Pedal-Box

The Pedal-Box provides support for the brake and clutch pedals. It can also provide reaction for the clutch over-centre spring. The Pedal-Box assembly is attached to the dash panel and the cowl. The combined system must provide sufficient stiffness to maintain braking capability during and after overload.


GTO was asked to verify and propose design changes that would be necessary to meet the internal requirements of a major Automotive OEM.

The acceptance criteria were:

Service Brake Pedal Proof Load - The vehicle service brake system shall be capable of withstanding 15 applications of the service brake pedal with a pedal force of 2.0kN without loss of system function.

Durability Test plus Performance at End of Test - The Pedal-Box is mounted onto a rigid plate and a single load cycle of 1.250kN is applied to the brake pedal. Permanent deformation of the Pedal-Box is permitted but shall NOT exceed 2.0 mm. The Pedal-Box is mounted onto a rigid plate and a single load cycle of 2.250kN is applied to the brake pedal. Permanent deformation of the Pedal-Box is permitted but shall NOT exceed 12.0 mm. This is commonly known as the AMS Test.

Pedal Travel Loss due to Dash and Cowl Deflection - The dash and cowl must provide sufficient stiffness so that the service brake pedal travel attributed to the dash and cowl deflection, shall have a maximum allowable deflection rate of 0.005mm/N and an allowable permanent set of 6.5 mm at 2.225kN load.

GTO successfully verified and developed the design of the Pedal Box that is now in production and used in a number of the OEM's vehicles.