Question about 2000 Volkswagen Golf

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Clutch pedal box has snapped off its mounting on vw polo

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1-disconnect battery. 2- remove all lower dash plastic panels. 3- disconnect all plugs on steering coloumn. 4- remove shear bolts on steering coloumn, easy with a long 8" sharp chisel (get 2 x new shear bolts £0.50p each). 5-loosen & remove bolt at steering rack in drivers footwell, mark position of spline before removing this makes it east to refit (tipex). 6- pull steering coloumn out towards you & it will slide off the bush quite easy. 7- loosen clutch cable adjustment & remove cable nipple at pedal. 8-remove clutch pedal. 9- pull brake pedal out of plastic insert, this will break there is no way to remove this without breaking the plastic clip. get a new brake pedal clip insert for a Mk 3 golf £4 its the same (dont let VW sell you a new pedal) 10- remove 5 x nuts holding pedal box to bulkhead/brake servo. 11- cut 2 x cable ties holding throttle wiring & disconnetc plug above heater on drivers side. 12- push/pull brake servo slightly out of bulk head. 13- remove pedal box.
Cause of the problem- The clutch bracket is only held to the pedal box with 2 x spot welds & a 10mm tack on the top corner.
Repair- Fully Weld the clutch bracket to the pedal box. Great repair.
refitting reverse of above.
Duration around 6/8 hours Less if you get the spare parts before you start.
I wasted time trying to remove the brake pedal without breaking the clip impossible to do even with theVW tool. £4 on a new clip is well worth it.

Posted on Feb 22, 2010

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How on earth do you get the brake pedal back on? Ive pushed the new plastic clip back into the brake pedal but i cant push it over the ball on the brake shaft to master cylinder. How did you do it?

Posted on Sep 09, 2010

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I did this repair with a large square washer from b&q that had a 1/2 inch hole in it placed on the interior of the engine compartment where the clutch cable enters and connected the clutch cable to the pedal this raises the pedal 1/2 above the existing brake and accelerator but i can put up with that. i am thinking of making or finding a washer that has a dished shape of 1/2 to 3/4 inch to fit in the place of the square washer that would drop the level to match the other pedals i did this fix 3 months ago and has worked fine took about an hour

Posted on Mar 28, 2010

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  • John Benger Aug 02, 2010

    some strands of a hair or fibreglass are aparently coming out of my exhaust tail pipe .they are black in colour but dont appear to be sooty is somone interfearing with my VW or is there an explanatiopn

  • Lyndon Dec 10, 2011

    What a clever idea ! Was it successful and did the clutch cable manage to stay in one piece ?

  • OmletteDaggle Nov 27, 2012

    Hi leadbrickuk, I did the same as you, with the square plate over the hole in the firewall, but I found the cable was too short. I forced it in, but its destroying itself slowly around the bracket that hold it at the clutch end. Is there a slightly longer clutch cable available? how did you get round this problem? would appreciate any ideas. Bast. Omlette


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