MMC2023-001 – Brake Pedal Box Housing Improperly Welded – 2023 MMC Super 3 Motorcycles

SEOCONTENT-START

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-020
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Morgan Motor Company Limited JAN 17, 2024 NHTSA Recall No. : 24V-020 Manufacturer Recall No. : MMC2023-001 Manufacturer Information :
Manufacturer Name : Morgan Motor Company Limited Address : Pickersleigh Road
Malvern 00 WR142LS
Company phone : 7496562632
Population :
Number of potentially involved : 62 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2023-2023 test test Vehicle Type :
Body Style :
Power Train : NR Descriptive Information : test
Production Dates : FEB 28, 2023 – NOV 17, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2023-2023 Morgan Super 3 Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS
Descriptive Information : The potentially defective pedal box housing is only fitted to vehicles with a specific brake system. These are fitted on all US derivative Super 3 vehicles. This brake system will soon supersede the brake system fitted to all UK and European derivative vehicles and will be the only type.
Only 62 (sixty two) US derivative vehicles have been shipped to the US. Any subsequently shipped vehicles will not have these defective parts fitted. Production Dates : FEB 28, 2023 – NOV 17, 2023
VIN Range 1 : Begin : SA9M3TAA0PP202001 End : SA9M3TAA8PP202070 Not sequential Description of Defect :
Description of the Defect : The mounting plate where the master cylinder is mounted has become disconnected due to weld failure. This resulted in the master cylinder being able to move as the pedal is depressed as part of normal braking operation and
break the hydraulic seal where the hose fits the master cylinder. Part 573 Safety Recall Report 24V-020 Page 2 FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : The third party supplier who manufactures the pedal box housing for Morgan Motor Company has not manufactured the parts in line with the engineering drawing specification, meaning some welds may not perform as intended.
Description of the Cause : The third party supplier who manufactures the pedal box housing for Morgan Motor Company has not manufactured the parts in line with the engineering drawing specification, meaning some welds may not perform as intended. Identification of Any Warning
that can Occur : The brakes are likely to bind (stick on) which will be obvious to the driver, and the brake foot pedal will not return to its normal resting position, providing further warning to the driver that something is wrong.
The assembly is tested to 100 BAR post assembly and before being fitted to the vehicle by MMC. Although this test is for ensuring a sound hydraulic seal is made the test is a partial mitigation for identifying failures as this force is far greater than what is required to lock the wheels of the vehicle during aggressive braking. Involved Components : Component Name 1 : Welded Pedal Box Housing
Component Description : Main housing made from sheet steel which is folded and welded. Component Part Number : A221152 Supplier Identification : Component Manufacturer
Name : ADV Brightware Manufacturing Limited Address : 56 Bayton Road
Exhall Coventry Foreign States CV7 9EL
Country : United Kingdom Chronology :
12/13/23 US Dealer informed MMC of an issue with the pedal box. MMC contained stock in production stores and notified supplier (ADV Brightware). MMC conducted testing on a small sample of parts and showed some parts were below the engineering specification, but the weld performance well exceeded the likely force required to lock the wheels. On 12/14/23 ADV Brightware recovered all remaining parts held by MMC to check The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-020
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
the level of compliance of their parts to the engineering specification. On 12/21/23 ADV Brightware concluded their investigations and agreed their parts did not meet the engineering specification.
Based on these findings and out of the abundance of caution MMC has decided to recall 62 vehicles in the US to have the potentially defective pedal box housing part replaced with quality assured parts.
Description of Remedy :
Description of Remedy Program : MMC have instructed their supplier ADV Brightwork to resupply quality
assured parts. This is planned for 01/08/2024. MMC need to assemble these parts into the correct assembly and plan to complete sufficient (62 off) to satisfy all the vehicles currently in the US, likely to be by or before the end of January 2024. Parts will be sent to the dealers. A spread sheet exists but cannot be attached to this form.
A batch of parts with consecutive numbers 200 to 400 will differentiate them from the recall condition.
The remedial work will be carried out at no cost to the customer or dealer. Morgan Motor Company will look to recover costs from the third party supplier (ADV Brightware). How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Consecutive batch numbers from 200 to 400 will distinguish remedied parts from recalled parts.
The recall condition will be corrected in production by the supplier starting 01/08/2024. These quality assured parts will then need to be built into replacement assemblies by MMC, quality checked, and sent to the US dealers to carry out the recall work. Recall Schedule :
Description of Recall Schedule : The attached communication (US Dealer Recall Notification_Morgan
Motor ompany.pdf) was sent to the US dealers affected by the potential defective pedal box housing 12/27/2023.
This communication was sent to mitigate any vehicles which may be fitted with defective parts from being sold or delivered to end customers. Please note that the term noncompliant was used with respect to the engineering and quality specification NOT concerning FMVSS.
Letters will be sent to the end customers (purchasers) 5 days after submitting this notice to NHTSA. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : JAN 22, 2024 – FEB 23, 2024
* NR – Not Reported

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US NONCOMPLIANT PARTS RECALL
AFTERSALES FAQs
INTERNAL USE ONLY, NOT FOR CIRCULATION OUTSIDE OF U.S. MORGAN DEALERS
WHY DOES MY SUPER 3 NEED REPAIR?
The Pedal Box Assembly may exhibit reduced braking performance or complete loss of braking, increasing the risk of an accident.
This is due to a potential defect which has been identified with the Pedal Box Assembly.
The affected part is the welded pedal box housing, which forms the structural component to which all other parts contained within the assembly are attached.
The potential defect is caused by Morgan’s third-party supplier not manufacturing parts in line with Morgan’s engineering and quality specifications.
The malfunction that could occur is weld failure under heavy load braking. An indication that your vehicle is affected could manifest as either binding brakes and / or the brake pedal is not returning to the intended position. Should this be the case you should not drive the vehicle in any event.
HOW DO I GET THE WORK COMPLETED?
Morgan Motor Company will send your dealer the new Pedal Box Assembly for your car.
Please contact the Morgan dealer that you purchased the car from and schedule an appointment to bring the car to them.
WHAT WILL MY MORGAN DEALER DO?
Your dealer will replace the defective Pedal Box Assembly with a new, quality assured unit that is free of defect, free of charge.
The repair should take approximately 4 – 6 hours to complete. However, due to scheduling, your dealer may require your vehicle for longer. Your dealer should be able to provide a more accurate repair schedule.
CAN I STILL DRIVE MY SUPER 3?
Your Super 3 can be driven to your Morgan dealer to have the work completed.
We strongly recommend that you get the Pedal Box Assembly replaced with a new quality assured unit as soon as possible.
HOW MUCH WILL IT COST TO HAVE THIS WORK COMPLETED?
Your dealer will replace the defective Pedal Box Assembly with a new, quality assured unit that is free of defect, free of charge.
WILL MY TRAVEL COSTS BE REIMBURSED?
please contact your Morgan dealer regarding reimbursement of any fuel and road toll costs.
I DON’T WANT TO DRIVE MY SUPER 3 TO MY DEALER BECAUSE I LIVE TOO FAR AWAY. CAN YOU TRANSPORT MY VEHICLE TO THE DEALER FOR ME?
Please contact your Morgan dealer if you are not able to drive your vehicle to their premises and require assistance to take your car to the dealer.
WHEN WILL THE PARTS ARRIVE AT MY DEALER?
Replacement Pedal Box Assemblies are being shipped from the Morgan Motor Company to all US Morgan dealers. SEE SEPARATE SCHEDULE FOR ANTICIPATED PARTS ARRIVAL DATE AT EACH DEALERSHIP
WILL MY DEALER BE ABLE TO CARRY OUT THIS REPAIR CORRECTLY?
All US Morgan dealers will receive full instructions and technical support from Morgan Motor Company and are fully qualified to carry out the replacement of the Pedal Box Assembly.
CAN ANOTHER DEALER COMPLETE THE WORK ON MY CAR, OR MUST I RETURN TO THE DEALER I BOUGHT THE VEHICLE FROM?
The replacement parts will be sent to the dealer who supplied your Super 3 to you. If there is another Morgan dealer closer to you, please let your dealer know or contact recall_help@morgan-motor.co.uk
CAN I WAIT WITH MY CAR TO HAVE THE WORK COMPLETED? OR WILL I HAVE TO RETURN ON ANOTHER DAY?
Please speak to your Morgan dealer when you schedule the work to confirm with them when your Super 3 will be ready for collection. We anticipate that the work will take around 4 – 6 hours to complete.
CAN MORGAN SEND THE PARTS TO MY LOCAL INDEPENDENT REPAIRER FOR FITMENT TO MY VEHICLE?
The Pedal Box Assembly replacement can only be carried out by an official Morgan dealer. US Morgan dealers will receive full instructions and technical support from Morgan Motor Company and are fully qualified to carry out the replacement of the Pedal Box Assembly.
WHO SHOULD YOU CONTACT WITH FURTHER QUESTIONS OR CONCERNS?
If you have questions or concerns about this recall, please contact Morgan Aftersales at +441 684 573 104, or email recall_help@morgan-motor.co.uk

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Safety Recall – Super 3 (US) DISCLAIMER: This presentation contains information that is confidential or privileged and is intended only for the individual or entity it is shown/sent to. No one else may disclose, copy, distribute or use the contents of this presentation. Unauthorised use, dissemination or duplication is strictly prohibited, and may be unlawful. If you received this presentation in error, please notify us as soon as possible at contact@morgan-motor.co.uk. Agenda
Dealer Briefing 1. The Defect
2. What NHTSA stipulates
3. Customer Letter and Envelope
4. FAQ’s
5. Recall replacement parts
I. Shipping
II. Work Instruction
6. AoB © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 1. Problem
Description of what highlighted this issue The below photo shows the area of defect – weld failure:- Photo of the defective part where the weld has failed:- The below photo shows where the connection to the master cylinder has become disconnected due to weld failure of the mounting plate where the master cylinder is fixed. This resulted in the master cylinder being able to move as the pedal is depressed as part of normal braking operation:- Connection to master cylinder disconnected. Weld failure © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 2. What NHTSA Stipulates
Recall Steps 1. Manufacturer files a Part 573 Defect Information Report (DIR):
I. Identifies a safety defect
II. Must be filed within 5 working days and it knew or should have know the defect exists
III. Include how and when the manufacturer identify the defect
IV. Identify the affected population
V. State the safety risk posed
VI. Plan for the proposed remedy 2) Issue owners of affective vehicles with a notice of recall:
I. Submit the proposed notice to NHTSA 5 days before mailing
II. Send owners no later than 60 days after filing Part 573
III. Must reach as many owners as possible and motivate them to get free repair
IV. Letter and envelope must state “IMPORTANT SAFETY RECALL”
V. Provide owners with clear statement of recall issue, safety consequences and risks, and precautions to take
VI. Explain how and where to have the vehicle repaired
VII. If remedy is not available in 60 days must send initial letter followed by second letter when remedy available 3) Report recall completion rates for at least 6 quarters © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 3. Customer Letter
NHTSA Template © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 3. Customer Letter
MMC Draft page 1 of 2 © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 3. Customer Letter
MMC Draft page 2 of 2 © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 3. Customer Letter
Envelope © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 4. FAQ’s
What you may be asked … © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 5. Replacement Recall Parts
Current Status • 62 off Pedal Box Assemblies have been sent to 9 Dealers
o Tracking details have been forwarded by e mail. • A Work Instruction has been developed and will be posted on the Dealer Portal and the Morgan Technical Hub (‘O’
Build
o Walk through the instruction … © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. 6. AoB © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction. © 2021, Morgan Motor Company. This presentation contains information that may be confidential or privileged and is intended only for the individual or entity direction.
Discover more about
The Morgan Motor Company:
CONTACT US:
contact@morgan-motor.com
+44 (0) 1684 573104
www.morgan-motor.com
SOCIAL MEDIA:
morganmotor morganmotor morganmotor
VISIT US:
Morgan Motor Company Pickersleigh Road Malvern Link Worcestershire
WR14 2LS

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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
https://obuild.morgan-motor.co.uk/engineering-bulletin-usa-super-3-pedal-box-removal-alteration-refit/ 1/86
USA Super 3 – Pedal Box Removal/Alteration & Refit
Date Created: 11.01.24
Version: 1.0
Author: A.Blackwell, Global Technical Support Officer.
Approved by: J.Bower, Aftersales Manager, Morgan Works – Malvern
Vehicles: USA Super 3
Issue: The Pedal Box Assembly may exhibit reduced braking performance or
complete loss of braking, increasing the
risk of an accident. The potential defect is caused by the welded Pedal Box Housing
Assembly.
Solution: Replace the defective Pedal Box Assembly.
Labour Time: Remove the existing Pedal Box Assembly from the vehicle, carry out
alterations and fit the new Pedal Box Assembly – 4 Hours.
Claim Code: SUP3-010US
All instructions in this manual must be adhered to for this stage. Read
all instructions carefully and study the photographs. While learning this procedure,
quality of work is more important than speed of assembly.
Take care to avoid damage to components throughout. Clean up any spillages
promptly.
Safely store all removed parts for the re-fitment process, unless stated otherwise.
Tools Required: 7mm Socket, 15mm Socket, 19mm Socket, Extension Bar, Ratchet,
Torque Wrench, 11mm Spanner, 13mm Spanner, 14mm Spanner, 4mm Allen Key or
Allen Key Socket, Small Flat Head Screwdriver, Long Nose Pliers, Hose Clamps,
Paint Pen, Loctite 243, Brake Vacuum Filling Unit (if available).
PARTS REQUIRED:
SA221480 – PEDAL BOX ASSEMBLY (1 OFF).
The following parts will be attached to SA221480 – PEDAL BOX ASSEMBLY but will
require removal prior to assembly:
MGN0027 – NUT M6 X 1 STEEL HEX NYLOC (2 OFF)
U010017 – BOLT M6 X 1.0 X 20 GR8.8 HEX FLG (1 OFF)
F011028 – NUT M8 X 1.25 HEX FLG NYLOC (4 OFF)
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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Y011054 – BANJO BOLT M10 X 1 (1 OFF)
Y011055 – M10 CRUSH WASHER (2 OFF)
U011035 – WASHER M6 X 1.6 X 18 STEEL FORM G (1 OFF)
U590003 – CIRCLIP 8 X 1.1 STEEL TYPE E FLAT (1 OFF)
Y191073 – SERRATED WASHER (1 OFF)
USA Super 3 – Pedal Box Removal/Alteration & Refit
It is recommended that this instruction is not printed. The oBuild site is updated
regularly and should be checked often for the latest instructions and updates.
PREREQUISITE:
Prepare the vehicle ready for the work to be carried out. Apply protection around the
bodywork of the vehicle. Apply protection to the centre tunnel of the vehicle. The
vehicle should be lifted using specialist equipment.
CAUTION: Take great care when lifting the vehicle. Refer to the Super 3 Owner’s Handbook for
instructions and safety information regarding lifting the vehicle.
CAUTION: Never use a 4 post ramp or inspection pit.
CAUTION: Ensure that the engine is not operating before lifting the vehicle.
CAUTION: Only lift the vehicle using the reinforced jacking points (reference owner’s handbook).
Super 3 – Pedal Box Removal Procedure
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the rear seat base from the driver’s side by lifting it upwards, disconnect the heated seat (if
fitted).
• Remove the front seat base from the driver’s side by removing the (x2) bolts with a 4mm hex key.
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• Remove the steering wheel centre by pulling it outwards.
• Use a 19mm socket and ratchet to remove the bolt in the centre of the steering wheel.
Make sure the steering wheel is paint marked (if not already marked) to aid the reassembly process
later on to ensure the steering wheel is refitted in the same location.
Discard the serrated washer as this MUST NOT be reused.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• If fitted, lift up the luggage rack to allow access to the boot (trunk).
• Open the boot (trunk).
• Remove the boot (trunk) lining by unscrewing the rubber fixings.
The next steps may differ depending on the equipment available within your dealership.
The following steps have been shown using a brake vacuum unit. If a brake vacuum unit is not
available the brake fluid can be removed from the brake lines with a aid of another person sat in the
vehicle who will be required to pump the brake pedal whilst each caliper is opened to remove the
brake fluid.
• Unscrew and remove the brake fluid reservoir cap.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum pump to rear calliper (if available). Use an 11mm spanner to open the bleed nipple.
• Start the vacuum process to remove the brake fluid (following vacuum filling manufacturer’s
instructions).
• Continue to the next steps checking the vacuum filling unit periodically.
• Apply protection to the footwell (if not already done as part of the prerequisites).
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 4mm hex key socket with ratchet or 4mm Allen Key to remove the heel plate in the footwell.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Unplug the wheel speed sensors on the front left and right wheels.
• Undo the (x4) mudguard securing M6 bolts using a 10mm socket and ratchet.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Lift off and safely store the mudguard.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the (x4) wheel nuts using a 19mm socket and breaker bar or impact gun (if available).
• Lift off and safely store the wheel.
CAUTION: Take great care when removing the wheels. Refer to the Super 3 Owner’s Handbook for
instructions and safety information regarding lifting the vehicle.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Repeat to remove the wheel on the other side of the vehicle.
When the rear brake calliper is finished and as much brake fluid is removed as physically possible,
carefully remove the vacuum pump unit. Be sure to clean any spillages as the pipe is removed.
• Remove one of the front brake calliper bleed nipple dust covers.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum pump unit to one of the front brake callipers using an 11mm spanner to undo the
bleed nipple.
• Start the vacuum process to remove the brake fluid (following vacuum pump manufacturer’s
instructions).
• Continue to the next steps checking the vacuum pump unit periodically.
• Remove the foot step retaining bolts using a 4mm socket and ratchet. Remove the foot step from the
footwell.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the accessible bolts retaining the footwell base plate. Removed the plate and store safely.
When the first front brake calliper is finished and as much brake fluid is removed as physically
possible, carefully remove the vacuum pump unit. Be sure to clean any spillages as the pipe is
removed.
• Re-fit the bleed nipple dust cover.
• On the other side of the vehicle, remove the front brake calliper bleed nipple dust cover.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum pump unit to the front brake calliper using an 11mm spanner to undo the bleed
nipple.
• Start the vacuum process to remove the brake fluid (following vacuum pump manufacturer’s
instructions).
When the brake calliper is finished and as much brake fluid is removed as physically possible,
carefully remove the vacuum pump unit. Be sure to clean any spillages as the pipe is removed.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum pump unit to the clutch slave cylinder using an 11mm spanner to undo the bleed
nipple.
• Start the vacuum process to remove the brake fluid (following vacuum pump manufacturer’s
instructions).
When the clutch is finished and as much brake fluid is removed as physically possible, carefully
remove the vacuum pump unit. Be sure to clean any spillages as the pipe is removed.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Undo the hose clamps on the brake fluid reservoir for master cylinder and clutch feed lines using a
7mm socket and ratchet or a flat head screwdriver.
• Suck out any remaining brake fluid from the reservoir.
• Carefully try to remove the brake master cylinder and clutch feed pipes from the reservoir.
CAUTION: Take great care not to damage the brake fluid reservoir or the feed lines. Carefully use a
flat head screw driver or pliers to pry off the feed lines.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the hose clips from brake fluid rubber lines and remove the grommets from the bulkhead
closing plate.
• Clean up any residual brake fluid which comes out of the brake fluid lines.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Using a trim tool (shown opposite) or similar, to very carefully lift up and remove the cable tie push fit
clips (x2) to release the wiring harness to the bulkhead closing plate.
• Remove the clutch pipe from union on the bulkhead closing plate using a 12mm spanner.
• Place the clutch pipe out the way for easy access to the pedal box.
• Clean up any residual brake fluid which comes out of the clutch pipe.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 10mm socket and ratchet to remove the accessible pedal box closing plate bolts.
• Remove the brake fluid reservoir from the vehicle and place to one side.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 15mm socket and ratchet to remove the rear brake circuit union from the bulkhead closing
plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 19mm spanner to remove the pedal box position adjustment cable.
• Use a 10mm socket and ratchet to remove the remaining bolts to fully remove the pedal box closing
plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Thread the brake fluid reservoir feed lines through the closing plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Underneath the vehicle, remove (x4) grommets underneath the footwell base plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Underneath the vehicle, remove the inner front footwell base plate retaining nut, washer and rubber
washer. Store the washers for re-fitment later – discard the nut, replacements are supplied as part of
the kit.
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• Underneath the vehicle, remove the remaining (x3) footwell base plate retaining nuts. – discard the
nuts, replacements are supplied as part of the kit.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the footwell base plate. (It may be necessary to adjust the position of the pedal box to
access to the base plate).
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Disconnect the electrical connectors on the pedal box which connects it to the main vehicle harness.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the brake union using 14mm and 13mm spanners. Store these parts for re-fitment later.
• Clean up any residual brake fluid which comes out of the brake line.
• Use suitable hose clamps or place bolts in the ends of the brake fluid reservoir feed lines to prevent
fluid leaks.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Release the clip on the back of the clutch master cylinder and remove the clutch pipe.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the pedal box from the vehicle.
It may be necessary to rotate the unit through 90 degrees to remove it.
Clean any residual brake fluid which is left in the pedal box area.
Super 3 – Pedal Box Alteration Procedure
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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Prior to starting the Pedal Box Alteration Procedure the following parts must be removed from the
supplied Pedal Box Assembly (as per the picture opposite):
Y191073 – Serrated Washer.
U590003 – Circlip 8×1 Steel Type E Flat.
The other supplied parts are easily identifiable but must be removed prior to assembly:
MGN0027 – Nut M6x1 Steel Hex Nyloc (2 off).
Y011054 – Banjo Bolt M10x1 (1 off).
Y011055 – M10 Crush Washer (2 off).
F011028 – Nut M8x1.25 Hex Flg Nyloc (4 off).
U010017 – Bolt M6x1.0x20 Gr8.8 Hex Flg (1 off).
U011035 – Washer M6x1.6×18 Steel Form G (1 off).
• Remove the bungs from the new supplied pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the feed lines from the old brake master cylinder on the old pedal box.
• Clean up any residual brake fluid which comes out of the feed lines.
• Feed the removed lines into the new pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Push in the feed lines.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the grommets to the feed lines and secure using a flat head screwdriver.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 14mm spanner to undo the bolt to remove the rear brake pipe from the old brake master
cylinder on the old pedal box.
Discard the copper washers and Banjo Bolt as these MUST NOT be reused.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Feed the rear brake pipe to the new pedal box.
• Fit a new copper washer (as supplied as part of the kit) onto the new Banjo Bolt (as supplied as part
of the kit). Feed the Banjo Bolt through the brake line and then fit another new copper washer.
• Secure and tighten the pipe to the new master cylinder using a 14mm spanner.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the grommet for the rear brake pipe to the new pedal box and secure using a flat head screwdriver.
• Remove the adjustment lever from the old pedal box by undoing the nut with a 10mm spanner.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the adjustment lever retaining plate from the old pedal box.
• Fit the adjustment lever retaining plate to the new pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Tighten the adjustment lever retaining plate bolt.
Ensure the new pedal box runners are slid to the fully forwards position.
• Lock the pedal box plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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There should be 4-5mm of free cable between the pull handle and the cable outer, adjust the cable as
necessary to achieve this.
• Tighten the adjustment lever locking nuts with a 10mm spanner.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Apply a paint mark with a suitable paint pen or similar to the locking nuts.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the master cylinder circlip from the old clutch pedal.
Discard the old circlip as this MUST NOT be reused.
• Remove the clutch pedal retaining bolt from the old pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the clutch pedal.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the clutch master cylinder retaining bolt from the old pedal box.
• Remove the clutch master cylinder.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the clutch master cylinder to the new pedal box using a tilting motion as shown.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the clutch master cylinder retaining bolt to the new pedal box and tighten to 24Nm using a Allen
Key socket and torque wrench.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Apply Loctite 243 to the clutch retaining bolt.
• Fit the old clutch pedal to the new pedal box, fit the clutch pedal retaining bolt and tighten to 10Nm
using a 10mm socket and torque wrench.
Make sure the clutch pedal return spring is located correctly in the pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the pedal clevis pin into the clutch master cylinder.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the new circlip (as supplied as of part of the kit) using pliers.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove wiring connectors and clips from the rear of the old pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Remove the accelerator pedal retaining bolt from the old pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Locate the alignment hole on the new pedal box to fit the accelerator pedal using the retaining bolt.
• Refit the wiring clip to the rear of the new pedal box.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the brake light switch connector.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the clutch switch to the rear of the new pedal box, by depressing the tags and sliding it into the
holes.
• Fit the plate to the rear of the new pedal box.
• Fit the plate with the new nuts (as supplied as part of the kit) to the rear of the new pedal box and
tighten up with a 10mm socket and torque wrench to 10Nm.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the brake line grommet to the new pedal box.
Super 3 – Pedal Box Refit Procedure
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Fit the new (altered) pedal box into the vehicle.
It may be necessary to rotate the unit through 90 degrees to refit it.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the clutch pipe into the back of the clutch master cylinder and make sure the retaining clip is
secured correctly.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the brake union using 14mm and 13mm spanners.
Once the brake union is tightened up, please check the brake line connection fixing to the union
inside the vehicle is tight.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the electrical connectors on the pedal box which connects it to the main vehicle harness.
• Refit the footwell base plate. (It may be necessary to adjust the position of the pedal box to access to
the base plate).
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Underneath the vehicle, fit the (x3) new footwell base plate retaining nuts (as supplied as part of the
kit).
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the inner front footwell base plate retaining washer and rubber washer. Then using the new nuts
(as supplied as part of the kit) Torque up to 24Nm using a 13mm socket and torque wrench.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Underneath the vehicle, refit the (x4) grommets underneath the footwell base plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the closing plate to the vehicle.
• Thread the brake fluid reservoir feed lines through the closing plate.
• Reft the pedal box closing plate. Use a 10mm socket and ratchet to refit the bolts.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 19mm spanner to refit the pedal box position adjustment cable.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Use a 15mm socket and ratchet to refit the rear brake union to the bulkhead closing plate.
Once the brake union is tightened up, please check the brake line connection fixing to the union
inside the vehicle is tight.
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• Use a 10mm socket and ratchet to refit the accessible pedal box closing plate bolts. Tighten all bolts
to 10Nm.
• Refit the brake fluid reservoir to the vehicle.
• Refit the cable tie push fit clips (x2) to secure the wiring harness to the bulkhead closing plate.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the clutch master cylinder and brake master cylinder feed pipes to the brake fluid reservoir.
Ensure clutch feed pipe is fitted to the front upper outlet.
• Tighten up the hose clamps on the brake fluid reservoir for master cylinder and clutch feed lines
using a 7mm socket and ratchet or a flat head screwdriver.
• Refit the accessible bolts retaining the footwell base plate. Tighten to 10Nm.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the heel plate in the footwell and secure the retaining bolts with a 4mm hex key.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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Refit the steering wheel and align to the marks previously made, to ensure the steering wheel
alignment remains correct.
Please ensure the Serrated Washer is replaced prior to refitting the steering wheel bolt – Part
Number Y191073
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• Torque the steering wheel bolt to 42Nm using a 19mm socket and torque wrench.
• Apply a paint mark across the centre of the bolt and on both sides of the steering wheel.
• Refit the steering wheel rubber centre boss.
• Refit the front seat base to the driver’s side and refit the (x2) bolts with a 4mm hex key.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the heated seat connector (if fitted) and refit the seat base to the vehicle.
• Refill the brake reservoir with brake fluid.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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The next steps may differ depending on the equipment available within your dealership.
The following steps have been shown using a brake vacuum unit. If a brake vacuum unit is not
available the brakes can be bleed with a aid of another person sat in the vehicle who will be required
to pump the brake pedal whilst each caliper is opened to remove the air from the braking system.
• Attach vacuum pump to rear calliper (if available). Use an 11mm spanner to open the bleed nipple.
• Start the vacuum process to refill the brake fluid into the rear brake lines (following vacuum filling
manufacturer’s instructions).
• Bleed the rear brake caliper until air can no longer be seen in the fluid emerging from the caliper.
Check the brake fluid level and top up as required.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum filling unit to the front right brake calliper using an 11mm spanner to undo the bleed
nipple.
• Start the vacuum process to refill the brake fluid into the front right brake lines (following vacuum
filling manufacturer’s instructions).
• Bleed the front right brake caliper until air can no longer be seen in the fluid emerging from the
caliper.
Check the brake fluid level and top up as required.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum filling unit to the front left brake calliper using an 11mm spanner to undo the bleed
nipple.
• Start the vacuum process to refill the brake fluid into the front left brake lines (following vacuum
filling manufacturer’s instructions).
• Bleed the front left brake caliper until air can no longer be seen in the fluid emerging from the caliper.
• Refit the front brake caliper bleed nipple dust covers on both sides of the vehicle.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Attach vacuum filling unit to the clutch master cylinder. Undo the bleed nipple using an 11mm
spanner.
NOTE: the bleed nipple needs to be opened quite a lot to allow the fluid to flow.
• Start the vacuum process to refill the brake fluid into the clutch lines (following vacuum filling
manufacturer’s instructions).
• Bleed the clutch slave cylinder until air can no longer be seen in the fluid emerging from the clutch
slave cylinder.
Check the brake fluid level and top up to the maximum mark. Refit the reservoir cap and plug back in
the electrical connections.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit both front wheels. Refit the (x4) wheel nuts using a 19mm socket and breaker bar or impact gun
(if available).
CAUTION: Take great care when refitting the wheels. Refer to the Super 3 Owner’s Handbook for
instructions and safety information regarding lifting the vehicle.
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• Refit the (x4) mudguard securing M6 bolts using a 10mm socket and torque wrench. Tighten the
bolts to 10Nm.
• Repeat the process on the other side of the vehicle.
• Plug the wheel speed sensors back in on the front left and right wheels.
1/23/24, 11:36 AM Engineering Bulletin – USA Super 3 Pedal Box Removal/Alteration & Refit[L][L] – Morgan TechHub
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• Refit the boot (trunk) lining and secure by screwing in the rubber fixings.
• Close the boot (trunk).
• If fitted, lower the luggage rack over the boot (trunk) and resecure.
CAUTION: Take great care when lowering the vehicle. Refer to the Super 3 Owner’s Handbook for
instructions and safety information regarding lifting & lowering the vehicle.
• With the vehicle on the ground, torque the front wheel bolts (x8) to 100Nm with a 19mm socket
torque wrench.
Make sure the pedal can be adjusted backwards and forwards and securely locks into place.
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Perform a road test to check the performance of the brakes and clutch. Please also check the
steering wheel alignment to ensure the steering wheel is straight.
If you experience any issues with these instructions or require further guidance, please submit a DSC
case to the MMC Technical Team.
END OF SUPER 3 PEDAL BOX REMOVAL/ALTERATION & REFIT
MY23 Plus Line MY22 CX Generation MY21 CX Generation Super 3 M3W 4/4 Plus 4 Roadster Aero 8 & Plus 8
MMC Diagnostic Tools & Software
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