Pedal Box information

[AlpineWhite]

Hi all, (and please bear with me on this one!)

As you might have read, my pedal box broke the other day . I'd like to fix it myself to save paying a garage to do it.

obviously the steering wheel needs to come off, and I need to disconnect the battery so that i don't set off the airbag.

but when i come to reconnect the battery, will the alarm go off? I know it did when i changed the battery on my polo 6n.

the problem is, my alarm is not very co-operative. the key won't sync to the car (i've tried many a time). at the minute i lock/ unlock the car by the passengers door, which doesn't activate the alarm (the drivers side does).

if the alarm goes off when i reconnect the battery, how do i turn it off? I've only got the door/ignition fob for the car.

hope you can help!

cheers
anthony

 

[Brummy]

is it just the weld seam broken ? if so cant you do what I did on my old one and drill both sections, where they overlay each other and put a lock bolt through ?

 

[AlpineWhite]

i haven't had a good look at it yet mate - i will tomorrow when it's a bit lighter.

the pedal is really spongy for the first couple of inches of travel. after that it's the usual stiffness but quite creaky. i'm assuming it's the pedal box that's broken.

can you describe what i'm looking for a bit better?

 

[Dolly_Gti]

i thinking the nut and bolt idea is my kind of idea... save alot of messing about even if its tempry or whatever

 

[AlpineWhite]

yeah, sounds good to me, will be having a good look at it tomorrow.

 

[Brummy]

did my old one about two years ago.. its STILL working now and i sold the car on seven months ago!!

 

[AlpineWhite]

awesome, so it's a fairly good fix then.

what am i looking for, when i get my head under the pedals tomorrow?

 

[Brummy]

if I remember correctly the 'plates' should over lay.. lyou need to do (if its just the spot welds that have come undone , like on my one) is relign them, clamp them, then drill a hole through the both parts.. once done, put a lock bolt through and tighten.. one I used was just one of the ones with the plastic inside the nut and Hey Presto..

 

[AlpineWhite]

cool, self locking nuts then. cheers fella, here's hoping the spot welds have failed.

 

[ibiza_95]

yea i did mine with a bolt aswell

also, probably best if you change your clutch cable too, you can get them off ebay for 20 pounds, itll just be a bit lighter and stop pulling on the joint as much

 

[AlpineWhite]

ok well i've had a look. it looks like a metal bracket that was welded to the main assembly has broken off.

it had one small weld at the side and what looked like two spot welds at the back.

i think it could be drilled, but what's the best way to get the two pieces together? Do i need to disconnect the clutch cable first to release the tension? Because at the minute I can't pull the two pieces of bracketry together to clamp em.

thanks
anthony

 

[AlpineWhite]

brummy, ibiza_95,

is this what you had too?

i've disconnected the cable so that the pedal is no longer under tension.

looks like i can now clamp it (G clamp or mole grips - what did you use?) and get drilling when i get my grubby mits on a friends drill.

 

[ibiza_95]

i cant really tell whats going on in that photo, but ive just taken 2 of what mine failed at so you can see on yours if its a bit clearer, i lightened them too so you can see the parts a bit better...

The bolt goes through 2 metal plates...

EDIT...
Now looking at your photos its easier to see with the pics i took, that it is the same bit thats broken, and you need to be drilling where youve noted 2 failing welds next to each other...

It might be worth pointing out that if you can, buy an allen key head grade 12 bolt, as my bracket snapped before i bought the car so already had a bolt through it... but the head sheared off that, hence why i needed to do it again.

 

[AlpineWhite]

awesome, thanks for that.

yep your pics are a bit better! not the easiest place to take a photo.

may the drilling commence, will let you know how i get on

 

[Brummy]

sorry fella, just got in from work.. hope it went well for and the drilling. its a pain in the ass thing as you kinda have to set yourself at a wierd angle ...

 

[AlpineWhite]

well i've got a slight problem in that i don't have a drill So i'll have to wait until tomorrow or maybe monday to get my grubby mits on one

doesn't look tooo bad, but i see what you mean about being at a funny angle. I took the drivers seat out which helps a bit.

 

[Fl@pper]

mine actually snapped across the top so i stripped it and welded it

added a brace on the outside too

as for your alarm - use the door lock - should turn it on and off anyway

 

[AlpineWhite]

well i've now drilled the hole and put an m4 grade 12 allen head bolt in. Ended up rounding the head off.... so i take it that's tight enough.....

yet to do a test drive, i've been double parked . It feels ok just pushing on the pedal though.

thanks to everyone in this thread for your help and pics.