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How to Make Denso Shims

The accelerator pedals in Toyota automobiles either come from Denso or CTS manufacturers. The CTS accelerator pedal has a demonstrable tendency to stick because of a friction arm design. Shims are a necessary, but temporary, modification that brings the pedals closer to the quality found in a Denso accelerator. These shims can be bought and installed at Toyota dealerships. But a Denso shim also can be crafted with basic metalworking skills.

Instructions

1

Determine the thickness required for the shim. Locate the part number stamped near the top of the accelerator pedals neck. A chart in the accelerator module recall documentation indicates the shims required thickness based upon this part number. This value ranges from 0.055 inches (1.4 mm) to 0.114 inches (2.9 mm). A majority of these replacements will require either a 0.070-inch (1.8 mm), 0.079-inch (2.0 mm) or 0.091-inch (2.3 mm) thickness.

2

Use metal cutters to cut a square shim out of steel measuring one inch (25 mm) on each side. The thickness of the shim should fall between 0.008 inches (0.2 mm) to 0.020 inches (0.5 mm) greater than the requirement outlined in Step 1.

3

Position the shim in a metal press so that a 0.079-inch (2 mm) lip is exposed on either side. Use the stamp to squeeze the metal until the center of the shim is the required thickness, but the lip remains at its original thickness. The result resembles a "U" shape.