Itsavanman
Adventurer
Now, I know what your thinking, why is this guy creating a new thread? weeeellll the "hi everyone" thread was filled with a buncha im gonna's so I figured I would write a new thread showcasing what I am actually doing. the concept was if I'm going to swap transmissions to go 4x4, than its gonna be a manual.. How hard can it be to put a clutch pedal in my van.. hoo-boy, it was a pain in the bum.. first pulling out the original pedal box was a chore, as it was also the steering column support. since the manual pedal box shifts the master and booster over about 2.5" new holes had to be drilled to mount the box, and a block off plate had to be made to cover up the original hole. it started with cutting out the plate
and covering up this
got that plate cut out and new bolt holes drilled, then it was time to make the big hole for the booster to poke through, armed with a can of pb blaster and a wood hole saw i managed to chew a nice purdy hole through the block off plate and the firewall.
after the hole was drilled I went to set in the 94 f150 booster into its new home, it won't go.. what gives!? geez the electrical connector in the firewall is now in the way.. so everything back out. with the same hole saw and pb blaster (now 3/4 empty) i drill a new hole about 2" to the left so the booster will clear the connector. now we have 2 holes in the firewall lol, still need to fabricate a block off plate to cover up the old hole, but for now its in, then the booster goes back to slide home, due to one mount hole being slightly off it took me an hour to get it to sit right.. and voilla! ready for the pedal box.
now since the firewall is a bit different the pedal box wasn't quite right, so another 20 minutes of pushing pulling wiggling and pop! onto the booster studs it slides.
a quick tightening of the nuts and we have a pedal setup! WOO! the pedal arms do need some tweaking as the clutch pedal is a little low, and so is the brake, but because the booster hits the windshield cowling I can't raise the assembly to make it right, so now since I have a few extra pedals lying around, I will be using a bend or 2 from those to graft onto whats now there. now with the master bolted back on, will the aux coach battery still fit?
yup! tight squeeze but everything just barely makes it.. hooray!
Now we have an issue of the wiper motor hitting the clutch return spring, so out it came, since the motor is clocked at about 5 o'clock the plan is to rotate it to 6-7 o'clock and stuff it at the extreme right hand side of the drivers footwell. now since the nuts are captured on the wiper trough to hold the motor, I either had to find a way to put new captured nuts, or relocate the nuts to the wiper motor itself. to granger I went and got a few rubber isolators with 1/4-20 threads on the inside, now since the original wiper isolators had a groove to hold them to the wiper motor, I took a hack saw and made a groove in the new isolators.
now wasn't that easy. now the wiper motor will park at a different degree now that its rotated, but the plan is to set it up turn it on then off, and wherever its parked put the wiper arms back on on their parked position and it should work. so that's what I got so far..
and covering up this
got that plate cut out and new bolt holes drilled, then it was time to make the big hole for the booster to poke through, armed with a can of pb blaster and a wood hole saw i managed to chew a nice purdy hole through the block off plate and the firewall.
after the hole was drilled I went to set in the 94 f150 booster into its new home, it won't go.. what gives!? geez the electrical connector in the firewall is now in the way.. so everything back out. with the same hole saw and pb blaster (now 3/4 empty) i drill a new hole about 2" to the left so the booster will clear the connector. now we have 2 holes in the firewall lol, still need to fabricate a block off plate to cover up the old hole, but for now its in, then the booster goes back to slide home, due to one mount hole being slightly off it took me an hour to get it to sit right.. and voilla! ready for the pedal box.
now since the firewall is a bit different the pedal box wasn't quite right, so another 20 minutes of pushing pulling wiggling and pop! onto the booster studs it slides.
a quick tightening of the nuts and we have a pedal setup! WOO! the pedal arms do need some tweaking as the clutch pedal is a little low, and so is the brake, but because the booster hits the windshield cowling I can't raise the assembly to make it right, so now since I have a few extra pedals lying around, I will be using a bend or 2 from those to graft onto whats now there. now with the master bolted back on, will the aux coach battery still fit?
yup! tight squeeze but everything just barely makes it.. hooray!
Now we have an issue of the wiper motor hitting the clutch return spring, so out it came, since the motor is clocked at about 5 o'clock the plan is to rotate it to 6-7 o'clock and stuff it at the extreme right hand side of the drivers footwell. now since the nuts are captured on the wiper trough to hold the motor, I either had to find a way to put new captured nuts, or relocate the nuts to the wiper motor itself. to granger I went and got a few rubber isolators with 1/4-20 threads on the inside, now since the original wiper isolators had a groove to hold them to the wiper motor, I took a hack saw and made a groove in the new isolators.
now wasn't that easy. now the wiper motor will park at a different degree now that its rotated, but the plan is to set it up turn it on then off, and wherever its parked put the wiper arms back on on their parked position and it should work. so that's what I got so far..
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