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Well my attempt at getting the assembly installed today was only partly successful. I did get it in a lined up with the studs, but the damn master cylinder and cruise control switch are fighting me at every attempt to get them in. I think Ford designed the pedal assembly around that switch and...

I did the welding. Not an A+ job, but reinforced enough. I did remove the bushings, and I was able to remove the lock rings without damage and reused them. I used a socket to tap them back on. I tried to find replacement bushings, but no luck online or with Ford or big box parts stores. I...

Well my back is still feeling the pain of getting the pedal assembly out. I got the clutch pedal re-welded and went ahead and did the brake pedal too. The factory welds were only about 40% around the shaft on both sides. Today I'm gonna try to reinstall everything.

I am in the middle of this repair and have used this thread and a couple of others for help. I finally got the assemble out, and rewelded both the clutch and brake pedals. I recommend removing the trim piece that holds the sunglass tray. It allows you to see a little better plus I reached...

I went ahead and filed a complaint on NHTSA. Maybe it will get to the point of a recall.

Well I installed a new safety neutral switch on the clutch and as I was testing to see if it fixed my clutch issue (it didn't) the check engine light went off. (no longer on) So as of now no code P2014. So, I guess I'll run it and see how it goes. But first I have to pull the clutch pedal...

Well dammit. I put the new switch in and it seemed better for a little bit, but the issue came back. Crawled under the dash this evening and was able to see a crack. Guess I'll be getting a workout and removing the assembly to re-weld. Pics of the old switch and crack attached. (Crack is...

I'm gonna keep an eye on this thread, as I have the code for Bank 1 after repairing the Bank 2 IMRC rod. Hopefully my issue is just a connector or easily repaired wiring issue. When it stops raining, I'm gonna pull the manifold again and check. I'll also get part numbers for the position...

Yes, it is a pain to get under there. Hopefully the welds are good and I don't have to go down that road. It is difficult enough just to get to the switch. I have seen a couple of videos on removing and installing the clutch pedal assembly and they don't look like much fun.

I'm still going to check for a cracked weld as mentioned earlier.

A quick update and question on my repairs. The new cam cover seemed to have stopped the oil leaks. Old oil is almost completely burned off the exhaust manifolds. (No more smoke, just a little smell) The random misfire and cylinder 8 misfire codes are gone, so I am assuming the repaired runner...

To update this, I think I have narrowed the issue down the the safety neutral switch keeps popping out of the bracket and interfering with the pedal movement. When I look pictures of replacements online, I notice that mine is missing a tab. I remember finding some plastic in the floor board...

From your picture the top looks fairly flat. Try using a center punch and then a left handed drill bit. I used one for the first time Monday on a broken stud and was impressed. Luckily the stud broke fairly square and even with the top to the head. If you can't get a center punch to it, use...

Good to know on the sensor.

This is from my other thread: Well some good news. I got the correct covers from Summit. The first set they pulled however were exactly like the set from Levittown. I told the sales guy that their website showed that they had 10 in stock and I was willing to go through every box in hopes of...

If it ends up being your valve/cam covers, just go ahead and replace them with the Ford Performance aluminum ones. They come with all new gaskets and the correct number of mounting bolts. I just finished this up on my son's 2005. By the time you pull the plastic ones, drill the missing holes...

Made some good progress today after work. Bolt came out easy peasy with a left handed 1/8 inch drill bit. I soaked it in 3 and 1 oil last night, then today hit it with a center punch and luckily after about 2 rotations it loosened up and I unscrewed it by hand. After that in installed the...

My grandson was with us Monday, Tuesday and Wednesday and Thursday I went to visit my mom, so no work until this afternoon. Got the cam covers on, new dipstick tube, COP's, most of the cooling hoses attached as well as the new reservoir. However my torque wrench failed to click when torquing...

Well some good news. I got the correct covers from Summit. The first set they pulled however were exactly like the set from Levittown. I told the sales guy that their website showed that they had 10 in stock and I was willing to go through every box in hopes of finding the correct ones. They...

Kudos to Levittown for responding to my emails on a Sunday. They said it is a manufacturing issue with no solution at present time. They also sent me return label so I can return these. I ordered from Summit in Arlington and will go pick them up tomorrow so I can put eyes on them before I...