brakes Pedal cluster rebuild

[vacca rabite]

The foam/insulation on the back of the pedal cluster pod is coming off. Can it be replaced or should I just scrape it off?

 

the pod need to be blasted and painted. 

 

Zach

['76mintgrün'02]

you will need to scrape it off to shine up the box.

replacement foam pieces are available.

I bought one, but have not installed it.

I also bought a new clutch master, which is leaking.

Which makes me glad I have not installed the foam.

[NYNick]

Took this off today. It is appropriately named a cluster.

[PaulTWinterton]

I have a strong opinion about the external foam cover for the pedal box.  I believe it was added for 2 reasons, 1) heat/cold insulation, and 2)  sound deadening.  The originals were very porous and soaked up fluid, oil, moisture and dirt.  Horrible mess and great for promoting rust on the box.   I think the new ones are better quality and have a thicker skin on the outside.   Definitely put a new one on.

 

As said, thoroughly remove the old foam and glue.  Media blasting is the best.  Once you've rebuilt your pedal box, prime and paint.  Let the paint cure for awhile.

 

Something I learned and will save you some grief.  Apply the new foam cover BEFORE putting the pedal box back in the car.  It is much easier to glue the cover on the box when it's not in the car.  The frame rail is in the way otherwise.   I used 3M Marine glue liberally spread over the outside surface of the pedal box and applied the cover.  Let stand until the glue sets.

 

I really enjoyed tidying up my pedals.  Very satisfying job.

 

Edited June 10, 2016 by PaulTWinterton

[vacca rabite]

Where should I go to find the replacement foam? It there a newer option that works better then the factory foam but does not trap water?  

 

zach

[PaulTWinterton]

The best option is still OEM from the dealer.  Not cheap, not too expensive.  No shipping costs, but you might have to wait a couple of weeks for delivery to the dealership from Germany. 

 

It's GOOD quality and worth it!  Don't worry, it won't trap water.  It's mostly hydraulic fluid that is your enemy.  Inspect your hydraulic system occasionally to make sure that it is not leaking fluid onto your cover.

 

http://www.realoem.com/bmw/enUS/showparts?id=2583-USA---114-BMW-2002tii&diagId=35_0195

 

Insulating cover pt# 35111102142 $43.00

[Dabliz02]

I just left mine off since I don't drive it in the rain and there is too much engine noise to notice.  I also like to see the floor pass right under me when I'm at the track.  Also weight reduction.  Every ounce counts!!! 

 

 

['76mintgrün'02]

I have a similar appreciation for the inside foamy insulation piece... but not so much the outer one.

My pedal box was pretty badly eaten up by rust and I feel like that wrap made matters much worse, over the years.

It is not so much a question of whether it keeps moisture out, but whether it lets moisture out.

Granted, my opinion is based on what forty years of 'weather' has done.

On a newly refurbished car, with a windshield that does not leak and elephant trunks kept clean, water should not get in there.

In theory, a new clutch master would not leak... but I was not so lucky.

 

I just put a piece of aluminum foil duct tape over the hole.  A surprising amount of dirt and crud goes in if you don't cover it.  I have not sold my new outer cover, so I guess I am still tempted to put it on, but not yet.