Clutch Pedal Upgrade Kit

One thing of the Elise 111 has almost been driving me crazy... that creaking clutch pedal!! Here is how to get rid of it..

Well.. there's more then just the creaking actually! After a while, it's not moving very easy anymore and can even get stuck!.
I've seen several threads on BBS's and several people with the same complaint, so when I got back to the dealer to ask for a solution (under warranty) the only thing I heard was the well known "They All Do That Sir".
The only tip I received was to empty a can of WD40 on the trunnion from time to time..

They could have done better! As of august 1999, Lotus has issued a Service Bulletin mentioning the introduction of synthetic bushes for the clutch pedal trunnion.

After finding out about the Service bulletin I order the Bush kit: A111J0167F
The kit consists of two synthetic bushes and a clutch pedal trunnion. It'll cost you around 10-15 UKP without labour. (and a sore back if you fit them yourself!)

The left picture above shows the old black trunnion. The problem with this part is the wear which will occur after a while. If you feel the pedal to be coming up in very little shocks when you genlty release your foot, it's due for replacement...
The system is quite simple, the trunnion is in the pedal, which is holding a pushrod which operares the clutch cylinder.

To remove the old trunnion, you will have to start releasing the grub screw which is in the center of the trunnion (below left picture). You will now be able to freely move the pushrod in the trunnion.
Then release the two bolts (inside) that are holding the clutch cylinder in place. When released, you can put the cylinder aside to create some room to take out the pushrod (above right picture.)

The right picture above shows the empty clutchpedal and hole where the clutchcylinder used to reside...

Now what's the difference between the old kit and the new one? Will the same problem return? Probably not! Below pictures show the new (left) and the old (black) and new kit including the pushrod.
As you can see, the old trunnion is one solid piece of Zylan coated aluminium. The new one uses synthetic bushes to move which will not wear as the old material did.

The two synthetic bushes have to be pressed into the pedal bore. Easyier said then done!
Please notice that the bushes have two sides (the chamfer side needs to be pushed in the pedal!)

First trials by hands where pretty unsuccesfull. Too much force needed to push the bushes in the holes...
So, be creative and make some sort of pressfit construction as you can see in below pictures.
As soon as you start turning the bolts, you will press the bushes in place. Needs a bit practice, but they'll eventually pop in place!

The picture below at the left hand side displays the pedal with the installed bushes..

At the right hand side, the pushrod as well as the clutch cylinder has been refitted. The adjustment procedure to be followed is:

1) Put some Permabond or Locktite on the grub screw and refit it loosely.
2) Screw the pushrod into or out of the trunnion untill the pedal just contacts the pedal box flange (upstop).
3) Apply 1/2 turn or preload to the pushrod, and tighten the trunnion lock screw to 5 Nm.