Horns, Air Intake, Steering Rack, Pedal Box Removal

This post covers the cleaning of the horns, the fresh air intake, the RH radiator brace and the old steering rack. A comparison of the old and new steering racks is made. The pedal box assembly with the single dual chamber master cylinder is removed from the car. New aluminum polished pedal covers are installed on the pedals of the new dual master “Sebring-type” pedal box. The replacement of the brake hydraulic pipes is begun with the removal of the pipe from the master cylinder to the brake pipe union.

The Hella horns were cleaned and the wiring checked out:

Horn with Mounting Bracket

Horn with wiring

Cleaned Horns

Fresh Air Intake Cleaned:

Fresh Air Intake

RH Radiator Brace

The original twin chamber master cylinder and pedal box were removed:

Twin Chamber 3/4″ Master Cylinder

Original Pedal Box and Push Rods

To be replaced with a “Sebring-Type” pedal box with separate 3/4″ master cylinders. New aluminum drilled and polished pedal covers were installed on the brake and clutch pedals:

Sebring-Type Pedal Box with Separate Master Cylinders

Aluminum Pedal Covers


This Video Episode Thirty shows the content described above:


The following steps are addressed in the video:

1:30 – Cleaning the horns, fresh air intake, RH radiator brace, and old steering rack. 

3:40 – Brake/Clutch master cylinder (Sebring-Type)

5:13 – Pedal Box removal

5:35 – Installation of new aluminum pedal brake and clutch pedal covers

6:08 – Removal of brake pipe from master cylinder to brake union

Chapter 13 – Cleaning and Trial Fitting

March 22, 2003

Rear Seats 

The rear seat pans were very rusty and pitted to some degree, but given that they are completely covered by upholstery we decided to reuse them. The bottom exposed side of the seats was painted with a rubberized undercoating paint. 

Rear Seats 1

Rear Seats 3

May 16, 2003

Canadian Delivery! 

Martin Jansen delivered the healey from his shop in Canada on the back of his pickup truck! Big day!

May 16 Arrival Day from Martin 1

Rough Body 2

Rough Body

Rough Body 3

The frame and superstructure looked great. The fit of the wings will have to be improved upon. Door fit is pretty good, but will also need additional work. New edges were put on the rear shroud and rough repairs to the front shroud lower panel were made as well as around the rear shroud taillight area. Seeing the interior panels without rust is hard to believe, but they sure look good now! One disappointment is that mounting holes for a number of things are not located on new panels installed by Martin. Seat rails, exhaust mountings, insulation panels and etc will need to be aligned and drilled.

Firewall 3

Firewall 2

Boot 1

July 15, 2003

Maple Hill Restorations 

After consulting with Jeremy Turner from Maple Hill Restorations we have decided to completely assemble the car while in primer to be ensured that EVERYTHING fits properly. This will prolong the project, and will probably lead to some short term frustration, but should also minimize problems with assembly once body work and painting is complete.

My first step is to determine proper fastener sizes and replace all original hardware with stainless steel, with the exception of higher load locations such as shock absorber and other suspension bolts. Those will be replaced with new grade 8 zinc plated hardware. Then we installed all of the rubber grommets in the firewall, footwell and other locations.

The Scientist at Work

Chased Threads and rubber grommets

Installed pedal box

Steering Bracket and Brace

Boot Grommets – The grommet for the battery cable and other bulkhead grommets were installed in the boot. The anti-theft battery switch and bracket were also installed.

Boot grommets

Battery box and switch

Bump Box

Boot Tire Buffer

Insulation Panels – Some of the mounting holes for the heat insulation panels on the firewall and footwell were also not drilled. We located the proper locations, drilled the holes and mounted the panels without difficulty.

Insulation 1

The Oil Pressure Line – The line was located and installed although new clips will be ordered.

Oil Line

The Dip Switch and Parcel Tray – These components were also located and installed. Note the original water bottle.

Parcel Tray & Bottle

Installed dimmer switch

Radiator Brackets – The brackets were cleaned and painted and were installed on the crossmember, and the painted air intake flange.

Radiator Mount 2


July 23, 2003

Hardware Reassembly

Door Staps – The original door straps (catches) were cleaned, re-zinced and installed on the door pillars.

Door Strap 1

Door Strap 2

Bonnet Hinges – The bonnet hinges were cleaned, primed and new stainless hardware was installed, and then mounted to the car.

Bonnet Hinge 1

Bonnet Hinge 2

March 22, 2003

More Cleaning 

Bonnet Latch Hardware – Disassembled and cleaned the bonnet latch assembly and the bonnet opening rod assembly for Jeremy Turner to media blast and paint.

Bonnet Rod Spring

Bonnet Rod Bracket grommet

Bonnet Latch A

Bonnet Latch B

Bonnet Latch C

Also cleaned the bonnet rod clip, the catch bracket, two safety latches, the brake reservoir bracket and two shroud brackets.





Chapter 11 – Disassembly

The Battery Cable –  from engine to boot. Eight to nine clips attached with screws to frame.

October 20, 2002

Shipping to Jule Enterprises

Martin Jansen – from Jule Enterprises located just outside of Toronto picked up the car for the trip back to Canada for frame replacement and restoration. John, Scott and I had visited his shop in Canada earlier in the summer to “check it out.” We were pleased with what we found and I arranged for Martin to pick up 4422  for restoration work.

Martin Jansen Picking Up the Healey 10-20-2002

Martin Jansen Picking up the Healey 10-20-2002 2

Martin Jansen Picking up the Healey 10-20-2002 3

Martin returned to Canada with the primed doors and four new aluminum wings to be fitted before bringing the BT7 back to Harrisonburg. In addition to fitting the old tub to the new Jule frame, he will media blast the body, epoxy primer the car, add new aluminum flanges to the rear shroud, and do rough repairs to shroud damage on the front and left rear. We anticipate a return date around the first of February. Lots of parts to clean between now and then.

November 9, 2002

Bonnet Hinges – After a very busy work month, this weekend provided some time to return to parts clean-up and restoration. Cleaned a primed both bonnet hinges and added stainless hardware.

Cleaned and primed Bonnet Hinges

Door Check Strap Assembly – Both door strap catches were cleaned. The Moment-Anderson Restoration Book states that these straps have a zinc plated finish rather than paint. The straps will need to be refinished at a later date and new washers added.

Cleaned Door Catches

November 17, 2002

Rear Axle

Rear axle disassembly –  Removed five lug nuts and the rear splined hub. Then loosen two Phillips head screws securing the rear brake drum and remove the drum.

Brake Drum Hub Nuts

Rear Axle Half Shaft

Removed the brake shoe retaining springs and slipped off the lower shoe. Disconnected the handbrake tension spring to release pressure and slipped off the upper shoe.

Removed the shoe adjuster by loosening two 9/16” nuts and knocked out. Note shape of pistons. Remove axle by loosening one 3/8” flat head phillips screw. Note paper gasket. Pull out axle half shaft. The left and right shafts are marked with an engraved “R” or “L,” because they need to be replaced to the original locations.

Rear Hubs – Removed the octagonal nut retaining the hub. One of the nuts loosens clockwise and one counterclockwise. Remove the O Ring, flat washer and retaining band. Remove the back plate by loosening 4 nuts and bolts. The bolt heads face the outside of the car. I ordered a special socket from BCS for this purpose.

left rear hub – nut removed

Shock Absorbers – Removed the rear shock absorbers by loosening 11/16” nut and kncked pin through the bushing and out of the bracket holding the shock.

Rear Differential – Removed rear differential from axle by loosening 12 nuts and lock washers. Top center bolt also retains the brake line clamp.

November 29, 2002

Rear Hubs

Left Rear Hub – Used a slide hammer to loosen and remove the hub from the axle.

Hub removal-too Slide Hammer

After the hub is removed the bearings can be knocked out with an appropriate tool.  The “made in England lettering is to the outside of the wheel. The paper gasket, and rubber “O” ring are removed as well. The hub also includes a rubber seal on the inside of the hub. I could not remove it, will have to learn the secret!  Later learned the secret is a screwdriver. The left hub nut loosens “clockwise” and the right “counterclockwise.”

Rear bearings

Brake Cylinders – Pulled off the retaining circlip from the rubber boot on the wheel cylinder. Remove the rubber boot cover and the rubber gasket from around the cylinder assembly. Pry apart the sliding plates that lock against one another. The lockplate with the tabs “up” goes against the backplate and the one with the open slots on the top. After removing the lower plate slide out the handbrake lever. Then take off the inside lockplate and remove the cylinder.

brake cylinder retainer clips

Brake cylinder retainer clips 2

handbrake lever

Shoe Adjuster – by loosening two nuts, note the position of the adjuster piston. Remove backplate by loosening the four retaining nuts and bolts. Finally, clean up the rear axle.

rear axle clean up

The handbrake lever assembly –  was removed, disassembled and cleaned. Note the replacement of the cloth/rubber “O” ring under the large nut, and felt washers at the connecting pins. The bracket itself can be removed by loosening two 5/16” – 24 x 3/4” bolts and nuts. The mounting clip for the return spring is located 2 1/4” from the post.

handbrake bracket 1

Handbrake Bracket 2

Handbrake spring location

Handbrake Bracket 4

January 25, 2003

This report is the first of my second year of working on the restoration of 4422! Lots of work remains in the disassembly and clean up stage before reassembly can begin. But progress has been made!

Rear Seat Back  

Unfortunately, I had installed speakers in the panel when in college. So I will need to buy a new squab or at least the plywood flat pieces before recovering.

Rear Seat Back Panel 1

Rear Seat Back Panel Clips

Rear Seat Back Panel 2

Clutch and Brake Pedal Bracket (Pedal box) -The box and parts were in very good shape. It was now time to disassemble and clean.

Pedal Box Assembly

Pedal Box Assembly 2

Striker pin assembly – The bonnet catch was a bit rusty, but restorable.

Bonnet Catch Striker Assembly 1

Bonnet Catch Striker Assembly 3

Bonnet Catch Striker Assembly 2

The Bonnet Latch Support Bracket – the mechanism was rusty also, but again, clean up made the parts usable.

Bonnet Latch 3

Bonnet Latch 4

Bonnet Latch Lever

Bonnet Latch Spring & Rubber Tube

The Throttle Linkage – is also reusable after cleaning, but we will probably replace with new hardware or a contemporary cable system.

Throttle Linkage 5

Throttle Linkage 3A

The accelerator pedal – the pedal and bushing and springs looked great. A little clean up and paint and it will be like new.

Throttle Linkage 2

Accelerator Pedal

Chapter 10 – Disassembly

August 17, 2002

Brake and Clutch Master Cylinders –  Loosened lines from cylinders. The brake line from the master cylinder to the 4 way junction has 3 clips and fasteners to the union facing the master cylinder (left side of the car). The clutch line also has three clips: 1 by the solenoid, and 2 on the firewall (high). 

Loosen the 1/2” bolts securing the clutch master cylinder. Pull the cotter pin on the master cylinder shaft to the pedal. Remove the master cylinder. Same procedure for the brake master cylinder. There are aluminum spacers on the top of each master cylinder between the cylinder and the body.

Master Cylinders

Brake Pipe Junction 1

Pedal Box Connections

Pedal Box Bolts

Pedal Box (Pedal Lever Bracket) 

Loosen two 1/2” bolts to remove pedal box mechanism. The box is painted black. Unit will then drop out.

Pedal Box 1

Pedal Box 2

Headlamp Dip Switch Wiring – Pulled the wiring through the pedal box with rubber grommet.

Dipper switch wiring

Dip Switch Wiring

Bulkhead Fresh Air Flange – Removed three phillips head screws securing the fresh air hose flange. Removed flange.

Air Tube Mounting

Brake Lines

The Brake Lines – fittings were loosened at the 4 way brake union to left front wheel – 2 clips at front cross bar to the front bottom union facing front of car at the junction.  Removed right front brake line from junction to right wheel – top union on junction facing front of the car.

LF Brake Lines

Front Center Brake Lines

Brake Junction

Brake Junction connections

Brake Junction Fitting

Brake Junction 3

Brake 4 Way Union & Pressure Switch – Removed the Union by loosening one 7/16” bolt to frame. Two wires must be disconnected. Green goes to terminal closest to the engine. The green with pink stripe wire goes to the terminal closest to the frame. One clip holds wiring harness extension to the brake junction located just above the junction mounting post.

Brake Pressure Switch Wiring

Master Cylinder Sealing Plate (blanking) –  Removed the Plate on the right side of the car. Four Phillips head sheet metal screws. The plate had tar paper on back to seal it. Four clip nuts are used to hold the screws.

Right Sealing Plate

Right Sealing Plate 3

Right Sealing Plate 2

Starter Solenoid. 

Disconnected the wiring for the starter solenoid. The terminal closest to the engine is for the high tension line from the battery. The terminal closest to the body is or the cable to the starter and the brown ignition wire. The white wire with the red stripe goes to the terminal on top.

Starter Solenoid Wiring

Starter Solenoid 2

Starter Solenoid connections 2 & Clutch Pipe Clip

Blanking Bolts – Removed 2 blanking bolts in upper right footwell. Remove two blanking bolts in engine compartment to frame.

Right blanking bolts

Right footwell Blanking Bolts

Steering Wheel Blanking Plate – Removed the blanking plate on right side of car. Located behind the asbestos insulation. Four sheet metal screws.

Slave Cylinder

Loosened one nut where hydraulic hose joins frame.

Slave Cylinder connection to Frame Clip

Slave Cylinder Mounting with Clip and shake proof washer

Fuel Line – Loosened the fuel line from the carb feed line and the fuel pump. Three to four clips run along the frame rail from carbs to fuel pump.

Wiring Harness – Carefully pulled the wiring harness from front firewall to the rear of the car. Approximately 10 screws through clips on frame. Also two screws and clips through asbestos insulation securing the harness.

Right wiring clamp

Voltage Box wiring

Wiring Clamps on Insulation 3

Firewall wiring clamp

Overdrive switch – Wiring connections: Left terminal – white/purple stripe. Middle terminal – 2 white/green stripe wires. Right terminal – 2 solid white wires. Bottom terminal – black wire from harness.

Firewall wiring harness

Overdrive relay

Relay wiring

Throttle Switch – Bottom terminal – white/ purple stripe wire. Top terminal – White/green stripe wire. See above.

Fuse Block – After disconnecting the wiring to the block, two #10 machine screws were loosened to release the block from the firewall. 

Fuse Block wiring

Fuse Block and relay

Voltage Regulator – Five terminals. Far left form driver’s perspective, labeled #1 with far left #5. 1 – black ground from adjacent screw. 2 – 2 solid yellow wires. 3 – 1 yellow/green stripe wire. 4 – 2 solid brown wires. 5 – 1 large brown/blue stripe wire. Note that there are three black ground wires to the adjacent firewall screw.

Voltage Box wiring

Voltage Box

Voltage Box (2)

Number Identification Plates – from the firewall. Both are secured with small chrome sheet metal screws.

ID Plates 3

ID Plate 1

ID Plate 2

Throttle Linkage – Four 7/16” bolts holding shaft under tunnel. Very hard to get to. Disconnect at pedal linkage. Remove accelerator pedal – two large pozi-drive screws. Remove throttle shaft locator collar from engine compartment wall, two screws and nuts.

Throttle Linkage 1

Throttle Linkage 2

Throttle Linkage 3

Throttle Linkage 6

Throttle Linkage 5

Throttle Linkage 4

Throttle Linkage 7

Accelerator collar

Accelerator pedal to firewall