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Discussion Starter · #1 ·
Hey guys,

So, lovin' our T4! But, have a slight issue, which I think should be an easy fix, and wondered if anyone else might have had the same issue.

We went to the beach on Fri(along with the masses...sheesh.)and on the way I noticed that the clutch pedal was feeling 'different'. Had to press pretty hard to open the clutch and when released the pedal popped up a lot higher than the brake and gas pedal. Initially I was a bit freaked out, thinking anything with the clutch was probably bad news! :eek: Once at the beach I had a look and found that where the little hydraulic lifter is bolted to the floor, or pedal box, the flange had just snapped off! The 1/8th steel flange was torn right off.

An interesting drive home later and I am trying to figure out the easiest way to repair it and wondered if anyone had a similar thing happen. I called the local VAG specialist and he said that I may need a new pedal box, but that seems excessive for such a stupid break. I am thinking of just welding it back together, or perhaps making a patch from a square shaped piece of flat steel and bolting the pieces back together. :*

I don't know. I'm off to the VAG guy right now to see if there is another way to mend it. I may just ask to borrow their welder as it seems simple enough or that. It would be better than the 1"x4" piece of wood I have jammed behind the clutch pedal at the moment! :D
 

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Send a pm to windwelder (trev).....he does exchange pedal boxes bud ;)
 

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Discussion Starter · #5 ·
Ahhh...I shall be in touch!

Guys at VAG place in town said it will probably need taking off and either a proper weld/reinforce or a 'new' one eventually. I had the guy do a quick weld as my welder is not working right now, not thinking it would cost much, but it was blinking £45 for a nasty looking patch job. No nice stitching, just blobs. :( Last time I assume something will be cheap before saying go ahead! I was expecting £10-£15, and would not have been happy with myself with a weld like it has now...but I suppose he did his best...

Anyway, at least I can shift now and it should hold until I can sort a long term fix. Thanks again for the contact!
 

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Discussion Starter · #7 ·
What them other said!


If I can help get in touch.

Cheers Trev.
PM sent sir! Hoping to use your extremely well rated service! I love this forum... T:
 

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The more I read these posts the more I am glad its not just me...Had same thing happen 2 months ago to my clutch pedal whilst away towing the caravan.

1st thought was a leak in the hydraulics but the brake fluid was ok so nothing lost there. Turns out to be the same thing. My garage welded pedal back in for me and so far is great. If they have to change the clutch cylinder its a big job so a weld is first choice if you can.

A word to the wise....get them to lift your carpet....I have spark / burn marks in a couple places. Not pretty.

Good luck.T:
 

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Pedal box guru
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The more I read these posts the more I am glad its not just me...Had same thing happen 2 months ago to my clutch pedal whilst away towing the caravan.

1st thought was a leak in the hydraulics but the brake fluid was ok so nothing lost there. Turns out to be the same thing. My garage welded pedal back in for me and so far is great. If they have to change the clutch cylinder its a big job so a weld is first choice if you can.

A word to the wise....get them to lift your carpet....I have spark / burn marks in a couple places. Not pretty.

Good luck.T:
Hi Dave,

Hope you have sorted it!

Though in my experience it is almost impossible to effectively repair the pedal box while it is in the van, because the part of the pedal box that is broken and needs to be repaired or replaced(not the angle plate that the master cylinder is mounted to) is not easy to get at with the pedal box still in the van.
The other thing is that unless the welder understands how the system works and what parts interact with each other then it will almost certainly be out of line to one degree or another.

Oh and the master cylinder is easy to remove two bolts, two pipes and a clevis pin and spring clip.

Cheers Trev.
 

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Discussion Starter · #11 ·
Hi Dave,

Hope you have sorted it!

Though in my experience it is almost impossible to effectively repair the pedal box while it is in the van, because the part of the pedal box that is broken and needs to be repaired or replaced(not the angle plate that the master cylinder is mounted to) is not easy to get at with the pedal box still in the van.
The other thing is that unless the welder understands how the system works and what parts interact with each other then it will almost certainly be out of line to one degree or another.

Oh and the master cylinder is easy to remove two bolts, two pipes and a clevis pin and spring clip.

Cheers Trev.
You sir are the master. Pics to come and I will happily be exchanging my pedal box for one blessed by you! :D
 

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Has anyone got some pictures of how the pedal box is supposed to look. I am sure mine has gone as the clutch biting point is really low, just dont know what to look for. Not sure of the set up.

Kev


You sir are the master. Pics to come and I will happily be exchanging my pedal box for one blessed by you! :D
 

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Has anyone got some pictures of how the pedal box is supposed to look. I am sure mine has gone as the clutch biting point is really low, just dont know what to look for. Not sure of the set up.

Kev
Hi Kev,


Sorry got no pictures of good pedalboxes, I have got loads of broken ones,repaired (badly) ones, and some damned right ugly ones too!

To check the pedalbox:-

stick your head in the footwell, press the clutch pedal with your hand, if there is ANY sideways movement of the master cylinder then your pedal box has failed.

if you are still not sure, locate the two bolts that hold the master cylinder to the pedalbox, gently feel between these two bolt heads, if you can feel a crack or a sharp edge then it is 100% broken.

If I ever get to see a unbroken pedalbox i'll remember to take a photo.


Cheers Trev.
 

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........if you are still not sure, locate the two bolts that hold the master cylinder to the pedalbox, gently feel between these two bolt heads, if you can feel a crack or a sharp edge then it is 100% broken.


Cheers Trev.


Hope this pic helps, this was mine before Trev changed it for me T:

The two bolts are the ones facing the camera in the picture, if you look closely you can see the brown line where the 'Tang' is cracked, also mine was cracked to the side, this crack is more visible from the litening hole.

Chris
 

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Mine is definately knackered. It looks as though it has been for a while as the previous owner has put a bolt through it to hold it. What are peoples experience. Is it worth changing the Cylinder too as this is likely to have wear in it too I would have thought.

Trev Looks like I'm going to need your help with this pne too!!

Kev
 

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Mine is definately knackered. It looks as though it has been for a while as the previous owner has put a bolt through it to hold it. What are peoples experience. Is it worth changing the Cylinder too as this is likely to have wear in it too I would have thought.

Trev Looks like I'm going to need your help with this pne too!!

Kev

Hi KeV,

Yep that's deffo cream crackered!

If the master cylinder is not leaking then it's looking good so far. Take a close look at the aluminium tube coming out of the top of the master cylinder, is it cracked? Is it still reasonably round, with the top edge rolled over!

If all of the above are good, then leave well alone.


Cheers Trev.
 

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Its a reasonably new cylinder put on before I bought it. Doing jobs by half!!!!!

I guess I'll leave it and just change the bracket.

Kev
 

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Hi guys, this seems to be the best thread running so apologies for jumping in.

i have (p) 1.9td my clutch pedal drops in the mornings and wont select gears properly unless.... i lift with my foot.

has been my morning ritual for a little while now waiting for glow plugs lifting clutch pedal before starting off.

after lifting pedal is fine all day. well was till the other day when it has started being crunchy going into 1st and 3rd.

have had new clutch and has been fine after until recently!!! ANY IDEAS????
 
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