Remember, I've just had a NEW clutch cable fitted too!THE Polo GTi Pedal Box Thread
Clutch cold
Have noticed that when the car is cold (left for a few days unstarted), then the clutch and /or cable takes at least 5 miles to warm up! This means that in the initial 5 miles, the clutch feels stiff and this makes if more difficult to engage gears. Once it's warmed up, the clutch pedal moves easier and gear changes are better too Remember, I've just had a NEW clutch cable fitted too!
Remember, I've just had a NEW clutch cable fitted too!Me too now!
OK, I went out at lunch time and noticed that when came back from shopping, I started the car and tried to engage reverse - it would not go into reverse gear!
So, back into neutral, I took my foot off the clutch and re-engaged the clutch again and reverse gear went in, but it made a slight crunch.
This is the first time this has happened to me.
Now, the only thing I can think of is that the clutch is not engaged properly (it's sticking).
Even though I've had a new clutch cable and I know the clutch lever is working on the gearbox side from testing this at the VW dealers, I think the clutch plates or pressure plate or release bearing are not working all the time as expected.
I think I need to tighten up the clutch cable another few turns of the nut again too now as the clutch pedal has dropped slightly again since having the new clutch cable fitted 1 week go.
So, back into neutral, I took my foot off the clutch and re-engaged the clutch again and reverse gear went in, but it made a slight crunch.
This is the first time this has happened to me.
Now, the only thing I can think of is that the clutch is not engaged properly (it's sticking).
Even though I've had a new clutch cable and I know the clutch lever is working on the gearbox side from testing this at the VW dealers, I think the clutch plates or pressure plate or release bearing are not working all the time as expected.
I think I need to tighten up the clutch cable another few turns of the nut again too now as the clutch pedal has dropped slightly again since having the new clutch cable fitted 1 week go.
Clutch and Pedal Box issues
There are a number of issues with this clutch mechanism which affects the gear box.
1. The clutch cable is too long
2. The cable to bent to far when coming out of the bulk head. This means the cable will start to fray or catch inside the shealth as it wears on the crease created by the excessive bending of it where it comes out of the bulk head.
3. The spring dampening on the cable/clutch lever is insufficient and in effective as the adjustment on the cable (engine end at gearbox clutch lever end) has to be wound in to get any decent leverage on the clutch pedal.
4. The pedal box breaks when trying to re-fit a clutch cable. This is a known problem - the plastic is not sufficiently strong enough for the manual clutch mechanism on the Polo GTI. Note: This may be fine for the hydraulic clutch on other models though.
5. The pedal box breaks whilst using the breaks, clutch in normal operation due to plastic failure and possibly due to the adjustment needed to bring the clutch pedal up off the floor - there is not dampening and therefore excessive strain is placed on the pedal box.
This is dangerous and needs to be addressed as a safety issue with VW engineering.
6. The clutch plates or release bearing appear to seize. This is particularly noticable when starting the VW GTI from cold after letting it stand for 48 hours. Evidence of this can be seen when the clutch seems to be particularly difficult to engage initially when selecting 1st gear after leaving the car standing for this amount of time.
7. These issues make it difficult to engage gears. This means the gearbox is suffering from increased wear and tear.
Recommendations: VW look into this and review the following:
1. the length of clutch cable and spring strength for dampening.
2. the routing of the cable (attached to the bulk head) as this causes it so bend excessively
3. Review why the clutch seizes after 48 hours standing - this may be related to the cable dampening.
4. Review the whole VW pedal box, clutch cable and clutch assembly.
5. Recall and Renew VW Polo GTI pedal boxes with metal (or similar)rather than the weak plastic fittings currently used.
1. The clutch cable is too long
2. The cable to bent to far when coming out of the bulk head. This means the cable will start to fray or catch inside the shealth as it wears on the crease created by the excessive bending of it where it comes out of the bulk head.
3. The spring dampening on the cable/clutch lever is insufficient and in effective as the adjustment on the cable (engine end at gearbox clutch lever end) has to be wound in to get any decent leverage on the clutch pedal.
4. The pedal box breaks when trying to re-fit a clutch cable. This is a known problem - the plastic is not sufficiently strong enough for the manual clutch mechanism on the Polo GTI. Note: This may be fine for the hydraulic clutch on other models though.
5. The pedal box breaks whilst using the breaks, clutch in normal operation due to plastic failure and possibly due to the adjustment needed to bring the clutch pedal up off the floor - there is not dampening and therefore excessive strain is placed on the pedal box.
This is dangerous and needs to be addressed as a safety issue with VW engineering.
6. The clutch plates or release bearing appear to seize. This is particularly noticable when starting the VW GTI from cold after letting it stand for 48 hours. Evidence of this can be seen when the clutch seems to be particularly difficult to engage initially when selecting 1st gear after leaving the car standing for this amount of time.
7. These issues make it difficult to engage gears. This means the gearbox is suffering from increased wear and tear.
Recommendations: VW look into this and review the following:
1. the length of clutch cable and spring strength for dampening.
2. the routing of the cable (attached to the bulk head) as this causes it so bend excessively
3. Review why the clutch seizes after 48 hours standing - this may be related to the cable dampening.
4. Review the whole VW pedal box, clutch cable and clutch assembly.
5. Recall and Renew VW Polo GTI pedal boxes with metal (or similar)rather than the weak plastic fittings currently used.
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nothin2lose
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SimonCorrigan
- Bronze Member
- Posts: 166
- Joined: Fri Feb 06, 2004 1:53 pm
- Location: Surrey, UK
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pedal box
had the pedal box replaced - now the clutch pedal is so stiff its very difficult to change gear. the car has been backwards and forwards to colbournes for them to sort it and the only explaination is that is needs a new clutch! have quoted me over £500 to do it. the car is still under warranty but its not worth the paper its written on as they seem to escape ever paying up using the `wear and tear' clause. won't be extending it again. also took them forever to replace the pedal box. not impressed vw - due a company car in august and its not looking like it will be a vw or audi - which is a shame as the polo gti is a laugh to drive.
See the letter thread
You may find you need a new clutch cable.
And, make sure the clutch cable is adjusted so that there is 1/4 inch play on the pedal. This takes the stiffness ou of the clutch mechanism and stops it jittering when you depress the pedal.
And, make sure the clutch cable is adjusted so that there is 1/4 inch play on the pedal. This takes the stiffness ou of the clutch mechanism and stops it jittering when you depress the pedal.
i've had my pedal box swapped now for some time and have found the clutch is becoming gradually worse, i've recently had a new clutch cable because the clutch was so heavy it wore through the rubber grommet on the guide (welded to the gearbox as you look into the engine bay)
i've been quoted £500+ for a new VAG clutch - which i've been told is only reconditioned!!!
Volkspeed in derby have told me that the problem is the 'diaphragm' on the clutch is too hard and this is putting too much pressure on the pedal box causing it to break... thus by fitting a stronger pedal box VW are moving the problem to another area (where they can use the 'wear and tear' clause)
as the car is a W plate where do you guys think i'd stand taking it to a dealers and asking for them to replace the clutch due to a manufaturers fault????
anybody else been told this?
cheers
scott
i've been quoted £500+ for a new VAG clutch - which i've been told is only reconditioned!!!
Volkspeed in derby have told me that the problem is the 'diaphragm' on the clutch is too hard and this is putting too much pressure on the pedal box causing it to break... thus by fitting a stronger pedal box VW are moving the problem to another area (where they can use the 'wear and tear' clause)
as the car is a W plate where do you guys think i'd stand taking it to a dealers and asking for them to replace the clutch due to a manufaturers fault????
anybody else been told this?
cheers
scott
Exactly the same for me only this week. I was informed by the stealer that the pedal box had been replaced earlier in the year by the previous owner and that the stiffness of the clutch operation was due to the clutch requiring replacement at £450 at a not very reasonable 50k. My Corrado is 0n 120k still on the original clutch and exhaust. Who says that VW build quality has improved 
You can get a GTI clutch fro GS&F for £69 +vat so I'll get my local mechanic to fit saving ££££££££'s 
My main dealer also denied that GTI alloys have corrosion problems.
You can get a GTI clutch fro GS&F for £69 +vat so I'll get my local mechanic to fit saving ££££££££'s My main dealer also denied that GTI alloys have corrosion problems.
i ended up taking mine to the guys at volkspeed and cost £300 inc. VAT and they fitted a sachs clutch so it was brand new not recon like the stealers!
i saw the old clutch and the guys explained the pressure plate was at fault and the wear was really uneven, still had fairly deep grooves in some places but other spots had worn right through the friction material!!
cheap valeo spanish parts to blame!!!!
i saw the old clutch and the guys explained the pressure plate was at fault and the wear was really uneven, still had fairly deep grooves in some places but other spots had worn right through the friction material!!
cheap valeo spanish parts to blame!!!!
ha i've been walking round with my left leg stronger than the other for months! lol
the new clutch is feather light, its never been like that in the 7 months i've had it!! gear selection is less sloppy and notchy and the bite is more precise, feels like the power feeds in straight away rather than more gradual if that makes sense...
the new clutch is feather light, its never been like that in the 7 months i've had it!! gear selection is less sloppy and notchy and the bite is more precise, feels like the power feeds in straight away rather than more gradual if that makes sense...