Well its been 1 week after opening up my pedals. Here are my results:
When I first opened them up, I was surprised to find grease all over the place. There was literally grease everywhere! I have the older model with the white plastic pots. It became immediately apparent that there really was no kind of mechanism to hold anything in place and that I would have to be very delicate when trying to do what I needed to do. The first thing I tried to do was tape the wires to the plastic floor, but the tape I had was really weak and there really wasn't enough wire in the middle to do it. After unsuccessfully trying to pull more wire into the base, I decided to leave that alone and pay attention to the pots.
It should be said that the pots, one for the gas and one for the brake, are supposed to fit in a small black groove (there should be a small, black "ball" [looks like the top of a flagpole] to help it fit). The problem is that its a lot more hard than it needs to be to actually keep it down there, as it comes out very easily. You have to be extremely delicate and precise with your movements. The pot for the brake pedal seemed fairly secure but the pot for the gas pedal was just out of control. I tried taping this too down but, once again, my cheap tape failed me
At this point I began to get frustrated because I couldn't get anything where I needed it to be. When I first read through this post, I had heard about how hard it would be to put the base back on and that you had to use your feet if you didn't have another helper. I don't know how you guys were able to use your feet to keep everything in place while putting the base back on, because I sure couldn't. When I tried to put it back together, I couldn't get the base to fit back on because the top of the springs (actually not springs at all, more like the metal clamps that go on the ends of a dumbell to keep weights in place during a benchpress) were too high. I tried adjusting the position of the pedals, but this only made the pot come back out of its groove.
By this point I thought I would never get my pedals to work again. But then, miraculously, as if some magic wand had been waved, everything managed to stay in place as I tried to put the base back on. Once I got it in place I hurried to screw in the middle screw to ensure that nothing moved around. Then the moment of truth. I plugged it in to my CPU and went to controller properties. The gas pedal works perfect. No stuck throttle, no non-full throttle. The brake pedal, however, was ever so slightly off a little bit. It read as about 5% depressed, but went to full brake pressure without problem. I tried it on my PC racing game and it worked fine, then on GT4 last night. Works perfect, and the partial braking isn't showing up. To tell the truth, I didn't think it'd have any chance of working.
I guess for mine I just needed to have the pots in their designated place. I was able to pull just a small amount of wiring into the base, but I definitely wasn't able to tape it down. I'm just grateful that I was able to fix my PS2 and DFP both in 1 weeks time w/o having to spend a dime. I would highly, highly recommend that if you want to to try this procedure that you get a helping hand to help hold everything in place.