Willys Jeep: Porkchop’s Clutch Arm Problem

Problem area

Problem area

This is a quick and dirty post to describe a particular problem that I’m having.

Part of what I have to do when replacing the master cylinder (that is, converting it to a dual master cylinder (MC) from the original single reservoir, making it safer) on the M38A1 (affectionately named Porkchop) is disassemble the pedal assembly bracket and modify it a bit so that the new MC can fit onto the frame.

I’ll likely revise this post in the future to describe what that process has been like, but I need to ask a question right now and see if anyone knows the answer to it.

I managed to work through the process of drilling through the pedal shaft assembly (as circled in red above), and – if I say so myself, cleaned it up so that it looked pretty nice.

Mostly installed

Mostly installed

 

However, when I attempted to replace the clutch pedal arm back onto the assembly, catastrophe stuck. In the image above, you’ll see a ‘notch’ located at about the “12 o’clock” position on the shaft. That fits into a notch on the clutch pedal arm, best seen here:

Right in the palm of my hand

Right in the palm of my hand

Even with considerable lubricant, I was having difficulty attaching the clutch pedal arm to the assembly, when I heard a very disturbing popping noise. Sure enough, the notch on the assembly – which I had thought was all one piece – came off.

Notch no more

Notch no more

Fortunately, I still have the piece of metal, but as you can see it’s not “broken” or jagged in any way. In fact, it almost looks like it was designed this way:

Half-moon horror?

Half-moon horror?

My question is simple: Have I screwed up the pedal assembly? This one is theĀ second one that I’ve gotten (because of another problem I had to go out and buy one) and I’d rather not if I don’t have to.

Any ideas?