> Someone posted some pretty detailed instructions on this
> operation recently. It involved using a bolt and socket to
> evenly draw the bushing into the hole. As I recall, you
This may have been me describing the various methods I tried. Here is a copy
of my posting:
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Well, I just finished the job (except for losing the throttle return spring
as it flew under the car somewhere). I would not have predicted this to be
such an ordeal.
Thanks to all for your advice. I used a bit of everyone's.
Here are my lessons learned:
1. As many suggested, I fit a 3/8" bolt through the bushings, put in my
electric drill and ran it against a file to take off about 1/8" from the
diameter of the button shaped flange on the bushing. The material did not
come off cleanly, it kind of softened up an shredded. I trimmed it with a
utility knife.
2. On the passenger (right) side, I used the utility knife to cut 4 V-shaped
slots in the flange to allow it to collapse as it passed through the
bulkhead. On the driver side I attempted to do the same, cut off too much
material and ended up with a flat side on the flange. I later cut a flat
opposite the first. I have seen bushings made both ways intentionally.
Neither seemed easier than the other to fit.
3. I boiled the bushings to soften them. I'm not sure if this helped because
by the time I got the bushings part way into place, they were already cool.
4. I pushed the bushings through from the inside of the car. It seemed
easier to work from there.
5. I attempted to press the bushings through with a bolt through the
bushing, bulkhead, and a large socket. Helped a bit on one side. Just
squashed the bushing on the other.
6. The basic technique for putting the bushing in place was to fit it part
way through the bulkhead and push on the slot between the two flanges with a
large flat screwdriver. After quite a bit of pushing and twisting it was
mostly in place. Then, I put the screwdriver into the bushing hole and
turned to get it well seated.
7. Replacing the shaft was tricky. Pull back the carpet at the lower left
hand side of the floor just in front of the clutch pedal. The shaft must be
angled up into the bushing from BEHIND the other two pedals. If you try it
from in front of them, it will run into the cylinder head. There should be
just enough clearance to get the tip of the shaft into the bushing. Then use
a screwdriver against the angled part of the shaft next to the pedal to pry
it up through the hole.
8. One thing I noticed when re-fitting the control lever onto the shaft: As
pictured in the Bently book, the retaining bolt on the lever shows washers
under the bolt head rather than the nut. Without thinking much about this, I
re-assembled them this way. This gave a very small clearance between the
bulkhead and the bolt head. In fact it was binding at one point -- a bad
situation for the throttle. More sensibly putting the washers under the nut
got rid of this problem.
I hope this helps anyone else that attempts this job in the future.
Regards,
Hugh Fader
72 TR6
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