Demon 408
Well-Known Member
I'm new to this forum, but instead of using the "newbie welcome" section, I wanted to post here to show my appreciation to the forum for their help with removing the over-center spring from my clutch. I used the "washers in the spring" method and it worked great.
Luckily, I'm still assembling my Demon so removing the pedal assembly from the car was easy. I do not have the master cylinder or the steering column in the car yet, so it was just a matter of removing four bolts and dropping out the pedal assembly.
Once I had the pedals on the bench, I measured the gaps in the spring with the clutch pedal released and depressed. I found that the gaps were larger with the clutch released (pedal is up when in the car). With a small hammer, I tapped 11 washers into the spring with the clutch pedal in the "up" or released position (see picture). The washers are 3/32 thick and 1.25" in diameter. Also, notice that the washers are inserted in the spring on the side facing the spring's hook open ends. This has the effect of opening the spring hooks when the clutch is depressed.
Once I had all 11 washers in the spring, I slid an old alternator bolt through the washers to hold them in place (probably not necessary or possible with assembly in the car). I then depressed the clutch pedal (down to floor). The spring is now loose, but still needed to be a pried a little before it would come off the pedal. I pried the spring from the assembly end that has the "hooked" piece connecting it to the assembly (small hook on spring, to the right of attached picture). Very little effort was required to pry the spring off at this point so I used a screwdriver.
While I had the pedal assembly on the bench, I installed a "light" pedal return spring to ensure the pedal would return without relying on the clutch. I drilled a small (1/8") hole in the clutch pedal arm just above the pivot point and another hole in front (dash end) of the assembly. I used a spring I bought at Ace hardware, nothing fancy, but it works.
Thanks for the idea, hope this post helps others.
Luckily, I'm still assembling my Demon so removing the pedal assembly from the car was easy. I do not have the master cylinder or the steering column in the car yet, so it was just a matter of removing four bolts and dropping out the pedal assembly.
Once I had the pedals on the bench, I measured the gaps in the spring with the clutch pedal released and depressed. I found that the gaps were larger with the clutch released (pedal is up when in the car). With a small hammer, I tapped 11 washers into the spring with the clutch pedal in the "up" or released position (see picture). The washers are 3/32 thick and 1.25" in diameter. Also, notice that the washers are inserted in the spring on the side facing the spring's hook open ends. This has the effect of opening the spring hooks when the clutch is depressed.
Once I had all 11 washers in the spring, I slid an old alternator bolt through the washers to hold them in place (probably not necessary or possible with assembly in the car). I then depressed the clutch pedal (down to floor). The spring is now loose, but still needed to be a pried a little before it would come off the pedal. I pried the spring from the assembly end that has the "hooked" piece connecting it to the assembly (small hook on spring, to the right of attached picture). Very little effort was required to pry the spring off at this point so I used a screwdriver.
While I had the pedal assembly on the bench, I installed a "light" pedal return spring to ensure the pedal would return without relying on the clutch. I drilled a small (1/8") hole in the clutch pedal arm just above the pivot point and another hole in front (dash end) of the assembly. I used a spring I bought at Ace hardware, nothing fancy, but it works.
Thanks for the idea, hope this post helps others.
