Date:         Fri, 19 Jan 2001 09:53:24 -0500
Reply-To:     Tim Hannink <hanninkt@IX.NETCOM.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Tim Hannink <hanninkt@IX.NETCOM.COM>
Subject:      Vanagon Clutch Pedal Rebuild - 87 Camper
Content-Type: text/plain; charset="iso-8859-1"

I've been getting a lot of strange noises from the clutch pedal lately. I
oiled it a couple of months ago and it had been quiet. After reviewing the
Bentley and Haynes manuals, and looking in the archives, I have some
questions for the list.

The Bentley says to remove the instrument panel to remove the pedal assembly
while the Haynes says to remove the instrument panel, dashboard and steering
column. I plan on just removing the instrument panel and seeing how it goes
but would like some input about this.

I also would like to find out which parts typically need to be replaced. By
looking at the various drawings I came up with the following list:
Brake pedal bushings (2)
Clutch pedal bushings (2)
Brake pedal return spring (1)
Clutch pedal return spring (1)
Brake booster clevis, pin washer and retaining split pin
Clutch cylinder clevis, pin washer and retaining split pin
Pedal pivot shaft (1)
Pedal pivot shaft retaining clip (1)
Pedal Pivot shaft roll pin (1)

I read in the archives that the pedal pivot and clevis pin attachment points
on the pedal assembly itself can wear and need to be welded and re-drilled.
I assume that I could do the same with the pedal bracket assembly if I
needed to. The dealer said that the pedal pivot pin was 18mm x 109mm so I
would need to find a suitably sized drill bit to re-size the holes after
welding.

I stopped at the VW dealer this morning and had him check price and
availability on everything mentioned above. They said that everything but
the pedal pivot shaft was available. The clutch pedal itself was still
available for around $85.00. I could probably have a replacement pivot pin
machined if I needed to. Does the pivot pin wear or is it harder than the
other components in the assembly?

I also plan on replacing the clutch master cylinder at the same time since
the Haynes manual recommends removing it before removing the pedal assembly.
The van has 170,000 miles on it and has never had the clutch master cylinder
replaced.

TIA

Tim Hannink
Winter Park, Florida
1987 Wolfsburg Edition Westfalia Camper - "Goldibox"
http://hanninkt.home.netcom.com/