Which Pedal box to go hydro?

[Naz]

Hey guys, been doing a search but cant find the bits i need.

i have been thinking about changing to a hydraulic clutch on my 98 Cordy 16v. anyone done this yet?? any that go straight in with no mods?

which pedal boxes can i use to convert? im guessing i cant go really old skool and use mk2 golf/corrado boxes?

would i be limited to mk3 golf and mk3 ibiza cupra?

cheers

 

[Fl@pper]

mk2 tdi is hydraulic but you'll need the whole pedal box + (i believe) bulkhead mods oooh and master cylinder reservoir

mk3 golf master cylinder looked the same but i only looked into using them by drilling and converting a cable box and decided as it wasn't a saturday Am bolt in job as hoped ill look at it later

slave cylinder bolts straight into the 16v mk2 + golf 3 16v/tdi box but remember the actuator rod to go with it as it's a different length to the cable one iirc but i can check later bearing in mind i've only grabbed the bits from a scrapper and had a quick look by eye so far but certainly one job i've wanted to do a long time so if i can help any gis a shout

got the bit's in the shed somewhere with an electric sunroof motor i haven't got round to yet

 

[Naz]

cheers, as its my daily driver and i do 40 miles a day to work and back, i cant take the heavy clutch sitting in traffic, just checked my pedal box as it was creaking and has been since i got it, but its been welded already and it looks like its a damn good job too, no flex and the creak isnt coming from there, so must be the cable even though thats been replaced once with a copy part.

been wanting to do go hydro but my mech isnt sure what to use as he doesnt know what the ibiza bulkhead is like? he was thinking at first we could use passat/corrado and that era.

from what i remember seeing the brake pedal bit coming from the servo is the round ball type which is the same as a ibiza 20v cupra but the master cylinder is shorter on the cupra, (i know this as we had to use a cupra mc in the mk1 caddy to clear the block as we have moved the 16v servo! a lot of work)

my brake reservoir bottle looks like a mk3 golf jobby as its got the peice sticking out which usually goes to the gearbox side but this bottle has a cap on it, not sure if thats standard or been changed though.

hmm..interesting is the electic sunroof???? did ibizas have that as an option or is that a mk3 golf or ibiza jobby? or is it just the motor you need to put in and use the mk3 golf courtesy lamp trim

 

[Fl@pper]

ideally need to get some close up pics of a Tdi + 16v bulkhead to see what goes where as i've only compared it to the Mk3 golf so far

i had always hoped I could drill out the cable bulkhead for 3 holes/plate to mount the master cylinder but realised it would still need the tdi pedal and box is listed different so may as well get a complete one out of a scrapper and see what was what from there when it was out

reservoir seemed easy enough as did the pipework and slave end fitted fine too, was tempted to weld a mount on and modify the cable pedal but knowing parts were about to bolt in is always nicer/cleaner to do

with your's being iffy would be an ideal time to look at it if there is time - saying that mine's been sat on drive for 9 months so i should have done a proper look at it myself already - sorry


sunroof you got it mk3 motor/trim as it was never electric option on a slide/tilt only the 'Air' model ruffle roof but as the manual winderbox is the same gears as the electric one i have had a motor fitted on mine - need to get the motor and roof in the exact spot for fitting as you can only get at it with it open but again another one left for summer

 

[Fl@pper]

just to note i found the listed pedal box was for Ibiza/cordoba 97-99 only

none of the VAG alternative's came up with the same pedal box number even the caddy/Inca SDI which was hydro but still a different pt number

 

[M1KEH]

Do you want close ups of my bulkhead flapper?

 

[CraigW]

The creaking you have could be the cable. I fitted a brand new pedal box back in August which was reinforced and I still get creaking. So it must be the cable as the pedal box isnt flexing or anything.

 

[Fl@pper]

Do you want close ups of my bulkhead flapper?

ooh yes please, inner pedal and outer cylinder area would be good but whatever you can manage is appreciated - cheers

*Edit

9.33 Spooooky , workshop next door just called an order through and as it's sunny i thought i'd walk it round myself instead of sitting here surfing getting fatter and greyer as usual, walk in and voila - one Cordoba Vario TDI on the ramp one camphone later ill upload some pics in a minute woohoo

 

[jenk]

A new clutch and cable does wonders, I used to hate my mk2 for the heavy clutch but on its return it came with a brand spanker and its now nearly as light as the mk4.

 

[Naz]

i changed my clutch cable last august and its been heavy and creaking since then, but was creaking before the cable changeover, im going to go for a clutch change soon (vr) and see how it goes, i think the creaking is coming from the plastic sleeve that fits on the pedal side.
until then ill have to put up with the heavy clutch!

definately interested in seeing these bulkhead differences, there was a readers ride thread by someone with a red mk2 built by midnight motors or was it a silver one, and the guy was saying how the 2 cars he converted to 1.8t with hydros had different bulkheads???

 

[roly]

If it's any help there's a pic on the 1st page of my build thread showing my modded bulkhead so i could run a hydro clutch

I've got a before pic somewhere on the laptop at home.

One thing to be wary of is the bulkheads seem to be different between models, Martin's 16v ibiza had a ridge right where we cut the hole which made fitting the master cylinder a bit more interesting, i think it's only air con models that have this ridge but with all mk2 based things this seems to be hit and miss aswell.

 

[Fl@pper]

Bang On Roly didn't even think of looking for a 20vt thread

parts wise it's a full bulkhead and lists the only differences apart from chassis being hydraulic and/or A/C also so that ties up with what you've found too