Rick;

This certainly makes the point of how important that lowly cotter pin is...I typically replace cotter pins with "hitchpins" of the appropriate size (including at that clevis... even the one on Brakedrum nut)...these are a bit beefier, and not split, but solid and can be reused indefinitely...this seems to me to be more consistent with the philosophy of the entire car!

To Derek's mention of point-of-wear...since the clevis pin makes contact edge-on on both pedal and yoke, these edges are susceptible to wearing the holes in the pedaltube oval (after a few hundred thousand miles, and a few hundred million pushes of that pedal...damn...those Volvos just don't last!)...a dab of grease on these wear areas keeps the rate of wear to a minimum. HA's suggestion of adding a bushing would be a possible solution as it increases the bearing area...I'd be real careful about taking any material away, or weakening pedaltube further in any way by drilling...I think I'd prefer opening up the hole only enough to TIGging in a steel bushing with a close ID clearance for the clevis pin, and grease that...I don't think a full-blown bearing is really necessary here...

Cheers