Dongfeng VL truck parts Process assembly of foot pedal cover 8405930-C4100

Crafted via a one-step injection-molding process (using a 1,200-ton hydraulic injection machine), the assembly eliminates weak points from or bonding, ensuring uniform structural strength across all pedal cover components. The molding process uses high-precision steel molds (tolerance ±0.05mm) to replicate the VL pedal’s contour, with a wall thickness of 2.5mm (±0.1mm) that balances lightweight design and durability. Post-molding, the assembly undergoes a 120°C annealing treatment to relieve internal stress, reducing deformation risk by 60% compared to multi-piece assemblies. The integrated design also includes pre-installed rubber gaskets between each cover and the pedal body, eliminating rattling caused by component friction—common in separate pedal covers—and enhancing overall assembly stability during 200,000+ pedal cycles (equivalent to 150,000 km of road use)

Built to withstand frequent, high-force (up to 550N for brake/clutch, 300N for accelerator), the assembly uses a high-density PP+20% glass fiber composite. This material delivers a flexural strength of 82 MPa, impact resistance of 9.5 kJ/m² (notched Izod at 23°C), and a Rockwell hardness of R110—resisting scratches from work boots and deformation from repeated use. It maintains structural integrity in extreme temperatures (from -40°C to 110°C), preventing brittleness in cold climates or warping under engine bay heat. The composite also exhibits excellent chemical resistance, withstanding spills of diesel fuel, brake fluid, and road salt without discoloration or material degradation (tested to 500 hours of chemical immersion). Compared to standard PP covers, this reinforced composite extends service life by 75% under heavy-duty use

Tailored to the unique function of each pedal, the assembly features zone-specific anti-slip textures: the clutch/brake covers have a raised grid pattern (1.5mm tall, 5mm×5mm spacing) with a coefficient of friction (COF) of ≥0.8 when wet, while the accelerator cover uses a striped texture (1.2mm tall, 8mm spacing) for precise pedal modulation. These textures trap mud, water, and oil from work boots, reducing slip risk by 70% compared to smooth covers—critical for emergency braking or clutch engagement in rainy, muddy, or mining environments. The texture is molded directly into the composite (not added via or coating), ensuring it doesn’t wear off even after 100,000 + cycles. Additionally, each cover has a colored edge (red for brake, yellow for accelerator) for visual pedal identification, aiding driver awareness during long shifts

Designed for quick, DIY-friendly replacement (no tools or mechanical expertise needed), the assembly uses a multi-point snap-on system with 12 integrated nylon 66 clips (tensile strength ≥180N) that lock onto the VL pedal shafts and brackets. Installation takes 5–8 minutes: align the assembly’s inner recess with the entire pedal row, press firmly until all clips “click” into place, and verify no movement during pedal testing. The clips’ flexible design allows for easy removal during maintenance, without damaging the pedal body or assembly. The assembly also includes a thin, adhesive-backed foam strip along the bottom edge that adheres to the cab floor, further stabilizing the assembly and blocking dust from entering the pedal mechanism. Each unit undergoes clip retention testing, dimensional inspection via CMM, and anti-slip performance checks, backed by a 18-month warranty against defects (e.g., clip breakage, texture wear, composite cracking)