IMPORTANT: Brake pedal sticks after Pedal Box replacement

[morrismen]

Can you all check this as it may be affecting your own VW GTI after the Pedal Box replacement.

1. Start the engine.

2. Check the brake pedal return... With your hand, push down the pedal all the way and let go - it should spring back quickly to the top where it first started, just above the line of the clutch pedal.

3. Press down the pedal again all the way and let it off really slowly. Does it return to the top or stop half way in line with the clutch pedal? If you then nudge it or pull it slightly, does it then return above the line of the clutch pedal?

If you have have problem in 3 above, then you have the same problem I have post pedal box replacement.

As the brake pedal is not returning on soft braking, then this makes the brakes bind on and they will smoke after a while of driving, overheat and wear out the discs. It is also dangerous as it's to do with brakes - safety.

And, your petrol consumption will be doubling which is how I first noticed this problem

My VW Dealer is looking into this today. It may just be a return spring possibly, or is could be something more serious, servo?

And so I have another loan car, 1.2 Polo 3 cylinder (yorn).

[Prash]

As I think u may know I had to have the whole of the brake pedal replaced during the time they carried out the safety recall for the clutch as they broke a clip, is this what u think may have happened to u but they haven't either bothered to do anything or not noticed

[morrismen]

I don't think they broke a clip on the brake pedal. If they had, it wouldn't function correctly anyway I feel... and the reputation of this dealer is good and their engineers would have said if they'd broken a clip. They certainly would't allow their reputation to be tarnished by me driving out of the garage with a broken brake clip on the brake pedal - you'd hope no VW Dealer would allow this!

This is a more fundamental mechanical problem, like something is preventing the brake pedal returning.

Either the brake return spring is weakened or something is preventing it's return since the pedal box was fitted.

I think other GTI owners need to check their pedals function correctly as this can't be the only incidence as I'd be a 1:3500 case so the odds are against it if everyone gets their pedal box replaced!

[morrismen]

Prash, seems my GTI had the same problems as yours... the VW Dealer is replacing the whole brake pedal assembly today as the pedal was sticking down post pedal box replacement. As they consider the return spring is at fault on the brake pedal, they had to replaced the whole brake pedal assembly just as you had done.

So, as I have said previously, this is a likely consequence of the pedal box replacement and I would urge other Polo GTI owners to check their brake pedal operation as described previously, with a view to replacement if it's sticking as this is a major safety concern as well that is introduced when the Pedal box has been replaced.

[cyhliu]

Thanks for this, going to make sure that my dealer knows about this before returning tha car back to me...hopefully they won't break any more bits that are on factory back-order!

[Prash]

Hope they sorted your brake pedal out morrismen, let us know how u got on

[morrismen]

I got a brake pedal fitted in it now, but there are apparently a large number of faulty brake switches out there. (doh!)

My dealer fitted 3 and they were all faulty - each one left the brake lights on when fitted.

And when each is removed, cos they are plastic they break up.

So, it's still in the dealers awaiting a "working" brake light switch rom VW Parts.

VW Customer service are aware of this problem now as well. I told them last night.

[morrismen]

Got my car back!

After fitting in the Pedal Box and me testing it, it went back in the next day as the VW Dealer had to fit a new brake pedal (it was sticking down) and finally got some brake switches that worked and weren't faulty. Anyways, the brake pedal comes back up really quick now and nearly throws me in the back seats. (snarf)

As usual, they put it all together and the drivers side A/C pipes are not lined up under the dash and blow cold air into the dashboard instead of on my legs, and the handbrake didn't go down properly as the centre console was too far back... You'd of think they would have checked this from the last time they had the dash out.... So, I fixed these myself when I got home.

[cyhliu]

jeez...I hope mine isn't returned like that...it was perfectly alright when I took it in but they'll return it in a worser state than before? Just great!

How did you know the A/C pipes was blowing in the dash? (because it wasn't cold?).

[morrismen]

If you look under the footwell, you'll see 3 holes in the bottom dash plate above the pedals. This screws on and locates at the back into a slot. The 3 A/C vents should go through the 3 holes. It is a squeeze, but they do go through. If they don't, then the air is only cooling the inside of your dash.