First of all ots a 6N2, 1.4 16v. I know I had another thread about the pedal box, but this is different. Does anyone know what the differences between the original pedal box, and the new revised one is?
As I'm sure mine was replaced (sheer bolts replaced with new bolts, a nut missing on the pedal box), but yet it was hard going from 5th to 4th, ground when going into reverse, clutch cable was replaced by previous owner 2 months ago, clutch pedal was lower than the rest, during the clutch pedals travel it would get "harder" half way through like it's getting caught, them free it's self up.
On removal the pedal box looked fine. From my understanding the part that breaks is the left hand side of the box, where the cable runs through. On the one on the car, it had one continious smooth weld between the little "block"? Which is what normally snaps, but on the new one it seemed to have 2 separate tack welds? I thought it was the other way (old version had the 2 tack welds)
What do people think? Of both the symptoms and the pedal boxs
Any help is much appreciated thank you
Jamie
Pedal box differences
Pedal box differences
On the original pedal boxes they were spot welded at one of the seems which when the clutch was depressed and pressure put on the spot weld the weld fractured and split. On te revised pedal boxes where there was the spot weld before which cracked on original boxes this had been replaced with a mig weld which goes the entire length of the join not just the spot which made it a heck of a lot stronger
Re: Pedal box differences
Well I picked brand new pedal box up from VW and it has 2 spot welds on the seem? The one on the car has a full one going the full length of the join other than that there identical
Pedal box differences
Take it back and ask for one with a mig weld! My original was spot welded and it went with 50k on the car. I spoke to the dealer and asked for then to reimburse me somewhat but they were having none of it but he assured me that with the mig weld the join was a lot stronger than the spot welds. It was a recall issue if you got it early enough they'd do it for nothing
Re: Pedal box differences
The thing is I might stick with the pedal box that's on the car. It seems it was all in my head as the pedal box is fine. And it has the thorough mig weld, looks much stronger than the part VW mugged me off for. I think it was changed before as both sheer bolts had normal bolts in it, and one of the nuts was missing off the bulkhead. Only thing is, what do you think of these symptoms?
Slight squeak (think iv traced it down to the cable rubbing on the bulkhead as the correct size grommet was never replaced by the last tool and they just left a massive ne near the hole, but not filling it)
Clutch pedal was lower than the brake pedal, and had a bit of play where you could "lift?" the pedal up, and nothing cutchwise would change
Was hard dropping from 5th to 4th at times (at reasonable speeds too!)
Reverse some times grinds as if I haven't got the clutch down, but in fact it's fully deprressed
During the pedals travel, about half way the pedal gets stiffer, as if it was snagging on something, then abruptly release, again could this be part of the grommet issue?, would explain the snagging)
ALSO, just to add more confusion, we played around with the adjustment of the cable when releasing it to change the pedal box, and that seemed to take away the lowness of the pedal, and the play in moving it (as in it was solid, you couldn't lift it) but didn't try anything else. Could that be the problem (along with the rubbing/snagging cable) and iv wasted 60odd quid?
Sorry Iv asked s**t loads, I kmow little about cable clutches, and this whole pedal box rubbish. If you could reply Id appreciate it so much, might even buy you a beer If I ever meet you!!!
Slight squeak (think iv traced it down to the cable rubbing on the bulkhead as the correct size grommet was never replaced by the last tool and they just left a massive ne near the hole, but not filling it)
Clutch pedal was lower than the brake pedal, and had a bit of play where you could "lift?" the pedal up, and nothing cutchwise would change
Was hard dropping from 5th to 4th at times (at reasonable speeds too!)
Reverse some times grinds as if I haven't got the clutch down, but in fact it's fully deprressed
During the pedals travel, about half way the pedal gets stiffer, as if it was snagging on something, then abruptly release, again could this be part of the grommet issue?, would explain the snagging)
ALSO, just to add more confusion, we played around with the adjustment of the cable when releasing it to change the pedal box, and that seemed to take away the lowness of the pedal, and the play in moving it (as in it was solid, you couldn't lift it) but didn't try anything else. Could that be the problem (along with the rubbing/snagging cable) and iv wasted 60odd quid?
Sorry Iv asked s**t loads, I kmow little about cable clutches, and this whole pedal box rubbish. If you could reply Id appreciate it so much, might even buy you a beer If I ever meet you!!!
Pedal box differences
Ah yeah they are pedal box symptoms but can also like you said be cable issues. Don't wanna scare the ahit out of you but I've also had to have gearbox replaced in mine. I'd say from the symptoms though sounds like adjustment of the cable needed doing, the reverse gear crunch is fairly common anyway due to how the synchro in the gearbox works also problems changing gear sometimes. If you have trouble changing down a gear release Tw clutch back put in neutral and pop it back down to change. Aurally sorts it, pedal boxes have gone up mine was only £40 last year.
If there's no sign of a crack on the pedal box definitely keep the one on there now keep the new for spare
If there's no sign of a crack on the pedal box definitely keep the one on there now keep the new for spare
Re: Pedal box differences
Yeah gearbox is something that is plaguing me to be honest.. No whining just yet though! I'm gonna put it all back again tomorrow with the decent welded pedal box and play with the adjustment, hope that does sort it... Thanks a lot for your help mate, youve actually been invaluable
Quick question actually, how the f**k do you put these brake clips back on?! The one the servo clips on to haha (yeh I did but a new one)
Quick question actually, how the f**k do you put these brake clips back on?! The one the servo clips on to haha (yeh I did but a new one)
Pedal box differences
Couldn't tell you on that I'm afraid mate 
you mean the one for the servo pipe??
You'll know of the gearbox goes I lost 1st 3rd and 5th :p but there were no real signs of it going till one day that was it
you mean the one for the servo pipe?? You'll know of the gearbox goes I lost 1st 3rd and 5th :p but there were no real signs of it going till one day that was it
Re: Pedal box differences
Yeah that's the one cheers anyway bud.
Ah that sounds assuring, definetlly as I just found tons of oil on my air box.... And I'm hearing Alot of people saying piston rings! Haha
Ah that sounds assuring, definetlly as I just found tons of oil on my air box.... And I'm hearing Alot of people saying piston rings! Haha
Re: Pedal box differences
Another problem came up today....
Everything is bolted up, pedals on and connected, go to put the steering column back in and now the holes at the top(where shear bolts go) don't line up? Can get one to line up but the other doesn't and it Looks like the column is coming at a different angle. What would cause the problem? The bolts are all tight on the pedal box, I took them all out and I even when I clip the column on to the box, i can get the holes to Iine at the top. Should I do the top bolts up so that the holes should be lined up?
Everything is bolted up, pedals on and connected, go to put the steering column back in and now the holes at the top(where shear bolts go) don't line up? Can get one to line up but the other doesn't and it Looks like the column is coming at a different angle. What would cause the problem? The bolts are all tight on the pedal box, I took them all out and I even when I clip the column on to the box, i can get the holes to Iine at the top. Should I do the top bolts up so that the holes should be lined up?
Pedal box differences
In response to the servo pipe mine didn't even have clips. And this was such a long time ago I can't remember about lining up just take it apart and put it back together again :p make sure you readjust the brake switch properly too 
Re: Pedal box differences
What you mean adjust the switch :O? So that it's touching the pedal?
Pedal box differences
Yeah so that when the pedal is raised it is depressing the switch slightly, then you press it releases complicated stuff this ruined mine because I didn't adjust it correctly and brake lights were stuck on
Re: Pedal box differences
Well we didn't know how to adjust it, for some reason it couldn't rech the pedal? Haha
Pedal box differences
Might be broken then :p they're £8 from vw when you twist it to take it out the springs released you then put it back on he hole for it release te pedal and then twist to lock it set