I didn't mean to do a whole writeup on a stupid bushing, but I have so many great pictures of this that I did it anyway.
GM likes to use odd ball sizes. The bore on the brake pedal is
13/16, and the original shaft that it rides on is 47/64 with a very
thin
bushing in between. I was replacing the whole brake support assembly anyway, so I changed
to a more common 5/8 shaft and thicker bushing, both of which are off
the shelf McMaster parts.
After removing the original bushing, I cleaned up the pedal bore with a
brake hone. I am not trying to increase the bore size, just to remove
rust and crud from the bore.
The replacement bushing is just a little oversize and presses in nicely. I use WD40 in the bore as a lubricant while pressing, and I put the bushing in the freezer before hand to try to reduce it size slightly. What you dont see here is that the only bushing I could get with the correct diameters is only 3/4 inch long. The pedal bore depth is nearly 1.5", so pressed two bushings into the bore, one from each side.
After this, the bushing ID needed to be resized. It seemed to shrink slightly from pressing it in, and there is also the issue of two bushings in the bore, which I cant expect to be perfectly aligned. This might have been a good place to use the brake hone, but I did it a different way.
I had already bought a 5/8 reamer to build the brake support assembly, so I also used this to true up the inside of the bushing. I used a left over piece of 5/8 shaft to get the pedal bore aligned to the drill press. I sanded a few mil off the end of this shaft so that it fit in the under size bore.
Then very gently run the reamer through.
There is only about 1/16 of excess bushing sticking out, so I suppose you could just leave it there, but I have a mini-mill available at work so I trimmed this off with the mill. There is a custom jig (barely visible in this picture) which is holding the pedal in alignment. The vise is just keeping it from moving.
The jig is just a piece of scrap aluminum and a short piece of 5/8 rod fit into it. This holds the bushing square with the mill table.
Thats about it. Much ado about a bushing.