Lotus Elan

S4 Brake/Clutch cross shaft

PostPost by: redhatman » Tue Dec 11, 2012 8:37 pm

I need to replace the bushes on the brake-clutch cross shaft. I've removed the whole pedal assembly and found that the brake pedal and operating arm are both welded onto the main cross shaft. Presumably I need to grind of the weld on either the brake pedal or arm to get at the worn bushes and replace them. Any advice..
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PostPost by: patrics » Wed Dec 12, 2012 5:37 pm


I have done this.
I used a file to remove the weld from the brake operating arm, leaving as much original material as possible ? turned out to be easy enough. Before removing any material make sure you center pop each bit so that you can put it back together in the same place.
The bearings are readily available ? on mine some were missing which might have been an error or just to help with alignment.
Weld or bush the push rod holes etc.
When re-welding back together, use a removable shim or bit of paper to create a small amount of side ways play between each of the pedals .
Chop approximately 20 mm off the bottom of the accelerator pedal in case you fit a cage with side and foot well bars. That?s just an approximate guess as I did mine some time a go.
Mount / test the stop light switch in case any work is required on the bracket.

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