Adjustable pedal fix!

[Curless]

O.K., there has been a ton of talk about how to permanently fix the pedal assembly that fails on our cars. I have such a repair. I had a gear designed today made out of brass to replace the one that is plastic.

If I can get a group order of 35, the cost will be $75 for the gear shipped to your door. If not its going to be $100 each due to set up charges.

The gear is locked onto its shaft by being stamped, this will require grinding the shaft end down so that the washer can be removed and the offending gear can be taken off. Then you would instal the new gear, set the washer back in place and tack weld it on. For some this may be an issue, if that is the case just send me your pedal assembly and I can do it for you for an additional charge.

Let me know what you guys and gals think! I will post complete pics and instructions in the next day or so.

[DOOM]

I'm in for one.

Can you do the fix in Louisville??? :D

[Curless]

You know...it could be done...we would need a 110 welder and a way to grind off the end of the shaft...hmmm parking lot repair???? Yes, it could be done.

[HiHoSilver]

Nice fix, It should have been brass from the factory!

[Bigdogjim]

You know...it could be done...we would need a 110 welder and a way to grind off the end of the shaft...hmmm parking lot repair???? Yes, it could be done.
I can see the line wrapping around Hotel and out of the parking lot and down the street:lol:

[Curless]

We could do this, just have to be able to get the pedals out and then do the repair!

[TUXrauder]

put me down for 2 of them

[Ms. Denmark]

Subscribing. Someone be a guinea pig and give it a try. It would be great to have a permanent repair for this. I have a pedal assembly already out of my car with the gear removed. Had a new assembly installed a year or so ago.

[Curless]

I am a computer moron...can someone help me set up a way to get list going? I have seen them on other threads here and other sites.

[Ms. Denmark]

You can do a poll or you can make a list by having people post and placing them on a list that you edit each time to add their name. It's simple.:)

[Curless]

We need to start a list...

Tuxrauder X2
Doom X1
BigCars4Ever X1
1 bad merc X2
Screamn X1
Haggis X2
Imorb1994 X1
drac X1
Breeze X1
Green 96 X1
RF Overload X1
Gryphonzus X4
Myblackbeast X1
GreekGod X1
Rocketman X1
03MMMonroe X1
HG M75 X1
N40GL X1
Chevy Guy X1
MS Denmark X2
Grand Marquis X1
Tom Blahous X1
CLMRT X1
drobin X1

[BigCars4Ever]

I'm in for one!

[Curless]

I logged on to CVC but I can't figure out where I should post it...anyone have any ideas? Or if you know of other sites lets see if we can get a decent sized order going so the price can be dropped.

[DOOM]

I can see the line wrapping around Hotel and out of the parking lot and down the street:lol:

Hey Russ (03mmmonroe) did about 15 EATC repairs in the parking lot last year at Louisville! :beer:

:bows:

[Curless]

Hey Russ (03mmmonroe) did about 15 EATC repairs in the parking lot last year at Louisville! :beer:

:bows:


Get the list to grow and I will come up with the tools!

[DOOM]

Get the list to grow and I will come up with the tools!

Yeah baby! :banana2:

Can I get my gear in chrome? :coolman:

[RF Overlord]

Can I get my gear in chrome? :shake: That's our Doomie...

[Blackened300a]

Just for a idea, instead of tacking the washer back on, why not use a shaft lock collar? Or maybe drill the shaft and insert a cotter pin to hold the washer? A lot more people have access to a drill then a welder.

http://www.vexrobotics.com/276-2010.html
http://www.vexrobotics.com/media/catalog/product/cache/11/image/296x/5e06319eda06f020e43594a9c23097 2d/c/o/collar_1.jpg

[Mr. Man]

One of those things won't fit under the plastic cover^^^^

[Green96]

If you can figure out the pitch and the number of teeth you can get brass gears from McMaster Carr. Some even have set screws. You might need a bushing to press in the ID to get it to the right size, but it might be a hell of a lot easier than making the entire gear.

If someone (Paula) wants to sacrifice their bad assembly and send me it, or just the gear I can figure out if a standard gear would work. It is possible that the modified the gear form so that a standard would not work, but it is unlikely.

[Blackened300a]

One of those things won't fit under the plastic cover^^^^

Then this will. It's a push nut retainer. Put the gear on and slide this on. Mack trucks uses these for window tracks and inside the dash to hold harnesses.
http://i32.photobucket.com/albums/d12/blackened300a/3B93A95F-C3EF-45DD-B30B-B0AB077F8685-1673-000001C6BB75F8B6_zps81ab577c.j pg

[Mr. Man]

Then this will. It's a push nut retainer. Put the gear on and slide this on. Mack trucks uses these for window tracks and inside the dash to hold harnesses.
http://i32.photobucket.com/albums/d12/blackened300a/3B93A95F-C3EF-45DD-B30B-B0AB077F8685-1673-000001C6BB75F8B6_zps81ab577c.j pg
Maybe but as I recall I was thinking to tap and use a screw to hold it in place and wasn't sure if that would fit back under the plastic cover. There isn't much room.

[GreekGod]

I appreciate Chris working on this repair. Perhaps the gear is a standard count & pitch? Perhaps a Shimano (bicycle) speedo gear, or some other application will be adaptable? Yes, McMaster-Carr is a good place to try.

[Curless]

There is no room for "extra" locks or washers in the assembly. The gear is an acme thread on the inside and a worm gear type on the outside. There is no simple off the shelf part we can use t fix it. If there was, someone would have already done it.

[Curless]

If you can figure out the pitch and the number of teeth you can get brass gears from McMaster Carr. Some even have set screws. You might need a bushing to press in the ID to get it to the right size, but it might be a hell of a lot easier than making the entire gear.

If someone (Paula) wants to sacrifice their bad assembly and send me it, or just the gear I can figure out if a standard gear would work. It is possible that the modified the gear form so that a standard would not work, but it is unlikely.


I cut my original pedals all up yesterday, I have all of the pieces in my hot little hands. There are not off of the shelf pieces. You can't get the acme shaft out of the pedal assembly without destroying the assembly.

[Curless]

Yeah baby! :banana2:

Can I get my gear in chrome? :coolman:


How about polished Brass???:beer:

[1 Bad Merc]

I am in for two! Just let me know:)

[Curless]

Here's the guts to the moveable part...the longer shaft is the one that needs the washer put back on...there is no way that we could easily tap it or add a locking collar.

[Curless]

We are up to 6 so far, at 10 I will get things rolling. Remember at 35 I can get the price to drop.

[DOOM]

I'm in regardless of price!

Been waiting YEAR'S for someone to come up with a permanent fix!

[Ms. Denmark]

Just my 2 cents but shouldn't we try it out once a gear is available to make sure it works reliably? I want a fix but I want it to be tested. :beer:

[GreekGod]

Here's the guts to the moveable part...the longer shaft is the one that needs the washer put back on...there is no way that we could easily tap it or add a locking collar.

Nice job on the disassembly. Some tiny acme threads on the I.D.! Quite strange that Ford (or their supplier engineer?) went with a plastic gear, as it appears to be a nice part, otherwise.

I'm guessing you could order 1,000 of them and sell out in short order - especially if a non-welding attachment means was devised. Someone like Dorman should rescue us.

[Curless]

Just my 2 cents but shouldn't we try it out once a gear is available to make sure it works reliably? I want a fix but I want it to be tested. :beer:
I totally understand your point here, the factory part would live if it was not a pressed fit...a brass one is not going to break. The plastic is pressed onto a steel sleeve, the hole in the plastic has to be smaller than the o.d. of the steel so that there is an interference fit...problem is that the tightness is too tight and it breaks...but it if was too loose it would slip...

I will see how quickly I can get one made and installed.

[Curless]

Nice job on the disassembly. Some tiny acme threads on the I.D.! Quite strange that Ford (or their supplier engineer?) went with a plastic gear, as it appears to be a nice part, otherwise.

I'm guessing you could order 1,000 of them and sell out in short order - especially if a non-welding attachment means was devised. Someone like Dorman should rescue us.


I agree...NO MORE WELDING! I have an answer for that now. Just tried about 25 different things and came up with a solution. A washer cap nut will work. I just used one and there is no way the electric motor can over come its grip. I had to knock it back off with a hammer and a chisel.

[screamn]

Curless, put me down for one (1).

[Curless]

Gotcha screamn, we are at 7. I am leaving right now for the gear shop. I will have an update shortly.

[Mr. Man]

I totally understand your point here, the factory part would live if it was not a pressed fit...a brass one is not going to break. The plastic is pressed onto a steel sleeve, the hole in the plastic has to be smaller than the o.d. of the steel so that there is an interference fit...problem is that the tightness is too tight and it breaks...but it if was too loose it would slip...

I will see how quickly I can get one made and installed.
I think if you have your prototype made and installed and put up a video or something that shows the new gear working you would get a lot more takers. I think a lot of of us want to see it work first.:)

[Curless]

The prototype should be ready Monday or Tuesday next week. Welding is no longer necessary, instal should be pretty simple. I need to get another pedal assembly as I had to destroy my old one. I am going to the salvage yard in the a.m. to get one. Working prototype should be instal ready by the end of next week.

[Ms. Denmark]

The prototype should be ready Monday or Tuesday next week. Welding is no longer necessary, instal should be pretty simple. I need to get another pedal assembly as I had to destroy my old one. I am going to the salvage yard in the a.m. to get one. Working prototype should be instal ready by the end of next week. Thank you for taking on this project.

[Curless]

Thank you for taking on this project.

You're welcome! I hope that we can get enough orders to get the price down.

[Haggis]

I'm in for two, but would like to see the finished product and directions first.

[Curless]

I'm in for two, but would like to see the finished product and directions first.

9, only one more to go. I will get the instructions all written and I may shoot a video of it too. Do you guys and gals want a step by step including taking the pedals out?

Thanks Haggis, I'll get you a ************ too!

[imorb1994]

Im in for 1

[Curless]

10...guess I better call the gear guys huh? As soon as I get the prototype here and know that its perfect I will post up a paypal and get things rolling. I was told I'd have my exact quote and time frame in the a.m. Friday.

[drac]

I will be in for 1.

been waiting forever for something like this to come along! Thanks for taking this on!

[Curless]

11, thanks for the support guys and gals. I understand that many of you don't know me so saying that you trust me is impressive. I would not ever put an inferior product on one of my cars nor will I sell one. The finished product WILL work correctly and the instructions WILL be clear and concise or I will not sell it. Come on gear guy....call me!!!!

[DOOM]

Curless thanks for doing this. :up:

And thanks in advance for doing my install in Louisville! :D

[Ms. Denmark]

If this works it will be the Curless Cure. :)

[Curless]

If this works it will be the Curless Cure. :)

LOL, oh no...here we go! :eek:

[Curless]

Curless thanks for doing this. :up:

And thanks in advance for doing my install in Louisville! :D


Like I said, if you guys don't mind getting the pedals out we can fix em! I have a complete travel set of tools, cordless impacts, I'll get a cordless grinder and we'll be good to go!:beer:

[martyo]

Nice job Curless!

[guspech750]

Chris da man!

I don't know if I need one. I set my pedals 3 years ago when I bought the car. And I have not moved them since.

Hmmmm. I'll have to check.


Sent from my iPhone

4.10's + Eaton swap = Wreeeeeeeeeeeeeeedom

[RF Overlord]

Right here is why the owners of mm.net are so proud of this site. Members helping other members save money and keep their pride and joy in top shape.

Thank you, Curless, for taking this project on. It's been a sore point for many years.


BTW, I'm in for at least one, possibly two depending on final price.

[GreekGod]

Curless Cure - the name is now set in stone!

[Haggis]

Like I said, if you guys don't mind getting the pedals out we can fix em! I have a complete travel set of tools, cordless impacts, I'll get a cordless grinder and we'll be good to go!:beer:

I'm next in line after Doom. The Curless Cure could be this year's Kentucky theme.

[Curless]

You guys are nuts! oh ************....I said nuts...!

[breeze]

I'd be down for one

[Curless]

I count 12 so far, please go back to the 1st page and check the list for your name. If its not on there please let me know and I'll add it.

Thanks again guys, I was wondering...any of you have any other Ford products that have the pedals that don't work? I really want to tear the other assemblies apart and find out if the gear is the same...if it is the audience gets a lot bigger and the price can be dropped more due to volume. Please let me know if any of you have a different car or truck with this issue.

Chris

[RF Overlord]

check the list for your name. If its not on there please let me know and I'll add it.You forgot me.

[Gryphonzus]

If the fix works put me down for four.

Sent from my SAMSUNG-SGH-I727 using Tapatalk 2

[Bigdogjim]

11, thanks for the support guys and gals. I understand that many of you don't know me so saying that you trust me is impressive. I would not ever put an inferior product on one of my cars nor will I sell one. The finished product WILL work correctly and the instructions WILL be clear and concise or I will not sell it. Come on gear guy....call me!!!!

Hey Just remember we know where you live, what you drive,etc:)

Thanks again for starting the project.

For what it worth I have moved mine sice I bought the car, 10 years ago.

When I meet you a few short weeks ago I know you fit right in:beer:

[MyBlackBeasts]

I haven't moved mine since I set them when 1st bought MM but put me down for one so I have it when it DOES puke. :eek:

Plastic pressed on steel = guarrantied failure... Dumb-ass engineers! :shake:

[GreekGod]

I will take one

[Green96]

Put me down for one. Thanks all the hard work!

[Curless]

I could not sleep at all last night, this project has my mind screaming. Went home at 9p.m. last night and came back to 8 more gears asked for! Chompin at the bit, I just want that prototype so I can try it out! Thanks guys!

[Curless]

20, that is the current total.

[GreekGod]

Like I said, I'm sure 100 will be easy to market, and 1,000 or more will eventually sell. With the Ford replacement (pedal assembly) so expensive, a shop could beat Ford's part price, and get a profit in labor. Getting the word out is important - once you have a proven product.

[Rockettman]

Sure...I'm in for one!

[Curless]

Like I said, I'm sure 100 will be easy to market, and 1,000 or more will eventually sell. With the Ford replacement (pedal assembly) so expensive, a shop could beat Ford's part price, and get a profit in labor. Getting the word out is important - once you have a proven product.

Yes getting the word out is important and the life of this product is limited since they no longer make this car. But what need to know is, does this gear fit the other Ford cars and trucks with moveable pedals? That may change things a bit...

[Haggis]

Our 2002 Explorer also has adjustable pedals, I will check on the gears this weekend and let you know.

[Curless]

Our 2002 Explorer also has adjustable pedals, I will check on the gears this weekend and let you know.


Thanks! I assume you know to just pull the cover off of the pedals and you can see the gear. Look at my pics of the gears, the large black one is the one we are looking at.

[Curless]

Sure...I'm in for one!

Gotcha, thank you!

21 total

[Haggis]

Thanks! I assume you know to just pull the cover off of the pedals and you can see the gear. Look at my pics of the gears, the large black one is the one we are looking at.

There's a cover!!! :banghead:

[Curless]

22 and counting!

[Hg M75]

Put me down for one.

[GreekGod]

We need an outer diameter & tooth count to play safe on interchange. It would be nice to find the blueprints from Ford - or it's supplier.

[Curless]

23, keep em coming!

Just got off of the phone with the gear guys. Looks like a week or so for the first one. :bigcry: Its killin me!

[Curless]

We need an outer diameter & tooth count to play safe on interchange. It would be nice to find the blueprints from Ford - or it's supplier.

Yep, you are right. The gear guys have my parts right now so I can't get it today. In the next day or so I will have to get the numbers so we can check it all out.

[N40GL]

Count me in for one. I sure would like to see the eventual instructions to know whether I can do this in my driveway, or I need a body shop or something. Most of what I've done to the MM over the past two years is reinforcing/replacing things likely to break, and this just fits rights in (no matter that I haven't move the pedals since I bought the car).

[RF Overlord]

the life of this product is limited since they no longer make this car.That may change things a bit...Even though they no longer make the Panther platform, there were billions of Grand Marquis' and civilian CVs and I'll bet there are adjustable pedals in many of them.

[Curless]

Even though they no longer make the Panther platform, there were billions of Grand Marquis' and civilian CVs and I'll bet there are adjustable pedals in many of them.

From my research today I see that one company builds the pedals for CV, MM, GM, Expedition, Navigator...I bet the gear is the same for all of them. The pedals became available in 2000.

[Curless]

Count me in for one. I sure would like to see the eventual instructions to know whether I can do this in my driveway, or I need a body shop or something. Most of what I've done to the MM over the past two years is reinforcing/replacing things likely to break, and this just fits rights in (no matter that I haven't move the pedals since I bought the car).


Gotcha, I will start writing the instructions this weekend. I am going to have someone video me doing the actual procedure on the bench. You have to remove the pedals from the car to do it.

I will add you to the list!

[screamn]

Surprising no upgrade from that one company that must have received numerous complaints regarding the above issues.

[Curless]

24 in about two days...now if we could reach all of the registered members on here...and CVN....holy smokes! I would have to go to a production shop instead of a job shop!

[Curless]

Surprising no upgrade from that one company that must have received numerous complaints regarding the above issues.

Remember that Ford calls the shots not the manufacturer. They will build whatever they are told to build. I agree though but change costs money.

[Chevyguy]

We need to start a list...

Tuxrauder X2
Doom X1
BigCars4Ever X1
1 bad merc X2
Screamn X1
Haggis X2
Imorb1994 X1
drac X1
Breeze X1
Green 96 X1
RF Overload X1
Gryphonzus X4
Myblackbeast X1
GreekGod X1
Rocketman X1
03MMMonroe X1
HG M75 X1
N40GL X1
Chevyguyx1


this is relevant to my interests!! My pedals are at least stuck down all the way thank god.

[Green96]

We need an outer diameter & tooth count to play safe on interchange. It would be nice to find the blueprints from Ford - or it's supplier.

You also need to make sure that the acme thread is the same. Need to check diameter and # of starts. I assume it is single start, but it could be more. I am not sure how to visually identify the difference.

[Green96]

Oh, oh, I remember. It is literally the number of thread starts at the end of the rod. If you look at the end of a standard bolt, there is one place where the thread starts. Acme threads can have multiple starts to increase the distance traveled per rev instead of just different thread pitch. My guess it that they will be single start (single start is self locking on acme threads).

[MyBlackBeasts]

Even though they no longer make the Panther platform, there were billions of Grand Marquis' and civilian CVs and I'll bet there are adjustable pedals in many of them.

Sables also. There were a Bazillion Sables produced. If same pedal the matket for the piece could be monsterous! :eek:

[Curless]

Gotcha Chevy Guy... 25

[Curless]

Sables also. There were a Bazillion Sables produced. If same pedal the matket for the piece could be monsterous! :eek:


The Taurus / Sable / Freestar / F - series are from a different manufacturer. I will have to disassemble one to see if they use the same gear.

[RF Overlord]

now if we could reach all of the registered members on here...and CVN....holy smokes! I just sent a PM to the owner of CVN. If he has no objection, I'll post up over there.

[Ms. Denmark]

From my research today I see that one company builds the pedals for CV, MM, GM, Expedition, Navigator...I bet the gear is the same for all of them. The pedals became available in 2000.
Interesting! I have an '03 Aviator with adjustable pedals which do get adjusted frequently between my 5'6" self and 6'3" Mr. Man. Wonder why they haven't broken? Better gear? (or dumb luck) We would be in for 2 gears; one for Eric's car and one to repair the (now spare) assembly I removed & replaced with a new one on my car. If I can find out if the Aviator also uses the same crappy gear then I may want a third Curless Cure.

[RF Overlord]

heh...Curless Cure...Wacky Wipers...FBM Fix (for the LCM)....anyone else see a pattern here? :D

[Curless]

Interesting! I have an '03 Aviator with adjustable pedals which do get adjusted frequently between my 5'6" self and 6'3" Mr. Man. Wonder why they haven't broken? Better gear? (or dumb luck) We would be in for 2 gears; one for Eric's car and one to repair the (now spare) assembly I removed & replaced with a new one on my car. If I can find out if the Aviator also uses the same crappy gear then I may want a third Curless Cure.

I'll add ya to the list!

[Curless]

27, and the list goes on!

[N40GL]

Here's a thought:

www.adjustablepedals.com

The world will beat a path to your door. Or at least the GM, CV, Sable and related owners.

[Curless]

LOL, I am not going to say that thing is gonna take off like that! If I can fix it for a reasonable amount of money and maybe make a buck or two while I am at I'll be satisfied.

[Grand_Marquis]

Definitely interested in this, put me down please!

I had a brand new set of power adjustable pedals installed on my '01 Grand Marquis in June of this year, which currently have less than 3,000 miles of use on them. Took my car in for some paintwork, and somebody moved the pedals forward while it was there. When I tried moving them towards the firewall, they just wouldn't move, but they do move about a centimeter forward (towards the seat). I guess now I know what the culprit is. :(

[Curless]

Definitely interested in this, put me down please!

I had a brand new set of power adjustable pedals installed on my '01 Grand Marquis in June of this year, which currently have less than 3,000 miles of use on them. Took my car in for some paintwork, and somebody moved the pedals forward while it was there. When I tried moving them towards the firewall, they just wouldn't move, but they do move about a centimeter forward (towards the seat). I guess now I know what the culprit is. :(

I will add ya to the list...only question I have is how bad will the shipping be???:eek:


#28

[slickster]

My Pedals come out but I have to keep messing with the switch to go back in? Is this a gear or bad switch?

[fastblackmerc]

My Pedals come out but I have to keep messing with the switch to go back in? Is this a gear or bad switch?

Bad switch. If the gear is bad the pedals won't move at all.

[GreekGod]

The Taurus / Sable / Freestar / F - series are from a different manufacturer. I will have to disassemble one to see if they use the same gear.

Please name/ID known manufacturers. I worked at a stamping plant that built & assembled all the older Corvette vacuum headlight door motors. You never know who-knows-who, and what is available. ;)

Hopefully, word will get out, and other vehicles that have the same problem will become known here.

[Grand_Marquis]

I will add ya to the list...only question I have is how bad will the shipping be???:eek:


#28

To avoid a double order, I've got myself down as White_Falcon_LS on CVN. Shipping wouldn't be a problem, as I have a forwarding address in Ohio. Once it arrives at that address, it will be forwarded onto Kuwait through DHL. :)

[Curless]

To avoid a double order, I've got myself down as White_Falcon_LS on CVN. Shipping wouldn't be a problem, as I have a forwarding address in Ohio. Once it arrives at that address, it will be forwarded onto Kuwait through DHL. :)

Gotcha, thanks!

[Curless]

Just got back from the Gear shop... First process is done, its coming along nicely.

[Curless]

With the list at CVN we are at 34...

[Hg M75]

Be sure to scratch me off the CVN list at AACoPD05.

[clmrt]

+1 for me, mine are stuck too.

[Curless]

Be sure to scratch me off the CVN list at AACoPD05.

Got it, I will handle that this morning.

[Curless]

+1 for me, mine are stuck too.


Added. 34 and holding...

[drac]

Just an update- I posted in CVN that i was interested in this also. Just want to make sure you don't order 2 for me... as i posted both here and on CVN that i was in on this. :)

[Curless]

Just an update- I posted in CVN that i was interested in this also. Just want to make sure you don't order 2 for me... as i posted both here and on CVN that i was in on this. :)

Got it, now holding at 33.

By the way none will be ordered until after we do a prepay buy in. I will set up a group buy paypal for a time period, once we reach the end of that time period we will add up the orders and see how many have actually sold and then determine a price with the supplier. If all goes well we will be over 35 so we get the better pricing!

[marauder410]

went out to check mine since havent touched that buttom in forever to see if they moved or not...

mine are moving but they dont move very much is this normal or are the pedals supposed to move up and down alot

takes like 2 seconds for them to be all the way to floor to lift them all the way up but dosent seem to eb moving very much?? is this normal or is the gear going up

[Curless]

went out to check mine since havent touched that buttom in forever to see if they moved or not...

mine are moving but they dont move very much is this normal or are the pedals supposed to move up and down alot

takes like 2 seconds for them to be all the way to floor to lift them all the way up but dosent seem to eb moving very much?? is this normal or is the gear going up


The should move a couple of inches...sounds like your gear is broken.

[Green96]

went out to check mine since havent touched that buttom in forever to see if they moved or not...

mine are moving but they dont move very much is this normal or are the pedals supposed to move up and down alot

takes like 2 seconds for them to be all the way to floor to lift them all the way up but dosent seem to eb moving very much?? is this normal or is the gear going up

The should not move "up and down" at all. They move forward and back LOL.

[GrandpasJalopy]

I'm new as of today because of this thread.
I'm in for two. My dad's town car's adjustable pedals are gone too.

[GrandpasJalopy]

Until we get the new gear in, is there a way to move the pedals? I noticed Hg M75 (http://www.mercurymarauder.net/forums/member.php?u=13852) had spoken of taking the gear cap off and moving it. Has anyone done a walkthrough? I'm planning a trip to Halifax and they got stuck when my 5'2" grandfather set them. At 6'2" there's a significant difference!

[Curless]

Until we get the new gear in, is there a way to move the pedals? I noticed Hg M75 (http://www.mercurymarauder.net/forums/member.php?u=13852) had spoken of taking the gear cap off and moving it. Has anyone done a walkthrough? I'm planning a trip to Halifax and they got stuck when my 5'2" grandfather set them. At 6'2" there's a significant difference!

The first thing you would have to do is remove the cable that links the gas and brake pedals together. The gas pedal would then move normally. Then, f you remove the white cover on the brake pedal assembly, you should be able to swing the pedal forward towards the fire wall, then re-instal the cover.

[Hg M75]

I just took off the white cover, 2 screws, so I could see the broken gear. I used a small flat screw driver to assist the broken gear to move past its stuck point while using the switch to make the motor move. The broken gear will rotate one revolution but then get stuck again when it comes to the broken point, in which the small flat screw driver is necessary to help it past the broken point again. This is an emergency procedure if, let say, someone moves your pedals all the way forward and you need to move them back. In no way will this fix it to function like new.

[RF Overlord]

mine are moving but they dont move very much is this normal or are the pedals supposed to move up and down alot

takes like 2 seconds for them to be all the way to floor to lift them all the way up but dosent seem to eb moving very much?? is this normal or is the gear going upFrom the owner's manual, page 63:

"The adjustment allows for approximately 65 mm (2.5 inches) of maximum travel."

[Curless]

I just took off the white cover, 2 screws, so I could see the broken gear. I used a small flat screw driver to assist the broken gear to move past its stuck point while using the switch to make the motor move. The broken gear will rotate one revolution but then get stuck again when it comes to the broken point, in which the small flat screw driver is necessary to help it past the broken point again. This is an emergency procedure if, let say, someone moves your pedals all the way forward and you need to move them back. In no way will this fix it to function like new.


Exactly, it can't pass the broken spot.

[Curless]

One more day! I am waitin...not so patiently!

[GreekGod]

I'm disappointed we don't know what other Ford cars have the same problem, or if any do. I'm starting to think it is only a "Panther" problem?

How about a tooth count, and outside diameter (but it won't matter is we have the only chassis with the crap gear).

=================

[Curless]

I'm disappointed we don't know what other Ford cars have the same problem, or if any do. I'm starting to think it is only a "Panther" problem?

How about a tooth count, and outside diameter (but it won't matter is we have the only chassis with the crap gear).

=================

I have two assemblies from other cars being delivered right now. The gears are all at the machine shop so I can't get you a count. If you search for issues with moveable or adjustable pedals you'll see we are not the only ones with issues. I just don't know which ones have the same gears yet.

[Curless]

Just spoke to the shop, tomorrow is still the day!

[GrandpasJalopy]

Thanks to both Curless and Hg M75 for the pointers!

[Haggis]

Just spoke to the shop, tomorrow is still the day!

Well? It is tomorrow.

[Curless]

Well? It is tomorrow.

I KNOW RIGHT???? Come on call me machine shop!!!!!!!!!

[Curless]

Guess what I have???

[Curless]

Now to reassemble the pedal mechanism and try it out!

[DOOM]

Guess what I have???

Where's the chrome one??? :confused: :dunno:

[Ms. Denmark]

Now to reassemble the pedal mechanism and try it out!
We can't wait ......:D

[Curless]

Where's the chrome one??? :confused: :dunno:


LOL, gotta try it first!:lol:

[guspech750]

Looks great.


Sent from my iPhone

4.10's + Eaton swap = Wreeeeeeeeeeeeeeedom

[Curless]

Thanks Gus! I have it reassembled and it moves perfectly on the bench. I need to put it into a car and try it out. One thing I need to know is does the gas pedal have a stop on it. Meaning, if we disconnect the brake pedal can the gas pedal move far enough to un-thread itself. The way I was hoping to "lock" the gear back on will not work, the gear has too much leverage over the "lock" and it can push it off. That may require welding once again, unless the gas pedal has a fixed stop then we may be all good! Now to go home and get my car out for tomorrows test fitting!

[Curless]

Will have the car in the shop shortly this morning. Taking pics and writing instructions today.

[drobin]

Please count me in for one also..

Thanks,
drobin (Donald)

[Curless]

Please count me in for one also..

Thanks,
drobin (Donald)

Gotcha. Should have instructions and pics up today!

[Curless]

34 and holding...

[guspech750]

Dang it. I keep forgetting to check my pedals out.


Sent from my iPhone

4.10's + Eaton swap = Wreeeeeeeeeeeeeeedom

[Curless]

The instructions are up, let me know what you guys think!

[Haggis]

Thanks Chris. :up:

[N40GL]

Where are the instructions?


The instructions are up, let me know what you guys think!

[Curless]

Where are the instructions?

http://www.mercurymarauder.net/forums/showthread.php?t=82699

[vegasmarauder]

Put me in for 10..yes TEN (I saw the price)...between all of ours and other people with CV/GM's with stuck pedals as soon as I fix one I will have to do all of them..

Great job on the manufacture!

[Curless]

Put me in for 10..yes TEN (I saw the price)...between all of ours and other people with CV/GM's with stuck pedals as soon as I fix one I will have to do all of them..

Great job on the manufacture!

Sent you the link in a PM, Thanks!

[vegasmarauder]

Got it, sent payment....There are a few couples with MM's and other panthers where he's 6'2" and she's 5'2" that are very happy....

[Curless]

Got it, sent payment....There are a few couples with MM's and other panthers where he's 6'2" and she's 5'2" that are very happy....

Glad to help! Thanks again for the huge order!

[Curless]

So in case you did not see my latest post about today....the pedal repair gear also fits July of 02 till Dec 03 Navigator and Expeditions as well! I bought an assembly today and tore it apart, SAME GEAR! Ford gave me the dates, I need to find pedals from other years to see what the difference is (mounting / brackets) or if its really completely different.

Well, not exactly the same...the inside of the gear has a different thread count. We can still make it but the tap is more expensive than the one for our cars.

[Ladyhawke]

So in case you did not see my latest post about today....the pedal repair gear also fits July of 02 till Dec 03 Navigator and Expeditions as well! I bought an assembly today and tore it apart, SAME GEAR! Ford gave me the dates, I need to find pedals from other years to see what the difference is (mounting / brackets) or if its really completely different.

How about 2002 Explorers?

[Curless]

How about 2002 Explorers?


I don't know, can you get me a pic of the brake pedal? I want to get one of those assemblies to tear apart soon. It also fits Taurus / sable / f-150...

[lifespeed]

Plastic pressed on steel = guarrantied failure... Dumb-ass engineers! :shake:

Accountants, bean-counters. Health care costs.

Not engineers ;)

[Marauderjack]

Actually it is plastic molded onto a steel center......look closely!!:rolleyes:

My guess is when it cooled it shrunk to the point of cracking in a short time....very, very poor design!!!:argue::mad2:

[vegasmarauder]

I just did 5 MM pedal repairs today....Some observations..The part and the instructions are great, Thanks Curless!.

I did notice that the gear should screw all the way down and be flat on the potmetal housing. It had one that would not go all the way down. Flipped the gear over and it went all the way down. Not sure if this was one gear that was on the outside of the tolerance, but I don't think the plastic housing will go back on if the gear does not seat all the way. Just in case someone else runs into this.

The original gear is nylon molded around the steel center. When the nylon shrinks or the metal expands, it cracks..nothing new there.

I had a brand new pedal assembly still in the Ford box and I put a new gear in it. The replacement units have an ALL nylon gear with no metal center...But...I pulled an assembly out of a MM that was stuck all the way up and lo and behold, it was a new pedal assembly with the all nylon gear. No idea why it got stuck. The only thought is that the pedals were not set correctly and the gear overtraveled to end of the shaft and got stuck. The accel pedal sets the limit on the travel. If the index marks are lined up on the brake pedal and the accel pedal lowered and then bumped back up off the lower stop just a bit there should be no problems.

[Curless]

I just did 5 MM pedal repairs today....Some observations..The part and the instructions are great, Thanks Curless!.

I did notice that the gear should screw all the way down and be flat on the potmetal housing. It had one that would not go all the way down. Flipped the gear over and it went all the way down. Not sure if this was one gear that was on the outside of the tolerance, but I don't think the plastic housing will go back on if the gear does not seat all the way. Just in case someone else runs into this.

The original gear is nylon molded around the steel center. When the nylon shrinks or the metal expands, it cracks..nothing new there.

I had a brand new pedal assembly still in the Ford box and I put a new gear in it. The replacement units have an ALL nylon gear with no metal center...But...I pulled an assembly out of a MM that was stuck all the way up and lo and behold, it was a new pedal assembly with the all nylon gear. No idea why it got stuck. The only thought is that the pedals were not set correctly and the gear overtraveled to end of the shaft and got stuck. The accel pedal sets the limit on the travel. If the index marks are lined up on the brake pedal and the accel pedal lowered and then bumped back up off the lower stop just a bit there should be no problems.


Yes, the new assembly from Ford has an all nylon gear on it. I heard from several sources that the nylon gear fails as well. I have not had one in my possession yet the has failed.

As for your issue with the gear not going completely down onto the potmetal housing...I only have two pedal assemblies here to check fitment on, one original (nylon with steel) and one new version (all nylon)...please let me know if you have anymore issues. The gears are the supposed to be the same size on both sides.

Thanks again for the feedback! Its great to hear!:beer:

[GetMeMyStogie]

The way I was hoping to "lock" the gear back on will not work, the gear has too much leverage over the "lock" and it can push it off. That may require welding once again, unless the gas pedal has a fixed stop then we may be all good!


So, what's the answer to this?

[Curless]

So, what's the answer to this?

The gas pedal has a stop as well. With that and the push cap we are good.

[GetMeMyStogie]

The gas pedal has a stop as well. With that and the push cap we are good.

So, there's no chance it might come apart? Even if, say, I'm pushing the brake pedal to the floor at a stop light, and hit the pedal adjust switch instead of the traction control button? Or while the gas pedal is to the floor and I hit the switch? In both cases, while the pedals are adjusted to their extreme one way or the other?

[Curless]

So, there's no chance it might come apart? Even if, say, I'm pushing the brake pedal to the floor at a stop light, and hit the pedal adjust switch instead of the traction control button? Or while the gas pedal is to the floor and I hit the switch? In both cases, while the pedals are adjusted to their extreme one way or the other?


No, if you are on the brakes or the gas the motor can't overcome that pressure. (this is actually how some of them get broken) If you push the button so that the pedals are all the way forward or back ward they come to a harsh stop. You could keep pushing the button, but it can't go beyond the first stop of the gas pedal...I did this to my own car, to make sure. As long as you adjust the pedals according to the instructions they will not come apart.

[GetMeMyStogie]

Okay, thanks for the info. I'm always suspect of things that might improve one situation while adding some new ones. Now to see if I can spare the coin for this gear...

[Curless]

Let me see if I can clarify this in written form...

The gas and brake pedal both have an adjustment screw, the gas pedal threads one way and the brake pedal threads the opposite way. When you move the pedals all the way forward, the gas pedal runs into the motor assembly and stops. It can't psychically move any farther ever without destroying the gas pedal assembly...which it does not possess the power to do. That being said, the brake pedal moves the opposite way, towards the push cap that I provide, it stops about 3 threads from the end due to the gas pedal bottoming out on its self. So it is impossible for the gear to come off the end of the shaft...

Lets say that the impossible did happen, if it did, the pedals would be adjusted all they way out (as far away from the driver as possible). The gear un threads off the end of the shaft, but due to the way its designed, the pedal is now in the fully lowered position, and it can't come back towards the driver...so its stuck forward and that is it. Either way, your brakes are always there, no matter what.

[ctrlraven]

My new gear was waiting for me when I got home last night. :)

[Curless]

My new gear was waiting for me when I got home last night. :)


:cheer: Glad they are all showing up!

[Hg M75]

Just finished installing my new gear. Works perfect. Thanks a million for taking on this project!

[Curless]

Just finished installing my new gear. Works perfect. Thanks a million for taking on this project!


Perfect! You are more than welcome!:beer:

[screamn]

Just got the gear in the mail on Monday.

Looks strong and built to last.

Now just gotta find the time to install.

Thanks Chris.

[lifespeed]

How long to install?

[ctrlraven]

Just finished installing my new gear. Works perfect. Thanks a million for taking on this project!
Want to do mine? haha

[Hg M75]

It took me about an hour I guess, I didn't have a lift so I had to do it on the ground.

Crtl, if you need a hand let me know.

[ctrlraven]

It took me about an hour I guess, I didn't have a lift so I had to do it on the ground.

Crtl, if you need a hand let me know.
An hour or so isn't too bad, I have some time off coming up later this month and next month, I'll give it a whirl then.

[lifespeed]

It took me about an hour I guess, I didn't have a lift so I had to do it on the ground.

Somehow I had envisioned this as a squirm-around-underneath-the-dash job. How would a lift have come into play?

[Curless]

Somehow I had envisioned this as a squirm-around-underneath-the-dash job. How would a lift have come into play?

Some prefer to lift the car up so you don't have to bend down to it...I actually took my seat out to do it...plus I got to clean under the seat real well then

[Hg M75]

Yea, laying on your back to look under the dash is fun for about the first few minutes.

[Rockettman]

Got my gear on Friday in the mail.
Top quality looking piece for sure!
- Going on the "winter project" list -
Thanks Chris for the work involved on this.

[Curless]

Anyone else put theirs in yet?

[Haggis]

Anyone else put theirs in yet?

I thought you were going to do it at the Louisville meet?

[Curless]

I thought you were going to do it at the Louisville meet?


We can set something up!

[Ladyhawke]

We can set something up!

Or you can come to maryland and do both cars. :P

[Curless]

Or you can come to maryland and do both cars. :P

Hmmm....You know I have never been to Maryland before...just sayin!

[Haggis]

Hmmm....You know I have never been to Maryland before...just sayin!

I could set you up in my garage, you can use the lift and do CAM members cars while you are here.

[Curless]

Hmmmm...out East trip...

[N40GL]

Add me to this list!!


I could set you up in my garage, you can use the lift and do CAM members cars while you are here.

[vegasmarauder]

By the way, I did a seperate post in Shop Talk in case the cruise control quits working after the pedals are repaired. Just in case anyone else runs into this..

[Curless]

By the way, I did a seperate post in Shop Talk in case the cruise control quits working after the pedals are repaired. Just in case anyone else runs into this..


Thanks for the info, I will add a step to check the switch out immediately.

[BAD MERC]

Hate to bump a thread from '12 but it's time to replace mine as well. 43K miles and the pedals are frozen and the motor only runs momentarily before they seem to bind. Is this new gear still available?

[lji372]

Hate to bump a thread from '12 but it's time to replace mine as well. 43K miles and the pedals are frozen and the motor only runs momentarily before they seem to bind. Is this new gear still available?

i'm certain they are. chris, hey chris, step away from the snowmobile!! there's no snow:D :D :D :D :D

[Curless]

Hey, I am currently out of em... but I can have more by the end of the week.... There is a guy on CV.net looking as well.... or are you one in the same?

[martyo]

Which post number has the how to install info?

[fastblackmerc]

Which post number has the how to install info?

Post #145 in this thread has a link to the instructions....

http://www.mercurymarauder.net/forums/showthread.php?t=82699

[BAD MERC]

Hey, I am currently out of em... but I can have more by the end of the week.... There is a guy on CV.net looking as well.... or are you one in the same?
Negative. It's time to tear mine apart and put her together perfect and flawless.

[Curless]

I'll get em coming guys!

[1Marauder]

When are you coming out to a WEST COAST MARAUDER PEDEL REPAIR TOUR!

I want to be your first two!
I am sure all the guys in the West will chip in... you can make a Marauder Vacation out of it!

[martyo]

Post #145 in this thread has a link to the instructions....

http://www.mercurymarauder.net/forums/showthread.php?t=82699

Thanks Jim!!!

[FordNut]

I asked a little while back but never got around to ordering. I'll be in for one too.

Then I'll have two to install.

[fordnut02]

need one myself

[1Marauder]

Curless,

We need a WEST COAST PEDDLE REPAIR TOUR!

I will help align it all... you can come visit and meet us all!

We will hook you UP!

Caiforni-vacation!

[fordnut02]

Mid west Meet Repair

[Limited360]

I've got one from the first Marauder I had... $100 shipped. It's basically Marauder gold right?

http://images.tapatalk-cdn.com/16/01/06/935af01408d8cd396c22a0596b1905 d3.jpg

I take PayPal.

Sent from my iPhone using Tapatalk so I may sound retarded.

[Logizyme]

In for at least one.

[Curless]

I have another round of em in stock, $85 to your door. mer@curlessautorepair.com is my paypal, DO NOT FORGET YOUR SHIPPING INFO AND WHAT CAR YOU OWN.

[1Marauder]

We need you to come install them! If not California, Arizona? Mike might let us use a lift. How 'bout VEGAS? If we can get four or six cars... Fly you and the Mrs out?

I am working hard here!!!!

[fastblackmerc]

I have a couple of gears and a spare set of pedals. Maybe we can start a swap program.

[Curless]

We need you to come install them! If not California, Arizona? Mike might let us use a lift. How 'bout VEGAS? If we can get four or six cars... Fly you and the Mrs out?

I am working hard here!!!!

LMAO! I have plans the weekend of Feb 26... other than that nothing set in stone. Louisville in April for all you guys on the East side I'll be there and can install them.

[Marauderman]

My DD '04 CV Sport has this problem--sure could use a fix! Problem is getting someone to do it with the right stuff.......

[fordnut02]

I have another round of em in stock, $85 to your door. mer@curlessautorepair.com is my paypal, DO NOT FORGET YOUR SHIPPING INFO AND WHAT CAR YOU OWN.


you have some ready to ship

[Master]

Does this have to do with the pedal not moving when you hit the button? Just starts to move then stops? Don't want to replace it if this isn't the problem it solves. Let me know?

[Curless]

you have some ready to ship


Yep sure do...

[Curless]

Does this have to do with the pedal not moving when you hit the button? Just starts to move then stops? Don't want to replace it if this isn't the problem it solves. Let me know?


Yes it is the only fix other than buying a new pedal assembly from Ford which they have discontinued. They still have some left at Ford, although they will fail the same way.

[Curless]

My DD '04 CV Sport has this problem--sure could use a fix! Problem is getting someone to do it with the right stuff.......

Umm, pretty simple fix... I do them in parking lots... did one on an expedition Monday here at the shop in the parking lot.

[fastblackmerc]

My DD '04 CV Sport has this problem--sure could use a fix! Problem is getting someone to do it with the right stuff.......

Coming to Cary any time soon?

[Marauderman]

Coming to Cary any time soon?

I just might have to make an early ,early Saturday run..................as expected...you got it figured out......super!!!!!!!!!!!!!

[Limited360]

I've got one from the first Marauder I had... $100 shipped. It's basically Marauder gold right?

http://images.tapatalk-cdn.com/16/01/06/935af01408d8cd396c22a0596b1905 d3.jpg

I take PayPal.

Sent from my iPhone using Tapatalk so I may sound retarded.

No one wants my Marauder Gold? :( Well back in the bottom of the toolbox it goes till I remember its there again...

[fastblackmerc]

I just might have to make an early ,early Saturday run..................as expected...you got it figured out......super!!!!!!!!!!!!!

Buy the gear before you come.

[Curless]

No one wants my Marauder Gold? :( Well back in the bottom of the toolbox it goes till I remember its there again...


$8.00 :dunno:

[Limited360]

$8.00 :dunno:


Good starting offer... Can I get $8.00 X 2 anyone?


Sent from my iPhone using Tapatalk so I may sound retarded.

[Curless]

Good starting offer... Can I get $8.00 X 2 anyone?


Sent from my iPhone using Tapatalk so I may sound retarded.

No you can't :beer:

[Shornaday]

Chris, could you tell me the size of the locking cap. Lost one from the last purchase. Would think I could get one at any FLAPS or Hardware Store

Anyone know if the gear is the same for a 2002 Ford 150 Crew Cab? Sure would be nice if it was.

[Marauderman]

Buy the gear before you come.

PM me the one to get for such a visit....

[Curless]

Chris, could you tell me the size of the locking cap. Lost one from the last purchase. Would think I could get one at any FLAPS or Hardware Store

Anyone know if the gear is the same for a 2002 Ford 150 Crew Cab? Sure would be nice if it was.


It's a 1/4 cap washer. NO, there is no fix for an F-150 that mechanism is a real treat to work on.

[Curless]

PM me the one to get for such a visit....

He means the gear that I sell...

[Marauderman]

He means the gear that I sell...

Ok Pm me what I need to do to you for it --It will do an '04 CV Sport =--right--.. Thanks

[FordNut]

LMAO! I have plans the weekend of Feb 26... other than that nothing set in stone. Louisville in April for all you guys on the East side I'll be there and can install them.

Incentive to make a trip to KY.

[fordnut02]

Incentive to make a trip to KY.

2nd that for Ky

[Curless]

Ok Pm me what I need to do to you for it --It will do an '04 CV Sport =--right--.. Thanks


Seriously? Post #201 :dunno:

[ab9sgken]

Is it still possible to get a gear sent to me or send it do a dealer for them to do the repair or would it be best if the dealer or myself send the entire pedal assembly out for repair and to where?

[ab9sgken]

What is the part number for the pedal assembly?

[lji372]

i have shopped a couple places by me to do the fix in order to help sell chris's gears. shops around me won't touch the job because their computer doesn't tell them how to fix the gear. they didn't care if i gave them instructions.

modern day part changers smh..............

[fastblackmerc]

Is it still possible to get a gear sent to me or send it do a dealer for them to do the repair or would it be best if the dealer or myself send the entire pedal assembly out for repair and to where?

Send the pedal assembly to me.... I have a few gears I can fix it with. PM me for a price.

[fordnut02]

Might do mine tomm, I will take in Jobs to do them once I get mine done

[Cobra432000]

I'm game for one!

[BigCars4Ever]

Pedal gear purchased 2012
Installed 2020
That may be some sort of record!:beer:

[justbob]

Pedal gear purchased 2012
Installed 2020
That may be some sort of record!:beer:

You sound just like me! So many parts around here still in box’s.. Some call it procrastination, I call it practicing patience.


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