finally sorted out my pedal box [Archive] - VW T4 Forum - VW T5 Forum

finally sorted out my pedal box

Tracktoy
15-02-09, 21:19
it was may 08 that I found the metal brace from my pedal box lying in the foot well, I made a temporary repair by cable tying a block of wood under the master cylinder and promptly forgot all about it I:, last week it started to make a clicking sound so I thought Iíd better have a look at it - I donít like to rush these things LOL:

first thing I did was to remove the pedal box from the spare scrap van I still have in the garden (as you do lol), I unbolted the whole thing from the engine bay and removed it from inside the van which was easy enough as there is no engine or dash in it, this allowed me to work out the best way of removing the one from my van

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/5.jpg

it was then that I realised that the pedal box on this one was broken too, so I got a decent pic of it to show what the problem is

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/7.jpg

the crazy thing about these boxes is that vw could have made them so much stronger in the first place, the gap between the tabs on the master cylinder is 14mm at the smallest point

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/8.jpg

yet the metal brace is only 9mm

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/9.jpg

5mm doesnít sound like much but would have made a big difference


I had originally wanted to swap this box over with mine but on closer inspection I realised the two were different- they were both Ďfly by wireí but completely different systems

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/3.jpg

So I set about removing mine- under the bonnet I removed the middle of the three bottom bolts (awkward to get to as its directly under the servo)

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/18.jpg

Then from the inside removed all the wiring and brake clutch switches then unbolted the master cylinder from the bracket
Removed the two 13mm bolts from the top of the box (shown in green)which are hidden from view but not too bad to get too

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/1.jpg

Removed the clip from the servo and undid the 4 nuts holding it on

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/16.jpg
http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/12.jpg

this next pic shows the pedal box form the old van stripped apart to give a better idea of what's needed-your the servo and back plate will stay in the van, your just removing the pedal box from it

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/15.jpg

then removed to box from the van, at this point the the clutch return spring fell apart, the top is attached to the box with a clip, the lower part just slides on the pedal and is held in place by the spring (shown in blue in pic 7)

this is the one from the other box completly removed to give a better idea of how it goes together

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/13.jpg

Once it was out I could see that mine was in a very poor state, not only had the brace fallen off completely

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/10.jpg

But it had also cracked behind the bracket, in fact there was only about 5-6mm of metal holding it on

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/4.jpg

So I cleaned it off and welded up the cracks up both sides and then welded the original brace back in
http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/20.jpg
http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/19.jpg

Then cut a small piece of 3mm plate tacked and then welded it into place

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/22.jpg
http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/23.jpg

Cleaned it up with a wire brush and gave it a lick of paint (I donít grind back the welds to give them a smooth finish as I believe it weakens them)

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/24.jpg

Refitted it back into the van which was a bit fiddly to say the least, with the clips and springs etc

http://img.photobucket.com/albums/v51/3dr-rally-slag/t4/25.jpg

I now have no clicking and absolutely no movement in the pedal, the clutch action seems so much more positive now- Iím a very happy bunny indeed:D

I know wind welder offers an exchange service on these and I donít want to tread on anybodyís toes but with so many people having trouble i cant see it being a problem, if anybody want their pedal box sorted out local to me then I would be glad to help, i can remove, fix and refit your box or just repair yours if you want to do the spanner workT:T:

boardman
15-02-09, 22:14
great info ,photos superp ,just what we need on the forum ,brilliant
but i was lost when i saw the third peddle.LOL:

jets
16-02-09, 10:05
Thanks 3dr, terrific writeup. Just took a look at mine & it's cracked like in the second pic.
I had no idea how extensive they crack. Mine looks like the RHS in pic 5.['01 model] What year is the assembly on the left?

Tracktoy
16-02-09, 10:43
great info ,photos superp ,just what we need on the forum ,brilliant
but i was lost when i saw the third peddle.LOL:

i take it yours is an auto;)


Thanks 3dr, terrific writeup. Just took a look at mine & it's cracked like in the second pic.
I had no idea how extensive they crack. Mine looks like the RHS in pic 5.['01 model] What year is the assembly on the left?

the one on the left is from a 1998 ('R' reg over here), the one on the right is from my 2001 combiT:

footballhead
16-02-09, 17:17
what a excellent how - to my pedal is beginning to sqeak a bit may have to pay you a visit where in south wales are you cheer,s T:

Tracktoy
16-02-09, 20:19
thanks for the comments, i'm just outside caerphilly so not too far for youT:

keep an eye on it though, you dont want to be paying out for a master cylinder too:(

footballhead
21-02-09, 13:49
you have pm

Climberian
21-02-09, 15:53
This is what this forum is all about good helpfull advice and pics to go with it wish i was closer need mine doing just had mine fixed by welding aplate on the clutch pedal bracket by afreind lets see how long it lasts T:T:T:

iwcs
03-03-09, 00:16
Top effort mate... cant fault you fair do's A:

Tracktoy
03-05-09, 15:40
cheers ian, and thanks everyone for the kind commentsT:


happy to help anyone else out if they need theirs repairedT:

Phoenixsp1
03-05-09, 21:34
Excellent info. A: cheers.