Clutch, Please help. I feel like crying.

[seanbranagh]

I took my '98 1.4 Ibiza to a local guy (who I trust) for a new clutch today because my pedal had gotten so stiff.
He said that he had gotten one like that before and it was not the clutch but the cable had pulled through the bulkhead causing it to be pulled at an angle hence the stiffness.
He said he would look and see if he could do a spot of welding. If this could not be done then the car would be scrap. Please please give me other options if this happens.
I have had this car for 3 years and I am completely in love with it compared with previous cars. It still has just less than 70k on the clock and almost a full years MOT. Absolutely no problems with it other than the clutch. I don't think I could bare to scrap this car and am not in a position to buy a replacement at the minute.
Please help!

 

[Fl@pper]

dont despair its not all that bad - loosk tidy and well cared for to me

im sure we will find a way round it

it might just be a new pedal box assy yet

 

[seanbranagh]

Thanks for the support.
Can this happen? I can only find threads that talk about the pedal box and in each case it can be fixed/strengthened. I have looked recently at mine and the part where the cable runs into from the top of the pedal does bend towards the pedal a bit when the clutch is pressed. I have circled this bit on a picture I got from Cupra Kid (I hope he does not mind.) I asumed that to be cos of the force due to the clutch being stiff. It this actually broken?

 

[seanbranagh]

I have been searching and found loads about the pedal box but no photos of how to bolt/weld this or how to fit a strengthining plate. Anyone have pictures?

 

[CraigW]

I have been searching and found loads about the pedal box but no photos of how to bolt/weld this or how to fit a strengthining plate. Anyone have pictures?

I may have some pictures of mine bolted back together. Tbh it doesnt look great because it was welded, bolted then welded again for more strength Its been like that for over a year and I havent had any further problems. I had a clutch and cable change aswell.

 

[seanbranagh]

I really don't care what it looks like as long as it holds. Going to get the clutch and cable anyway also. I did have a look at pictures from Cupra Kid but he glued his. I think I like the sound of the bolts and welds better.
I am going to phone the mechanic tomorrow (who has my car) and pass on the information. I am a little concerned that I may sound like I am telling him his job but it is my car and I want the best solution.

OK. So this is the story of my Ibiza and why I could not bare to change. I bought the car 3 years ago on a recomendation with 25K on the clock and full Seat service history. It was like the day it drove out of the factory in Spain. In the 11 years since I passed my test I have driven a range of cars, vans and a couple of bikes but upon driving the Ibiza I instantly fell in love and knew I would never spend money on any other make of car.
A couple of months later I left the car parked overnight in my local town in favour of a couple of pints. Next day when I went to collect it I found two of my doors kicked in and dents on the bonnet. Of course the police could do nothing. As it would cost more than the car was worth to fix I just done what I could and left it like that.
Since then I just gave up on looking after the car cos with the dents I did not see the point so I just kept buying petrol and driving. Only recently did I start servicing it again.
I now feel a little bad now cos of the clutch issues. I know it is riduculous but it is almost as if the car is giving up on me cos I gave up on it a couple of years ago so now I want to do everything I can to get another couple of years out of it, even with the dents. I know it is mechanically sound as it just went through the MOT with no work needing done and it still has only 70K on the clock.

 

[AlpineWhite]

Looks like you either need a new pedal box, or weld yours back together.

If you want to have a go at yours, have a look at my build thread for removal pictures (below) - mine failed in a different place but otherwise the procedure is the same.

 

[Cupra Kid]

Thanks for the support.
Can this happen? I can only find threads that talk about the pedal box and in each case it can be fixed/strengthened. I have looked recently at mine and the part where the cable runs into from the top of the pedal does bend towards the pedal a bit when the clutch is pressed. I have circled this bit on a picture I got from Cupra Kid (I hope he does not mind.) I asumed that to be cos of the force due to the clutch being stiff. It this actually broken?

Hey there, yup that bit always flexes a little even when bolted, glued, welded, its a crap design with poor support really. My glues working well (so far) but you would have to sand any paint off prior to glueing for it to hold its best.

Best solution is to buy a new pedal box, before fitting it to the car and fully reinforce it via welding and extra metal to brace that bracket circled then fit it. Oh and change the clutch cable at the same time.

I'll warn you though its an absolute bitch to swap.

 

[seanbranagh]

I will phone the mechanic tommorrow morning. He has had my car from Friday but will be looking at it tommorrow. I will pass on the suggestions and tell him to go ahead with a new clutch also. (I will change the cable myself.) He is handy with a welder so I will get him to do what he can. I could get the pedal box out myself but I am generally pushed for spare time. I am looking forward to getting this all sorted because my Mums 1.0 Nissan Micra is not doing anything for me! I know my Ibiza is only a 1.4 but at least I could overtake other cars in it!

 

[seanbranagh]

It is difficult to get to the other side of the bulkhead where the clutch cable goes through?
If this is possible would it not solve the problem by drilling through and bolting the clutch bracket to the bulkhead? Surely there would be no movement then.

 

[seanbranagh]

Spoke to my mechanic today. The pedal box was in a bit of a mess but not completely broken as the car was still driving. He attacked it with the welder in place (trying not to set fire to the car). The cable was also badly damaged due to the rubbing through the bulkhead so he has ordered one and is replacing it tommorrow. He has advised to leave the existing clutch to save expence as it still has plenty of bite on it. He said he will check how heavy it is once the new cable is in.
This is obviously a temporary fix. What I may do is order a new pedal box and have it welded up. At some point when I have a lot of time and patience I will swap it myself following Alpine Kid's very detailed and useful instructions. I do a little of my own work, servicing and such so I am happy that I could do this providing I start early in the morning with all the proper tools, a good breakfast and a cup of coffee to hand.

 

[AlpineWhite]

At some point when I have a lot of time and patience I will swap it myself following Alpine Kid's very detailed and useful instructions.

Is that a freakish combination of Cupra Kid and myself? Were there any mad scientists involved?

Good luck with the pedal box chap.

 

[seanbranagh]

Sorry, It is you. I am really bad with names.

 

[Cupra Kid]

Is that a freakish combination of Cupra Kid and myself? Were there any mad scientists involved?

Good luck with the pedal box chap.

That would be someone whose mechanically minded that likes glue! Love it!!

 

[seanbranagh]

My car is all sorted. I am picking it up about 7. Cannot wait to drive it again. The mechanic says the clutch is vastly improved with the new cable. Hopefully this fix will last at least a while. Now I just have to set Saturday morning aside to clean out the throttle body, change the air filter and fit a cold air feed as mentioned in another post.

 

[seanbranagh]

I have the car back and the clutch is like the day I bought it. Fantastic. The pedal box was split in 3 places so he welded the parts back together. He also welded the clutch bracket to the bulkhead and it is all working well. Hopefully this lasts for a while.
Nice shiny new cable also.
There is now a wirring noise when the clutch is pressed to the floor with the gearbox turning. I asume this is just the sound travelling through the cable and being amplified because it is welded to the bulkhead although I will phone him tommorrow about this.

 

[Cupra Kid]

Whirring could be the clutch bearing on the way out, nothing major. a new cable may have just pulled it a little tighter than its used to, may just have to bed back in.

 

[seanbranagh]

Three months later and one of the welds has failed. Pedal is still working but just waiting for it to go to the floor and stay there. I have a friend who is a welder and can build anything out of anything (as long as it is metal). Going to get him to look at it on Friday. Need to get a couple of months more out of it before MOT is up in August. Only 73K on the clock but at 11 years old it is not worth spending the money to keep it on the road. Hopefully I will have enough money put away by that time to pick up a second hand mark 4. Maybe a Tdi 130 if I really get my head down.

 

[truCido]

To weld it properly I think it really needs to come out so you can weld both sides....

 

[seanbranagh]

If it was going to come out I would just replace it with a new (reinforced) one. Too much work. I got 3 months out of the last weld in place and the guy that is looking at it on Friday is a much better welder. Fingers crossed.