Complete Pedal Repair Instructions

[Curless Auto]

1. Remove the three T-20 torx bolts from the black housing on your brake pedal

2. If you look to the left side of the black housing that we just took the bolts out of you will see two little tabs that stick through the main body of the pedal assembly. Using a small screwdriver, slip these two locking tabs out. This will release the outter black housing of the gears.

3. Now take an angle grinder / file / roloc disc and grind off the stamped end of the shaft. BE CAREFUL to only take the stamped part off, DO NOT GRIND IT WAY DOWN.

4. Twist the washer loose and remove the wave washer, plastic washer, and inner washer. DO NOT LOOSE THEM.

5. Lift up on the brake pedal, while holding up on it remove the old gear. You may have to give it a good twist.

6. Put a little grease (I use a product called sli-glyde #765-1351 from NAPA, any grease will do the job) on the shaft that the gear rides on. Instal your new gear so the that the threads just start to come out of the side facing you.

7. Re-instal the inner steel washer, the wave washer, and then the plastic washer.

8. Now take the cap provided with your gear, and using a small (8-10mm) wrench rock it up and onto the end of the shaft. You should hear it snap in place.

9. Put some grease around the outside of the gear and on its center face.

10. Push the pedal button and LOWER the gas pedal all of the way to the floor.

11. No re - instal your cover and bolts. YOU ARE DONE!

 

[Curless Auto]

Could not put the last pic with the others...

 

[Curless Auto]

Total time to do this job was about 15 - 20 minutes, I can't believe how easy it is! You DO NOT have to remove the pedal from the truck!

 

[JUST4FUN]

Your post have been moved to a a closed fourm that only admin and mods can see.
Your links are deleted until you get your vendor status complete.
user Shaggy can help you with the vendor update, please contact him in a PM

 

[Curless Auto]

Your post have been moved to a a closed fourm that only admin and mods can see.
Your links are deleted until you get your vendor status complete.
user Shaggy can help you with the vendor update, please contact him in a PM

I get it, just so you and everyone else knows I tried to find a moderator when I first joined and if you read my posts I said that I wanted someone to contact me so this did not happen...

 

[JUST4FUN]

I get it, just so you and everyone else knows I tried to find a moderator when I first joined and if you read my posts I said that I wanted someone to contact me so this did not happen...

This is going to admin Birdman to get vendor status , Its all good

 

[Curless Auto]

Just a bump for those thinking about tackling this project, its easy!

 

[ExpeditionAndy]

Just a bump for those thinking about tackling this project, its easy!

I got my gear last night when I came home from teaching at Harrison College. I'll probably tackle this tonight but it doesn't look like it's going to be too hard.

This gear is a well made solid piece of workmanship that should outlast me.

Update attached is a couple of pictures of the broken gear. This is why you pedals only move 1/2 inch.

 

[ExpeditionAndy]

Okay I made the repair tonight. It was a tight squeeze for an old fat guy like me. I'm on Advil therapy right now in anticipation of the aching back and leg muscles tomorrow.

It repair took me just shy of 2 hours, that included time spent looking for my Dremel cutoff wheel. I'm attaching pictures, it was relatively easy to do the top torx screw was difficult to reach but I did get it.

If you want your pedals to work this is a great way to fix them and Chris's (Curless Auto) gear will never break again.

Thanks Chris!

 

[Curless Auto]

Thanks for the nice write up Andy! I am glad you are happy with it!

 

[ExpeditionAndy]

Definitely happy with it. It works like its new again.

I didn't realize that the brake pedal mechanism worked off a drive cable from motor which is attached to the gas pedal. You are right it really is a very simple operation if you are thin and flexible enough to maneuver in the footwell.

Now you need to see if you can make gears for the blend door actuator and the other A/C system dampers.

 

[Curless Auto]

Just a bump for those who have not seen how to do the repair.

 

[KevinT]

I found this forum and thread while searching for info on jammed adjustable pedals and ordered the gear from Chris a week back.

Performed the gear replacement yesterday. Took me just under one hour because I was using a very light grinding disk on my dremel tool to remove the machined end of the post -- while trying not to damage the outside metal washer. After I reviewed the instructions a second and third time, I realized the external washer does not get reused, so I changed to a more aggressive grinding disk and had the external washer released in about 4 minutes.

Its great to have the adjustable pedals again!

Chris - Thank you for taking the time and making the investment to manufacture the gear and document the process.

 

[ExpeditionAndy]

I like mine. The funny thing is after adjusting it a few times I haven't moved it in months. I guess I just like the idea that I can.

 

[7405]

Need gear

I have a 2006 Expedition that is showing the same problems with the brake/gas pedals -- stuck in up position and only move slightly. How do I get the part(gear). Are written instructions supplied? Thanks

 

[ExpeditionAndy]

You can send Curless Auto a message and he will send the part. The directions are right on the first post on this thread. It is very easy to do.

 

[Wegner44]

Just finished my install.... Great instruction, super easy, soooo glad I did this!

Thanks Curless Auto!!!!

 

[Curless Auto]

Glad you are happy! Thank you for your order!

 

[ric75luz]

Do you have more gears available?

 

[Expedition007]

Wondering the same thing... is it the same gear for both the gas pedal and the brake pedal? I found the gas pedal gear is split and the worm gear was trying to ride up the teeth on the driven gear. I don’t know how long it’s going to work, but I filed the teeth on the both sides of the break and now the pedals are working just fine.