Pedal Cluster Removal?

Destructo · Posted: Wed May 30, 2012 8:43 am Post subject: Pedal Cluster Removal?

So I'm in the middle of my Auto to Manual transmission swap and I have everything transfered over to the new van, except for the clutch/brake pedal cluster. Here's an idea of where I'm at.

Image may have been reduced in size. Click image to view fullscreen.

btw, I stole this shot from ben, but this is exactly what I'm looking at now in my van.

The bentley doesn't do a great job at explaining how to remove these Items. I was hoping to remove the booster, master cylinders, resevoir and pedals all together. Is this possible? Any help is much appreciated. Once we figure this out, I'll take some pictures of the process.
_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

r39o · Posted: Wed May 30, 2012 10:03 am Post subject:

Unless you have the front windshield out, I do not think you can get all that stuff out at once.

If you lift it all out at once it will likely still drip. The fluid is nasty. Eats paint and stains carpet.

The booster is held in place with 4 nuts. Both masters are held in place with 2 fasteners each.

I would take it apart, but leave the pedals in place, if possible. Peddles are best done in a vise. Under the dash is not pleasant.
_________________
"Use the SEARCH, Luke" But first visit the Vanagon FAQ!

1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....

Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently)

Destructo · Posted: Wed May 30, 2012 10:35 am Post subject:

So here is my plan then.

1. Remove Brake Master Cylinder with resevoir still connected.
2. Remove Booster
3. Remove Clutch Master Cylinder
4. Remove Pedal Cluster

So how hard is it to remove the pedal cluster? Am I going in from the top once the Booster is out of the way? Boy do I have some fun ahead of me this evening.
_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

D Clymer · Posted: Wed May 30, 2012 11:10 am Post subject:

I saw your PM to me, but I'm really slammed today, so I thought I would just answer your question on here. It is possible to remove the pedal assembly with the booster and reservoir still attached. I just did this recently on my Subaru transmission conversion. I unbolted the brake master cylinder from the booster and left all the brake lines attached. The pedal assembly and booster can be pulled upwards to remove. You have to get things just right, but the pedals will fit between the crash member and the front of the van. The windshield does not have to be out of the van for this to work.

Let me know if I can answer any other questions.

David

squeegee_boy · Posted: Wed May 30, 2012 11:51 am Post subject:

Take the pedal pads off to buy yourself an extra couple of mm.

Robyn
_________________
1984 FrankenSyncro Westy. EJ25 RMW kit
1971 Super Beetle with an EJ22. Oh yes. Daily driver

FrankenSubySyncro · Posted: Wed May 30, 2012 4:11 pm Post subject:

X2 on not removing the windshield. I did this when converting to a syncro. Remove the booster and the pedal assembly comes out from the top, it took many tries to get it in the right position so it would come out. Twist and turn it till you hit the sweet spot.
_________________
Syncronize it!
1987 Franken Syncro (converted 2WD auto)
2004 2.5 SOHC Subaru
F & R lockers, decoupler, SS, 6.17 R&P
Trans Cooler
EMPI race prepped 930 CVs and axles
Bilstein coilover front, rear ProComp MX-6066R shocks, 14" hypercoil springs
30x9.5 15" BFG Muds
Custom skid plates
Nose job (custom front bumper) http://www.flickr.com/photos/subyvanagon/sets/72157624970330925/

Syncroincity · Posted: Wed May 30, 2012 4:57 pm Post subject:

Have a drip tray handy when you do this. I was rudely suprised by about a half quart of ancient brake fluid pouring out of the vacuum hose hole of the booster can... remove or shift the carpet before you start.

Two hyd lines on the brake cylinder, one down below on the clutch cylinder.

+1 on taking off the pedal pads, it does help.
_________________
'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

edgood1 · Posted: Wed May 30, 2012 6:15 pm Post subject:

on a somewhat related question.. can one remove/replace the brake master cylinder without the need to bleed the clutch? it seems possible if you just drain the reservoir and not the line going to the clutch master....
_________________
1987 Syncro Westfalia powered by Subaru
1963 Panel to Deluxe Bus project :::: (photo album)
'65 Westfalia

Destructo · Posted: Thu May 31, 2012 8:49 am Post subject:

Destructo · Posted: Thu May 31, 2012 9:08 am Post subject:

Okay, so that was way easier than I expected! Surprised

First I removed the two support bars that run across the whole assembly from the windshield to the steering column. These are the ones that the sheer bolts hold onto. This will make the two bolts under the booster easier to get at.
Then I took off the four 13mm bolts that surround the booster. Two up top and two below.
Next I disconnected the clutch feed line from the reservoir, the two hard lines connected to the brake master, the wiring connected to the brake master and finally the clutch master exit line.
After all that I just tilted the booster towards me and with a little twist here and there the whole thing came out!!
Thanks for the tip on taking off the pedal pads first, I can see now how they would hinder the process. I'll post a couple pictures later tonight for some visual stimuli.
Right now I'm a little vexed concerning the clutch master line. It looks as if I'm going to have to build a new one since the connections under the van are all corroded and keep me from bringing it up through the floor. I was thinking about having a hydraulic shop make me a line with flex hose, but that may be unnecessary.
So next up is getting this all into the other van and seeing if it works, but I think I'll post the results in my other post
http://www.thesamba.com/vw/forum/viewtopic.php?t=502804&highlight=tale+westies
_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

Ahwahnee · Posted: Thu May 31, 2012 9:50 am Post subject:

I haven't done this (but it's fascinating reading)... but if I had those pedals out & on the bench I would check for wear/slop where the clevis pins fit -- if the hole in the pedal arm is ovalled it can be welded and re-drilled for better action (and the clevis replaced of course).

More details + pics in this thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=500810&highlight=clevis

Destructo · Posted: Thu May 31, 2012 12:54 pm Post subject:

You're right there with me Ahwahnee! Before this project started, I was feeling the clutch pedel flop around on me, ever so slightly. So I'm gonna check that clevis pin for sure. Cool

_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

Syncroincity · Posted: Thu May 31, 2012 8:50 pm Post subject:

Time to grease it up too, my pedal axle was bone dry and getting polished. I flipped the axle over and drove the keeper pin thru to the other side.
_________________
'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

Destructo · Posted: Fri Jun 01, 2012 7:50 am Post subject:

Just because people like pictures...

Here's what I started with; dash out, cross members removed. You can see one of the 4 bolt holes above the booster that needs to be removed.

In this one I'm pointing to one of the lower bolt holes under the booster. I had to use two extensions on my ratchet to get in there.

After removing the fluid lines, booster vacuum line, and brake master wire connectors; all I had to do was tilt it away from the windshield and up and out!

Here's the whole unit after removal

_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

bryguth · Posted: Thu Jun 21, 2012 1:28 pm Post subject:

Quick question... did you have to disassemble the peddle assembly/brake booster before it would come out of the van? I am having a hard time getting the unit out without taking it apart....

Destructo · Posted: Thu Jun 21, 2012 3:23 pm Post subject:

Nope, no need to take it apart. Just remember to take off the pedal pads as they can get hung up. When I did this I remember I had to tilt it toward myself, lift the whole unit, twist/rock it back and forth, side to side, drop it back down a little and try again. the pedals just need to clear through the small opening. Keep at it and you'll get it. Cool

_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

bryguth · Posted: Thu Jun 21, 2012 8:22 pm Post subject:

Took a break and installed a new stainless RMW coolant exchange tower, then got back to the brake booster/peddle assembly....rock it that way, this way, pull, push and pop I got it out!!!! Thanks for the encouragement and technical support!!!!

Cheers
Bryan

vanagon1991 · Posted: Mon Jun 08, 2015 2:45 am Post subject:

OK...tbis is an old post but I have leaky clutch cylinder too and can't for sure find where the leak is coming from. i have the whole dash and heater blower off now anyways to replace motor. Might as well pull clutch/brake assembly and replace master cylinder. I need to add clutch spacer anyways because of smallcar conversion and its a pain to get too.

Thanks for the write up and pics. Not a mechanic but you gave me the confidence to do it.
_________________
1991 Tornado Red Vanagon Carat
(2003 Subaru 2.5 conversion/Smallcar kit)

Destructo · Posted: Mon Jun 08, 2015 10:51 am Post subject:

Whoah!! Blast from the post past!! I forget that there was a time where I was neck deep in Vanagon projects. I'm happy this post still serves it's purpose as a helper for those neck deep in their own projects.
Good luck and post here if you have any more problems or questions regarding this procedure.
_________________
1985 Wolfsburg Edition Westfalia Camper Bostig conversion

Dude, where's your van?

vanagon1991 · Posted: Mon Jun 08, 2015 11:28 am Post subject:

Thanks...will post update. I'm in spring grove IL!!
_________________
1991 Tornado Red Vanagon Carat
(2003 Subaru 2.5 conversion/Smallcar kit)


Hello! Log in or Register \| Help \| Donate \| Buy Shirts	See all banner ads \| Advertise on TheSamba.com

	Forum Index -> Vanagon	All times are Mountain Standard Time/Pacific Daylight Savings Time Page: 1, 2 Next
Page 1 of 2