clutch pedal snapped!

[Deejay]

Minding my own business coming home on friday, go to engage 1st at a busy road junction my clutch pedal sank to the floor ,cue mad panic and me pushing the car to the side of the road to get out the way whilst nearly being killed in the process

After a little investigation I've found that this is a very common fault as two spot welds on the pedal assembly give way very easily.

Anyhow,I sourced a new clutch pedal clip as that had also snapped but I was still stuck on what to do about the pedal weld as I was out of friends with a welding set.

bollox to it I thought how hard can welding be? one 10 minute venture to Machine Mart and a cheap small arc welding set was mine

As it turns out, arc welding is pretty damn hard, took me the best part of 2 hours to get the knack on a piece of scrap metal and as I didn't fancy welding it in the car I spent a further 2 hours figuring out how the hell the damn pedal comes out!
As with everthing on the mk3 ibiza cupra you have to move parts B,C,D,E.........to get part A out

Anyhow welded her up and were back up and running and all seems good again. The garage door hinge also works and the gate shuts properly.

happy days

DJ

 

[foxy42]

Nice work dude...how much is a 'cheap' welding kit, just out of interest?

 

[Garth]

Yep, happened to my Mk2 aswell. Absolutely turd design.

 

[F2 Stu]

Arc (stick) welding is easy.

Doing it with a cheap 'portable' set makes it difficult to strike up the arc as the 'set' hasn't got the ooomph even if you turn it up to the max (120 amp?)

Even when you get it the arc going its ony good for 3" of weld before the thermal switch cuts it out for like 20 odd minutes.

Mig is far far better

 

[Brummy]

Yep, happened to my Mk2 aswell. Absolutely turd design.

that was what was wrong when i bought my mk2 .. the guy 'THOUGHT' it was the gearbox....... oh joy of joys what a big old bolt can do...!!!!! just drilled thru the two bits.... stuck a bolt thru with one of the plastic inserted nuts thats supposed to 'stay-tight'....
no problems since!!!!!!! got the car for a 'steal' because of that , too....

 

[Deejay]

Arc (stick) welding is easy.

Doing it with a cheap 'portable' set makes it difficult to strike up the arc as the 'set' hasn't got the ooomph even if you turn it up to the max (120 amp?)

Even when you get it the arc going its ony good for 3" of weld before the thermal switch cuts it out for like 20 odd minutes.

Mig is far far better

Difficult to strike up an arc,nightmare. Deffo not the kit if its your profession but all the same for the price I paid it would of been the same to have do it for me. plus i've now got a welding set to add to my armoury of tools........

 

[Deejay]

Nice work dude...how much is a 'cheap' welding kit, just out of interest?

http://www.machinemart.co.uk/ranges.asp?g=105&r=2032

 

[scrob]

This happened to me last week too, went to drop her a gear to go out round a few cars and just as I was commencing my overtaking maneouvre i was minus a clutch - whooopdey****ingdoo!

Started her in first and got her stuck into second and trundled the 15miles home at 20mph, had to negociate 6 roundabouts and a set of traffic lights at 12noon on a saturday afternoon, lovely...

Anyway got a new plastic clip and got my dad's mechanic to weld the pedal and all is almost hunky dorey, BUT....

What is the plastic censor used for above the clutch pedal? As mine is hanging loose where the mechanic forgot to put it back in place. How do I get it clipped back in as I have had a play with it and cant get any joy with it

 

[m0rk]

lame as it sounds - do they come with instructions?

 

[Stevo1]

What is the plastic censor used for above the clutch pedal? As mine is hanging loose where the mechanic forgot to put it back in place. How do I get it clipped back in as I have had a play with it and cant get any joy with it

It is the clutch sensor (to do with the DBW system), it should just push back into the hole. Such a crap design though. Is your EPC light on? Mine came on when the clutch sensor came loose

 

[scrob]

Car aint back on the road, I drove it half a mile to make sure the clutch pedal was working fine (which it is) and no light came on, but its been sitting up on axle stands ever since as I have about 4 different wee jobs going on with the car at the min.

Sensor doesnt seem to want to "push" into the hole, I could force it in but dont know how far in to put it?

Anyone fancy being a real gent and taking a very quick picture for me?

 

[Stevo1]

Ive got one, sorry for the poor quality but you get the idea.

It doesnt clip in that far, just enough to hold it in. I thought about maybe having to force it but its not necessary.

 

[scrob]

Cheers boss

 

[F2 Stu]

http://www.machinemart.co.uk/ranges.asp?g=105&r=2032

Not bad price is that, for minor repairs etc, however not ideal for making your very own replica of the Angel of the North

I wouldent bother using anything bigger than a 1.6 - 2.0 rod with that one .

 

[flashbsd]

the white swityhc doesnt push it, it threads in!

the white clip on the clutch master cylinder is a bit of a git to get onto the end of the bar, but just make sure you grease it well and use a decent set of pliars, squeeze hard too!

buy a spare just in case, i was under the impression you cant buy the clips seperatly, as they come on the end of a new clutch master cylinder?

 

[DPJ]

Not bad price is that, for minor repairs etc, however not ideal for making your very own replica of the Angel of the North

I wouldent bother using anything bigger than a 1.6 - 2.0 rod with that one .

Blimey, they're cheap Do you think they'd be any good for a really, really small replica of the Angel of the North?

 

[Carr20vt]

Help needed guys.
The clutch pedal snapped (where it secures the white plastic clip) on my mates mk3 20vt yesterday.
How do we get the pedal off.
I've released it from the pin/bar and spring but can't clear the pedal left enough to get off due to the thing for the accelerator. Cant release the accelerator thing.
Does the whole pedal box have to come out?
Please help.

 

[scrob]

We welded mine with the pedal in place, didn't like the thought of having to remove it as it looked like a complete pain in the arse. Take your seat out and it'll give you enough room to get in and weld it - just.

Keep plenty of soaking cloths nearby to put out any fires, as my carpet caught fire a few times lol.

Removal of the seat is simple - undo the small bolt at the front of the sub frame, then remove the longer bar which determines which hole the seat "clicks" into, and the spring connected to it. Remove the two bits of plastic trim on the floor around the groove for the seat runners, and simply slide the seat fully back and "out" of the floor. Oh and disconnect the airbag plug under the seat

 

[Deejay]

Help needed guys.
The clutch pedal snapped (where it secures the white plastic clip) on my mates mk3 20vt yesterday.
How do we get the pedal off.
I've released it from the pin/bar and spring but can't clear the pedal left enough to get off due to the thing for the accelerator. Cant release the accelerator thing.
Does the whole pedal box have to come out?
Please help.

took me a while to work it out but:

1) take the pin off the end of the clutch arm mechanism
2) release accelerator cable, pedal arm to accelerator dbw sensor
3) move accelerator dbw sensor from fixing plate by 2x 8mm? allen key bolts (do not unplug sensor, you don't have too)
4) remove accelerator fixing plate by 2x 12mm? bolts.
5) unplug and then unscrew the clutch sensor dbw sensor and get it out the way
6) slide the clutch pedal toward the centre of the car, away from the pivet point arm.
7) you should now have enough room and it should just come out hopefully.
8) reverse to put back but will be more difficult as the spring that pushes the clutch pedal back up will now want realigning.

hope this helps and be prepared for a very sore back

DJ

apologies if the part names^ are not correct, thought I would use poetic license instead of "big black bit with a red sticker on it!!!!"

 

[Carr20vt]

took me a while to work it out but:

1) take the pin off the end of the clutch arm mechanism
2) release accelerator cable, pedal arm to accelerator dbw sensor
3) move accelerator dbw sensor from fixing plate by 2x 8mm? allen key bolts (do not unplug sensor, you don't have too)
4) remove accelerator fixing plate by 2x 12mm? bolts.
5) unplug and then unscrew the clutch sensor dbw sensor and get it out the way
6) slide the clutch pedal toward the centre of the car, away from the pivet point arm.
7) you should now have enough room and it should just come out hopefully.
8) reverse to put back but will be more difficult as the spring that pushes the clutch pedal back up will now want realigning.

hope this helps and be prepared for a very sore back

DJ

apologies if the part names^ are not correct, thought I would use poetic license instead of "big black bit with a red sticker on it!!!!"

Cheers guys.
Above is how i went (wanted to go) about it just can't get to the back 8mm allen bolt!
Knees and elbows red raw already but had to use crap tools at the side of the road......
When the cluth pedal spring released i did think oh sh$t that will be harder to get back on.
Towed back now so will try again after work tomorrow maybe with the seat out.
Thanks again for the replies.