No clutch - Broken plastic clip.

[Speed]

Yesterday I was driving home, pressed the clutch to change gear and snap. White plastic clip broke and as result pedal went to the floor. Hopefully I can source the clip today or else I'm stuffed. Anyone else had this problem before???

[dylan8]

Yep. Common as.
It wont just be the white plastic piece (bush?) A black cover will have come off and a metal piece on the back of the clutch pedal will have broken free (this holds the white plastic piece in place)

There is a few threads on it on here.

[Speed]

Yep. Common as.
It wont just be the white plastic piece (bush?) A black cover will have come off and a metal piece on the back of the clutch pedal will have broken free (this holds the white plastic piece in place)

There is a few threads on it on here.

The metal bit that holds the white clip (bush) is still fine - still attached to the pedal and still holds white clip.
If it is ok, do I need to order anything else other than the white clip and the black cover for the switch?

Apologies but trying to get it orderred now and down 2 staff at work asnd not very good at searching on this site.

All help appreciated.

Thank you!!!

[JustCruisn]

Once the white bit breaks the pedal can go flying down to the floor and can break the pedal stop too.
http://www.vwwatercooled.com.au/forums/images/imported/2012/08/sideviewJPG-1.jpg

I have a complete master cylinder in my shed with the white plastic bit on the end. If you need the whole thing gimme a PM, you need to bleed the line after replacing that.

Great DIY with lots pics -> http://uk-mkivs.net/forums/t/430716.aspx

[dylan8]

are you sure...
because I cant see how it would break unless the metal part has broken... sure you not missing a flat plate between the white and black plastic parts... im trying to find a pic to explain.

[Speed]

are you sure...
because I cant see how it would break unless the metal part has broken... sure you not missing a flat plate between the white and black plastic parts... im trying to find a pic to explain.

I apologise, you were 100% correct. Came off so cleanly that it didn't appear broken at first glance.


Once the white bit breaks the pedal can go flying down to the floor and can break the pedal stop too.
http://www.vwwatercooled.com.au/forums/images/imported/2012/08/sideviewJPG-1.jpg

I have a complete master cylinder in my shed with the white plastic bit on the end. If you need the whole thing gimme a PM, you need to bleed the line after replacing that.

Great DIY with lots pics -> Clutch Master Cylinder DIY Replacement 1.8T Golf MK4 - uk-mkivs (http://uk-mkivs.net/forums/t/430716.aspx)

Thanks but I'm picking up a new bush and pedal today to get me going, then I'll have my current one welded up as a stronger replacement.

Thanks for your help guys, most appreciated!
:)

[dylan8]

I apologise, you were 100% correct. Came off so cleanly that it didn't appear broken at first glance.



Thanks but I'm picking up a new bush and pedal today to get me going, then I'll have my current one welded up as a stronger replacement.

Thanks for your help guys, most appreciated!
:)

all good, just didnt want you to order bits then find you need more ha!
There was some revised versions of the pedal (none that improved the broken bit... ha) I found when I installed my new one it has some sideways movement, so have to install some washers either side of the pivot point to make it stay straight, might be worth keeping a eye on that...

We welded my old one too, but the weld was too big to put the black plastic cover back on, so keep that in mind too.
Grab some pics of the broken one if you can, I should have as it seems to be happening a bit and would be a good DYI/info thread

[Speed]

Update - I managed to get the spring and pedal out easily. What I don't know how to do is get the shaft and ball into the white clip.
Was I supposed to do this before I put the pedal back in? If so how do I do it?
I used a cable tie to get me home but would like to fix it properly tonight.

I've read other peoples threads on the issue but have not found one that describes how to get my shaft in the bush..sorry couldn't resist a bad pun :)

[dylan8]

ummm, from memory put the white bush over the ball end. then put the white bush into the pedal.
Sorry I missed a few bits when we first put it back together

[JustCruisn]

The white bit is very tight. I tried just now to remove the white bit an reckon it would break if put on too much force.
I'd say you need to just drive that shaft in between the legs and push it into the hole at the end. It should be lubricated too.

[Speed]

The white bit is very tight. I tried just now to remove the white bit an reckon it would break if put on too much force.
I'd say you need to just drive that shaft in between the legs and push it into the hole at the end. It should be lubricated too.


The white bit is very tight. I tried just now to remove the white bit an reckon it would break if put on too much force.
I'd say you need to just drive that shaft in between the legs and push it into the hole at the end. It should be lubricated too.

Thanks.

At this minute I'm absolutly ropeable.
My tip for the bush (white plastic clip) into the shaft on the master cylinder: Heat a pot of water on the stove.. chuck in the white clip for about 30 seconds, pull it out and flare out the "legs" with some needle nose pliers, then repeat a 2nd or third time if necessary.
Place the legs around the shaft and spread them with your index figures (I used both - Uno what they say, two hands for beginners!)
Whilst spreading the legs, push on the back end with you thumbs until it goes click! Done!

Still can't get the fu@#ing spring on! I've tried everything.. cable tied the spring, used a screwdriver pushing on the white end of the spring.. nothing! I can't for the life of me work out how I can't get it back on when it came on and off so easily before.

I'm ready to smash everything in my immediate radius with the biggest hammer I own! Why oh why is this so fi@#ing hard to do?
I'm seriously considering pulling out the whole pedal box (disconnecting the master) to get the spring in, then just bleed the clutch.

All of this because VW used a flimsy POS sheet metal without sufficient welds.
In case you can't tell, I'm seriously pissed off.

[dylan8]

Thanks.

At this minute I'm absolutly ropeable.
My tip for the bush (white plastic clip) into the shaft on the master cylinder: Heat a pot of water on the stove.. chuck in the white clip for about 30 seconds, pull it out and flare out the "legs" with some needle nose pliers, then repeat a 2nd or third time if necessary.
Place the legs around the shaft and spread them with your index figures (I used both - Uno what they say, two hands for beginners!)
Whilst spreading the legs, push on the back end with you thumbs until it goes click! Done!

Still can't get the fu@#ing spring on! I've tried everything.. cable tied the spring, used a screwdriver pushing on the white end of the spring.. nothing! I can't for the life of me work out how I can't get it back on when it came on and off so easily before.

I'm ready to smash everything in my immediate radius with the biggest hammer I own! Why oh why is this so fi@#ing hard to do?
I'm seriously considering pulling out the whole pedal box (disconnecting the master) to get the spring in, then just bleed the clutch.

All of this because VW used a flimsy POS sheet metal without sufficient welds.
In case you can't tell, I'm seriously pissed off.

its a huge PITA man, we had my gfs dad and I in the car arranging it (yes you can get two people in the drivers side... lol)
from memory we gave up and did the spring first, and left something else loose and added that after...
even my mechanic with the tools said its a huge pain

[JustCruisn]

Its a bit tricky with the pedal box out too. I could not imagine doing it in the car.
Getting the hydraulic line off the cylinder is a little tricky, bleeding is easy enough just make sure the bleed line runs lower than the nipple.

[grtuned]

The white clip and washer need to be fitted in the clutch pedal. Attach the clutch pedal using the shaft. Then you need to press down on the clutch until you hear a click. Be careful it can all come undone if not done correctly. And you could break the plastic clip again. It's difficult if not experienced. Done a s$& load in my time.

[ntails]

Hey mate, below is a a copy and paste from a thread i started about the same issue (search "clutch peddle issues" for the whole thread). Its a little bit of a fiddly job but its pretty easy once you know how. I had to do this job twice and the second time i ended up buying the VW speciality spring compressor for $50 to make my life easier.

By the time i got home after work it was already dark so i had to undertake this lovely job with the use of a 12v light.

For anyone who is doing this for the first time, i thought i would write down a couple of points i learnt along the way.

All you will need is a cable tie, a pair of pliers, 13mm socket, and a 13mm ring spanner or shifter.

- First of all, do it in the daylight.
- Like JMAC said, tack some extra welds on your new pedel or repair the old one. This way you shouldn't have to play around with it again.
- After you have pulled the peddle out compress the clutch spring with your hands and use one cable tie to hold it. Put the cable tie in a spot you will be able to snip with some pliers when it is back in location.
- Make sure you put the white plastic piece back on the shaft that connects to the master cylinder before you put the peddle back in.

If i had known these few point i probably could have had this job wrapped up in 30mins.

Cheers

Nick

[glf455]

Not sure if this will help but may as well post it anyway. Clutch Pedal Replacement (http://www.vwgolf.net.au/showthread.php?6888-Clutch-Pedal-Replacement)

This is one I made when I did mine, I had the intention of a detailed thread but at times got pretty pissedand lost the care to document it. May help a little though if you haven't already finished.

[Wighty654]

Mine has just done the same thing, does anyone know where I can buy the necessary parts or know any part numbers for the white plastic clip, the black cover and I think ill need the metal retainer as well. I've managed to fix it temporarily by getting a small bolt through some existing holes in the pedal and drilling the broken nylon so its holding for the moment but i would like to get it fixed asap.

[eri_12]

Jacksons should stock them - it happened to me not long ago and they had the stuff I needed.