Date: Thu, 5 Mar 2009 13:49:36 -0800
Reply-To: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Subject: Re: clutch linkage wear -photos
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reply-type=response
for Richard........
yep.............remove master cylinder......
it's an awful job. No need to remove the whole dash.
it goes like this -
instrument cluster out.
remove brake master cylinder ( disconnect hose to clutch master cylinder
first )
remove those two support brackets that pass over the master cylinder. If
they've not been touched before two of the bolts near the steering column
and bottom of the dash are anti-theft pointy round headed things........need
to overpower those and get them out. Install regular hex head bolts going
back together.
Then you can unbolt the booster and pedal assembly as a unit...........pull
it up toward you..........
then remove the booster from the pedal assembly.
Someone in there you need to get the clutch master cylinder from the pedal
assembly unbolted..
finally, you can just wiggle the pedal assembly out the top - tight fit,
but it'll come out that way.
I have also read about people removing the headlight in front of this area,
cutting an access hole, and being able to get at the clevis and pin that way
.......but I don't see how you could repair a badly worn one that way.
Have fun.
the adjustment for the clutch master cylinder push rod........the single
nastiest adjustment in a vanagon.
You need a deep 15 mm socket............like 4 or 5 inches deep. I had to
make one. - to adjust it with everything in place. The adjustment is a
struggle with the pedal assembly in place.
I think you could pre-assemble the clutch master cylinder to the pedal
assembly out of the van, and adjust free play on the clutch pedal that way
first, then install the pedal assembly into the van, and bolt up the clutch
master cylinder, with correct free play adjustment , last step.
whew.....
it's not a fun job at all, I'll tell ya !
Scott
www.turbovans.com
----- Original Message -----
From: "mark drillock" <mdrillock@COX.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Thursday, March 05, 2009 1:05 PM
Subject: Re: clutch linkage wear -photos
> Hi Rich. It has been a while since I have done it and it was a pain. I
> don't remember all the details of removing it.
>
> Welding up the hole and drilling it again has been done. You can get a
> new pedal from VW or buy it used sometimes. GoWesty sells a rebuilt
> pedal on an exchange basis and they add a bushing.
>
> http://www.gowesty.com/ec_view_details.php?id=4365&category_id=75&category_parent_id=
>
> Mark
>
> RICHARD KOERNER wrote:
>> Mark,
>>
>>
>>
>> I've got the "clinking/clunking" of the clutch pedal (85 GL with
>> 170,000 miles). The pictures explain well what is going on; I'm
>> worried about failure and want to address. I tried looking up
>> underneath with a flashlight and mirror....can't see the pin area. I
>> removed instrument cluster and tried looking down from above....still
>> can't see.
>>
>>
>>
>> This is starting to look like something beyond my skills. I reviewed
>> the Bentley and Haynes manuals. Seems you need to remove the "pedal
>> assembly", both brake and clutch, and before you do that you need to
>> remove clutch Master and brake Master. Is that correct?
>>
>>
>>
>> And, what about the fix? Yes, replacing the pin for sure, but what
>> about the pedal? Are these available? Or is this a
>> weld/grind/bore-a-new-hole job?
>>
>>
>>
>> Sounds like you've been there recently...hence your post.
>>
>>
>>
>> Rich
>>
>> 85 GL
>>
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