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Sun Dec 06, 2015 11:05 am

Heard and felt "pop" when putting car into neutral, clutch pedal fell all the way to the floor and just flops. I've taken the rear tire off and was loosening the wingnut for the cable, but the cable doesn't seem to be the problem--it can't easily be pulled out from the rear, which is the instruction I read from Rob & Dave.

I see a lot of posts here by people frustrated with their broken return springs, having a hard time installing new ones...however, I don't see anyone referencing their clutch going all the way to the floor. Does this symptom tell me anything?[/u]

Sun Dec 06, 2015 11:17 am

Look at the pedal end, most likely a broken/worn eyelet on the cable.

Sun Dec 06, 2015 11:43 am

And there's no way to see that without removing the pedal cluster, right?

EDIT: I can't see the clutch shaft, and http://noslocars.blogspot.com/2013/12/replacing-vw-bugs-clutch-cable-and.htm tells me I have to loosen the throttle cable at the carburetor, then remove the pedal cluster, to see that shaft...that all sounds correct. But Rob and Dave (who I have historically trusted) say nothing about either of those steps.

Sun Dec 06, 2015 11:47 am

Pretty much.

Sun Dec 06, 2015 12:03 pm

diderooy wrote: the cable doesn't seem to be the problem--it can't easily be pulled out from the rear, which is the instruction I read from Rob & Dave.

If you can pull more than like 6 inches through the rear, that means the cable eyelet at the front has broken, because that is way too big to fit inside the clutch tube inside the floor tunnel. Typically one removes a clutch cable through the pedal hole.

diderooy wrote: I see a lot of posts here by people frustrated with their broken return springs, having a hard time installing new ones...however, I don't see anyone referencing their clutch going all the way to the floor. Does this symptom tell me anything?

Yes the lever return spring on the transmission is a big hassle to replace (do a Search if interested) but that does NOT sound like your issue, based on the cable information you have supplied.

Clutch pedal going to the floor most likely due to:
1. broken clutch cable
2. broken clutch pedal itself
3. broken off hook on the part of the shaft inside the tunnel
4. broken clutch tube welds inside the tunnel

I've had 1, 2, and 4 happen to me, and #3 hook was once worn almost all the way down, look in my gallery and you'll find a photo of that.

I'm betting on #1 for you since you say you can pull the clutch cable rearward. I just disconnect the accelerator cable at the pedal side. Yes, there is a brake spring you'll need to disconnect, maybe take some photos for yourself as a guide since it sounds like you haven't done this before.

You'll guide a new greased cable into the hidden tube inside the tunnel with your left hand, don't forget the twist tie or rubber band trick to hold the cable eye on the clutch hook for the reinstallation step.

Sun Dec 06, 2015 12:06 pm

Or you can use a hole saw to make an access port, then you can peek in there and lubricate once or twice a year. Once the carpet is in you'll never know.

Sun Dec 06, 2015 12:11 pm

Be ready to replace the clutch pedal shaft in case it is worn.

This style is highly recommended on this site. I bought one for my bug but haven't installed it yet. If (and when) mine breaks I will be glad I have it on hand.

http://www.thesamba.com/vw/classifieds/detail.php?id=1087010

Sun Dec 06, 2015 12:28 pm

Zundfolge1432 wrote: Or you can use a hole saw to make an access port,

I've never actually cut an access port in my tunnel. Are you saying that any hole saw designed for metal cutting will be enough ? Or is something special required?

Sun Dec 06, 2015 12:46 pm

The hole saw idea is absolutely genius. That means you don't even really need to remove the pedal assembly to install a cable if it does break... may be a bit fidgety but I bet it is possible. One time of cutting and if you lose your cable in the middle of a drive at 2 am and you carry a spare cable (everyone should) it can be replaced in way less time than it takes to take the assembly out... AND you don't risk dropping the clutch pedal and having the cable fall off the hook... I say its a win win. Doesn't look like that hole compromises the structural rigidity of the tunnel either.

I can't imagine a hole saw wouldn't get the job done. (if It is for metal.)

-Frank

Sun Dec 06, 2015 12:50 pm

mikeonthebike wrote: Be ready to replace the clutch pedal shaft in case it is worn.

This style is highly recommended on this site. I bought one for my bug but haven't installed it yet. If (and when) mine breaks I will be glad I have it on hand.

http://www.thesamba.com/vw/classifieds/detail.php?id=1087010

I used one of these when I rebuilt my pedal cluster. Do not have much time on it yet but it seems to be light years ahead of the hook. It operates so much smoother now. Although that could have to do with cleaning and lubing everything.

Sun Dec 06, 2015 1:14 pm

Frank Bassman wrote: The hole saw idea is absolutely genius. That means you don't even really need to remove the pedal assembly to install a cable if it does break... may be a bit fidgety but I bet it is possible. One time of cutting and if you lose your cable in the middle of a drive at 2 am and you carry a spare cable (everyone should) it can be replaced in way less time than it takes to take the assembly out... AND you don't risk dropping the clutch pedal and having the cable fall off the hook... I say its a win win. Doesn't look like that hole compromises the structural rigidity of the tunnel either.

I can't imagine a hole saw wouldn't get the job done. (if It is for metal.)

-Frank

Thanks but I'm not the genius that came up with this, I saw it as a tech article back around 1990 from VW trends. The saw is easily obtained from any big box retailer, lowes. Use with a pilot to get started and prevent wobbling. Notice it's back a few inches and up from the floor. I've never seen the mod cause any problems with structural integrity but its also quite possible to cut a modified u shape and fold up for service then fold down when done. As I said this wasn't my idea there are probably shit loads of cars running around out in California with this mod done. Speaking of structural integrity I've seen tunnel cut in three places to install a clutch cable guide tube when making autostik car a four speed. Here's some pics to get an idea. Sorry Steve but there's still an interest in this procedure.

Sun Dec 06, 2015 2:07 pm

Removing the pedal cluster isn't that difficult. I purchased the bearing-style shaft from Uniqueparts (now called Custom bugs, or something like that) and the shaft was perfectly machined in every respect.

Removing the cluster and clutch shaft allows for you to clean years of old dry grease. Then you re-grease where the shaft goes through the cluster, and clutching is like the car was brand new.

I also greased the new clutch-pedal bearing really well--sides, inside the eye--all around and over the brass barrel bearing.

No squeaks, ultra smooth operation. What more could you ask?

Tim