VW Clutch Help!

[67BAJA]

Busted my clutch pedal/assembly this weekend out at Ocotillo. I am trying to figure out what this thing should look like, so I can decide to replace the pedal assembly or fabricate/weld something to replace the broken piece.

I attached some pictures of the assembly. The piece that broke is the piece that attaches to the shaft that runs to the clutch pedal. This piece sits in the tunnel, and attaches to what feels like a ring on the end of the clucth cable.

Should there be a hook or something at the end?
Does anybody have a picture or can give me a detailed description of how this piece should look/work (I own a Bentley book, but cannot find the darn thing anywhere)?

Thanks for the help.
*Edit: Can't upload pictures for some reason. I will upload them tomorrow morning at work!

[dislocated1]

There should be a hook at the end of the clutch shaft that goes in the tunnel. The easiest fix that I can suggest is slap another used pedal assembly in there. Let me know if you need a pedal assembly I have a few early and late model pedals floating around, they are yours if you need them

[NIKAL]

Eather three things have happend. 1 there is a pin on bottom of the clutch pedal that holds the pedal to the shaft. I have seen those pins sheer before. Easy to figure out. Follow the clutch pedal down to where it meets the assembly, wipe of any dirt or greese and look for a roll pin. If the pin doesn't look broke then you will have to unbolt the pedal assembly from the tunnel (2 bolts). Once you have the pedals out of the car look at the part that goes in the tunnel. You should see a hook that the clutch cable was hooked to. (You should have had to pull the cable off the hook when pulling the pedals out of the tunnel). If it is not there it has then sheered off. I've seen them break also. Go to your local VW/offroad shop, you can buy and replace the shaft. Buy a new pin for the clutch pedal as you will have to knock the old one out to remove the shaft. 3rd thing it could be is you broke a clutch cable. Once you have the pedals out you will be able to pull the cable right out. You will be able to tell if the cable is broke right away. Best deal is to bring the pedal assembly with you to the shop and they will be able to get you everything you will need to fix it. Also you should just put a new cable in as you will aready have it all apart. The parts are pretty cheep also.
Another thing to consider is carring a spare clutch cable. It makes for a long day in the desert with a broken clutch.

[67BAJA]

Well I tried to upload the pictures this morning, and same thing. I guess I won't be able to show the pictures.

Does anybody have a picture of what this hook should look like? I think I may just fabricated another one, and make it a little thicker than the stock one.

[BURLY]

Well I tried to upload the pictures this morning, and same thing. I guess I won't be able to show the pictures.

Does anybody have a picture of what this hook should look like? I think I may just fabricated another one, and make it a little thicker than the stock one.
Hey, Erik you can use the end of an open end wrench cut off and welded to the end of the shaft for the hook for the cable to attach to, Man you break alot of stuff!!!lol

[Ryan_P]

Erik, I think it's those new bypasses in the rear and the smooth body up front, better dampening(sp?) so that means you are driving faster/harder! lol

It's hard to get a visual, with a picture it would help a ton. You can't just use a frame clamp of some sort, like the use when routing wires front the front of the vehicle to the rear along the frame? Picture below.

-Ryan

http://www.boatersworld.com/graphics/boatersworld/products/199326489.jpg

[67BAJA]

Hey Burly thanks for the advise! I didn't break it, it was the ringer we hired to race our car. It must have cracked last lap of the MORE race and finally came apart this weekend.

[shrek]

There should be a hook at the end of the clutch shaft that goes in the tunnel. The easiest fix that I can suggest is slap another used pedal assembly in there. Let me know if you need a pedal assembly I have a few early and late model pedals floating around, they are yours if you need them


You can always count on some good solid VW advise from any representative from Phelan!!!

Shrek

[DMSRACE]

You can always count on some good solid VW advise from any representative from Phelan!!!

Shrek


And have the spare parts to give away!!!

[baja_driver]

Well I tried to upload the pictures this morning, and same thing. I guess I won't be able to show the pictures.

Does anybody have a picture of what this hook should look like? I think I may just fabricated another one, and make it a little thicker than the stock one.
its probably cheaper to replace the part(the hook assembley NIKAL explainned)..other wise you will not have the correct surface contact with the cable and possible to keep breaking cable at the loop where it attaches. cheap parts at any junk yard also.

[Racbaja]

Just a piece of advice, cut an opening on the opposite side of the tunnel to access the cable and to inspect for future use, it beats the hell out of taking the entire assemble off.
www.bajacoalition.net

[WannaB-class5]

First off listen to Racbaja....it took me 2 hours doing it by myself and it sucks anyway. It wont be that bad with your girlfriend helping, just have her hold the clutch cable when you hook it! Anyway here is what it looks like. If you want the pedals in the picture they are yours.... Just an old stock set, don't know what year.

[WannaB-class5]

Oh and what the heck are you doing in Ocotillo Wells at the end of June? Weather.com says it had a high of 108!!!! Those Parker pumpers do that much????!!!

[67BAJA]

No the weather was perfect!!! It got a little hot Sunday (low 90's) but Saturday night was the perfect temperature for cruising.



Oh and what the heck are you doing in Ocotillo Wells at the end of June? Weather.com says it had a high of 108!!!! Those Parker pumpers do that much????!!!

[67BAJA]

Crap!! I need to figure out the alignment now!

I went and bought a new shaft and tab from a local vw shop. The shaft on my assembly was welded onto the pedal (to avoid shearing the pin I guess), so I cut the broken tab off. I cut the new tab off as well, and I am going to weld the new tab onto the old shaft. I marked the alignment, but I am now second guessing myself.

Wanna-Be-Class5: about how many degrees offset is the center of the tab to the center of the clutch pedal, and in which direction counter clockwise or clockwise? As mine sits now, they both are about dead on, is this right?

I will try to upload a picture again, and see if it works this time.

[67BAJA]

I painted the hook yellow so it stood out against the red clutch pedal.

Looking at your pictures above, I can't tell if that is the brake pedal or clutch pedal lined up.

Thanks!!

[WannaB-class5]

Erik, that looks SUPER close. If I had to get crazy exact I would say move it counter clockwise like 1 or 2* but it can't make a difference. I just looked at mine for like 5 min now to be sure! Wouldn't want you missing the buggy meet up in a few weeks due to you crashing cause your clutch didn't work or something! Good luck.

PahlM

[67BAJA]

Haha, Thanks Pahl. Thanks everybody for the help, I think I should be rolling by 8:00pm tonight :)