made and it’s been sat about since then waiting to fulfil its purpose.
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Replacement bushes ready to be pressed in. I filed a small shoulder on them in order get them started into the pedal shaft.
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Not being the owner of a press, my grandfathers vice works just as well. A smear of grease helps things slip in smoothly
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New bushes pressed in
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Spot the difference. Seemingly, between 1967 and 1985, the hole for the mills pin was omitted. Given these shafts hold the brake and clutch pedals in place, its not something that I want to work loose. The mills pin keeps them located in place.
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I don’t have a press but I do have a pillar drill, so I drilled a 3mm hole through the shaft. Note the centre punch dent to make sure the drill bit goes where it should.
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All the way through
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Drilled shaft, mills pin, bushes pressed in and trunnion and spacer in place. Time to fit this lot to the pedal box
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Clutch master cylinder fitter to the tower and bolted to trunnion
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The finished item
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The bolt in the end of the shaft (drilled earlier) is there to allow a little oil to be poured in, so as to lubricate the shaft bushes. Once again, replacement imperial stainless steel fixing have been used.
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Now, onto the other pedal… Bushes offered up
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Bushes pressed in with the vice
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Bushes pressed in and greased
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Shaft and mills pin in place with head peened over
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CV (compression valve) and CB(compression barrel) master cylinders. The lower one (CB) is as specced in the 109 models, the upper (CV) is for the 88. It not clear if there is any addition in braking effect, plus the CB type is harder to bleed. Not sure why I’ve fitted it…. Other than it looks more purposeful than the CV model. Yes, thats probably it.
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Brake master cylinder fitted to the tower
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Finished…. Well, sort of. It was only later when I looked (again) in the manual, that I realised I had fitted the brake master cylinder into the clutch tower and visa versa. This is now rectified and the correct master cylinder is in the correct tower.