Help with Clutch Pedal...stays stuck down, freeplay...

[Selsk]

Hi Guys,

I'm having a problem with my clutch pedal on my 87 GL. It began with a creaking and now the pedal stays stuck down about 1/2 the times I press it. I then have to pull it back up with my toe, and this makes driving "inconvenient".

I'm in Los Angeles and I first took it to Bela's Foreign Auto Repair in Burbank. Bela is an awesome guy and he's 80+ years old, still working on VW's! He knows exactly what the problem is, and told me what a PITA it is to fix. I guess there is a linkage that is tucked away up under the dash and is extremely difficult to get to. He said he had to use a mirror to work on it and that he also cut a chunk out of the body, next to the headlights to get to the area. He showed me the part, and what needs to be done...but he cant work on my van anytime soon. He's backed up for at least a month.

Ok, so I then took my gorgeous van to Santa Monica. Westside Independent VW Repair. I've had Layne so some work for me in the past. I tried to explain to him what Bela had shown/told me. Well, Layne said he had never heard of a problem like mine in 20 years on the job. He figured it might be the slave cylinder...but shouldn't be a problem. Fast forward to a few hours and Layne calls me an tells me he is "going to walk away from this one". I guess they were at it for a few hours and there is just no way to get to the area...just like Bela said.

I apologize for the rambling story. Basically I need to get this fixed as it is currently my only vehicle. If anyone knows anyone in the Los Angeles area that can fix this crazy problem for me, please let me know. I would gladly pay any of you other samba members if you are mechanically inclined!

I appreciate the help.

[davideric9]

this is a known issue, clutch pedal bracket has worn into an oval. Pedal assembly must be removed, hole welded up and then redrilled. I've done it myself, not sure why your guys can't do this.

See this thread for details:
Clutch pedal replacement in 1/2 hour! (Pics)

_________________
1987 Syncro Westfalia, stock (bought 1994)
1986 Syncro Westfalia SVX, 3 knob (bought 2008)
1987 Westfalia (bought 2010)
1988 Wolfsburg GL (bought 2012)

[AndyBees]

I've been dealing with a very similar issue with my 84.

Back in 2012 when I was installing the TDI engine, I also did a lot of other work to the Van.

So, I pulled the dash to access the clutch and brake master cylinders for replacement. While in there, I pulled the entire brake/clutch pedal assembly to see why the brake pedal kept hanging....... mostly near the top!

Anyway, I polished the big pin for the brake pedal, greased and re-installed everything.... fast forward a couple of years and the darn thing commenced doing the same thing. I added an extra spring which seemed to help for a while.

Since I have the separate brake switch for the TDI ECU for cruise control, the brake pedal needs to come all the way to the adjustment set... it's a real bummer.

Anyway, the big job is pulling the dash to access all that stuff. The brake and clutch master cylinders have to be pulled as part of the procedure. Removing the dash involves complete removal of the steering column too. It's a good idea to remove the gear shift for additional working space. You'll be dealing with a lot of wiring... mostly just a PITA. The heater controls can drive you nuts... it's really a job that needs to be done where there is plenty of light.

Seems cutting a hole to get to the mechanisms would be okay. However, knowing exactly where to cut would be extremely important........ and, how big, etc.

Hope is helps....
_________________
'84 Vanagon Tin-top, ALH TDI, two trips to Alaska, 2014 & 16. 1989 Tin-top unmolested.
1983 Air-cool, 225k miles, 180k miles mine, seven trips to Alaska from 1986 thru 2003. 1975 Bay hopeful.

[pomfritz]

Go Westy sells a replacement clutch pedal as well as a kit to fix the ovaled hole, (just came out today as. new release)

Course the dash needs to come out, this is a project for me soon
_________________
83.5 265K. 1.8T, Power steering and AC from SAH. Almost like driving a modern car now. My German Frau named her Stefi

[Ahwahnee]

[Selsk]

Wow! Thanks for all the responses guys! What a huge help. I'm very happy with you internet saviors. I'm going to have a look at that new GoWesty clutch pedal as I think that will be easier for me rather than welding and drilling. But also...what the hell is wrong with my mechanics?

If anyone knows a good one in the LA area please do let me know!

Thanks again! Happy driving.

[Selsk]

Thanks again for the suggestions and the links. I managed to complete my pedal swap yesterday. I have to say it was one of the more difficult mechanical things I've ever done. Right from the start I was about to give up. Constant reference to this board helped me one step at a time. I'm a tall guy and my hands are quite large so it was so difficult to even catch a glimpse of what I was working on. Removing the front seat and laying on my back with my head pushing in the pedal was key for me to be able to get both hands up under there. Was definitely extremely satisfying to finally get the new pedal in. Motivated me to tackle more projects (and there is a long list!) rather than paying someone a very high hourly wage.

Thank you all!

[dobryan]

Great job! I understand the difficulties you encountered. I am 6'4" so getting on my back under the pedals was a challenge and my experience was very challenging but rewarding. 😀😀
_________________
Dave O
'87 Westy w/ 2010 Subaru EJ25 (Vanaru) and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

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[alaskadan]

Yeah thats got feel good. My list of mechanical things to be fixed/rebuilt grows shorter and this is one thing ive been avoiding. The slop in clutch pedal reminds me of it though. Good work.

[davideric9]

Can you post a picture of the worn clutch pedal you removed? Love to see it.
_________________
1987 Syncro Westfalia, stock (bought 1994)
1986 Syncro Westfalia SVX, 3 knob (bought 2008)
1987 Westfalia (bought 2010)
1988 Wolfsburg GL (bought 2012)

[Selsk]

It looks like I did this repair right before I was stranded.
I'm a little sad that I didn't adjust the rod length that goes into the cylinder.
Once I put everything together I felt that there is still about 1/2" of freeplay. But at least it feels 100% better than before...and if I ever want to brave it again I am now an expert.