Further to the plea for help regarding my little clutch problem, I've fixed it and here is
the how-to.
Note:- This How-to would be of benefit if you ever need to remove your clutch master
cylinder, as during my forum(s) search I noticed that a master cylinder failure is quite
common. Apart from the hydraulic side of the operation, most of the work is in the drivers
footwell and would be as follows. The master cylinder retaining nuts look like they are
accessed from the footwell side.
Anyway, my problem was that I was driving home, Wifey & Kids in the car.... went to change
gear, pushed the clutch pedal in and "BANG".... No clutch.
The above piccy shows what went bang (I used this piccy in my initial cry for help so please ignor the bit that asks if there's another clip).
The above piccy shows the broken pedal insitu prior to me removing it. Note:- The white clip
I refer to was never found..... it probably went boing and could be currently anywhere in the
footwell area... no doubt resting somewhere where it'll either rattle or cause some other
horrid problem.
To remove pedal (assumes you know a bit about 'cars' and how they work etc..... even so, this
IS NOT A NICE JOB.... A real fiddle):-
1, Remove lower trim from footwell area.
2, Release over centre spring. I used a long screwdriver and pushed on the white nylon end
piece until the spring popped out. There are some handy little recesses on the white bit that
will prevent your screwdriver slipping off.
3, Undo and remove the pivot nut and then wriggle out the bolt. (note I say wriggle as it
hits the steering column on it's way out.... it's fiddly but it does come out. Further Note
:- I fitted the bolt from the other side to avoid this problem on re-assembly).
4, If your master cylinder pushrod is still in position, you will now have to release it. The
ball is held in place by a white nylon holder..... press in the tags to release it. (see
piccy)
Above piccy shows my 'repaired' pedal and the location of the 'tags' that you need to press
in to release the master cylinder pushrod.
The above piccy shows how things are laid out in the car.
Refitting........
5, Fit new pushrod ball carrier to pushrod (65p from VW !!) I fiddled and swore for a while
but eventually managed to fit it with needle-nosed pliers. It will 'click' in place and will
NOT come off again if you've done it right.
6, Struggle to put pedal back in car.....Engauge pushrod / carrier into box section on pedal
first before you put the pivot bolt back in (remember bolt from the other side....)
7, .......Now the tricky part, the over centre spring. Can't explain it to well in text but
look at the piccies below. Where it fits you'll know from when you took it out. This is the
toughest part of the whole procedure, it took me ages. (If you do use the cable tie method,
remember to cut them to release the spring AND BE CAREFUL !
JOB DONE !!!
I got.....
Frustrated
'Sore' fingers
Carpet burns on my elbows...... Ooo-err (you'll understand if you have to do this)
Hope this helps if you ever need it.
Good luck