Hi,

Took the bite up in my clutch a good few weeks ago and recently it felt sort of weird. The clutch started to get really squeaky and then today it sounded like something snapped when I put the clutch pedal down to the floor. I managed to get the car home, just. Car wont select at all now. Popped the bonnet and seen that this metal part the clutch cable is attached to is bent and split in a bit.

Here are some pictures:

Any suggestions for fix?

Edited 14 June, 201214 yr by davidelliott294

I cant quite tell what your trying to show us there?

Common problem on 6n2's is the pedal box breaking a weld. Stick your head in the footwell and give the pedal box a good waggle.

Another one I've had in the past is the actuall clutch fork snapping inside the bell housing. Get someone to sit inside and press move the clutch up and down and see where your cable is pulling.

If you dont quite now your mechanics take it to a garage so they can diagnose.

I cant quite tell what your trying to show us there?

Common problem on 6n2's is the pedal box breaking a weld. Stick your head in the footwell and give the pedal box a good waggle.

Another one I've had in the past is the actuall clutch fork snapping inside the bell housing. Get someone to sit inside and press move the clutch up and down and see where your cable is pulling.

If you dont quite now your mechanics take it to a garage so they can diagnose.

After coming in for 10 minutes and giving myself time to chill I went back out, had a look in the drivers foot area and there was a piece of metal sitting there. Gave the clutch pedal a bit of movement and it seems that the weld has snapped on it. The photos I've uploaded show that the metal part holding the clutch cable seems to have bent, not sure if it was like this before though..

If weld has broken on the pedal box its terribly common..

Good news, an entire pedal box and bolts needed is/was under £40 from the dealer, bad news is, its a pita to do yourself but I got quotes of 2-500 to fit it, managed to get a random to do it for me under £70.

Is a few good DIY guides about to do it, but recommend removing drivers seat if you do.

If weld has broken on the pedal box its terribly common..

Good news, an entire pedal box and bolts needed is/was under £40 from the dealer, bad news is, its a pita to do yourself but I got quotes of 2-500 to fit it, managed to get a random to do it for me under £70.

Is a few good DIY guides about to do it, but recommend removing drivers seat if you do.

Me and my Dad will be doing it, I'm a student and don't have that sort of money lol. We do everything ourselves. Was thinking that myself, drivers seat will need to come out to make life easier. What part of the pedal box is it that snaps?

The clutch lever is meant to look like that see this

The clutch lever is meant to look like that see this

Ah right, cheers. That's fine then if it's meant to have a slight bent in it. I'm able to select 5th gear and reverse grinds like a bitch. Definitely pedal box then?

If weld has broken on the pedal box its terribly common..

Good news, an entire pedal box and bolts needed is/was under £40 from the dealer, bad news is, its a pita to do yourself but I got quotes of 2-500 to fit it, managed to get a random to do it for me under £70.

Is a few good DIY guides about to do it, but recommend removing drivers seat if you do.

Me and my Dad will be doing it, I'm a student and don't have that sort of money lol. We do everything ourselves. Was thinking that myself, drivers seat will need to come out to make life easier. What part of the pedal box is it that snaps?

What breaks is the top left next to the clutch pedal IIRC. It's down to a design fault so its weaker thus in a crash it collapses instead of crushing your feet in a crash but when the clutch gets heavier it puts too much force on the weld and it breaks...

You can "bodge" it in situ if you got a welder but its not advisable.

Just confirm that the pedal box is broke before you rip it out tho.

It's not THAT hard to do, but it's time consuming.

You're supposed to drill out the snap bolts but I couldn't get them to go, just disassembled the adjuster on the steering column itself (the bit that lets it go up and down) and bend a little tab of metal to wiggle it out.

It's all 13mm bolts, but you'll have scratched arms, a lot of swearing and shouting but it will go.. About 3 hours to get it out when I'd never done it before, total amateur at this point.

Allow yourself a day, and find someone with a welder!

It's not THAT hard to do, but it's time consuming.

You're supposed to drill out the snap bolts but I couldn't get them to go, just disassembled the adjuster on the steering column itself (the bit that lets it go up and down) and bend a little tab of metal to wiggle it out.

It's all 13mm bolts, but you'll have scratched arms, a lot of swearing and shouting but it will go.. About 3 hours to get it out when I'd never done it before, total amateur at this point.

Allow yourself a day, and find someone with a welder!

When you bend these little metal tabs can you bend them back without breaking them? What parts did you order?

My Dad is a welder and we have a welder lol.

http://s1244.photobucket.com/albums/gg576/...t=VIDEO0024.mp4 - clutch pedal springs back a little?

If your biting point moves a lot, if your clutch pedal isn't level with brake pedal and you're finding bits in your footwell you'll be looking at a pedal box failure methinks

I just bodged the old one, but a new one is like 40 apparently.

It's a common fault, just a new pedal box.

Yes, they'll go back in. :)

If your biting point moves a lot, if your clutch pedal isn't level with brake pedal and you're finding bits in your footwell you'll be looking at a pedal box failure methinks

Biting point never moved but they clutch pedal no longer sits at the same level as the brake pedal. As seen in the video, the clutch pedal comes up a little on it's on.

I just bodged the old one, but a new one is like 40 apparently.

It's a common fault, just a new pedal box.

Yes, they'll go back in. :)

What do you mean by bodged the old one?

So I technically could get away with spending nothing as I can have my dad weld the pedal box back together?

Edited 14 June, 201214 yr by davidelliott294

I thought you altered the biting point?

You could trait for free, the new ones have the issue sorted tho

I thought you altered the biting point?

You could trait for free, the new ones have the issue sorted tho

I altered it because I couldn't put it in gear unless the pedal was put right to the floor. I'm pretty skint right now so I think i'll just have it welded. Is there a how to on ClubPolo? I had a search but couldn't find any how to topics, just topics like these hmm.

There's a huge thread on club lupo, think its a sticky in one of the sections. Lotsa people showing what they did throughout it, just need to flick thru the pages.

Just had a look and sadly the repair guide pictures are dead links. Here are the links so if this thread comes up in the future people don't have to go searching for these topics.

http://forums.clublupo.co.uk/index.php?sho...%2Bpedal+%2Bbox

http://forums.clublupo.co.uk/index.php?sho...%2Bpedal+%2Bbox

It should be right at the top left of the metal frame methiks.

It should be right at the top left of the metal frame methiks.

If you were look up at the pedal box?

Yip, by the clutch pedal, hence why its only that pedal that gets affected

Cheers for your help lads! Hopefully get started on it tonight.

I managed to get it to engage but with great difficulty. I stick it in fifth rev it slightly to move forward and it doesn't stall..? To me that's a clutch failure symptom. Is this the pedal box or the clutch?

Edited 14 June, 201214 yr by davidelliott294

So uhmmm.. yeah:

Managed to get a weld in without removing the steering column. Seems to have worked, will know for definite in the next few days. Hopefully it's suffice. Feels pretty good to drive now .