For the past two days I've had the pleasure of driving a brand new (17k on it) Golf and getting back in my old Polo (S reg) today was horrible after 400 miles in a new car!

I've got used to it by driving it every day, but essentially the top of my clutch pedal's movement would barely be at the bite point on the Golf so there isn't a lot to play with and after driving for some time (30/40 miles) it becomes difficult to shift the lower gears on my car - 1st, 2nd, 3rd. It also grinds it's way in to reverse which is something it never used to do.

I've never really had any concern for this part of the car before as it was fitted with a new clutch when I bought it so just wondering if someone could point out the problem and a possible fix?

We've got a Corsa as well which has a really conveniently positioned clutch cable that you can easily tighten - does the Polo have one as well?

You can adjust the bite point / pedal height by twisting the little wheel one the end of the clutch cable under the bonne.

If you look to the right side of the engine you will see the top of the gearbox and there will be a cable which goes to the drivers side of the bulkhead. You should also check the clutch by parking the car and pulling the handbrake all the way up donut won't move. Then select forth gear and gently ease off the clutch, if it bites straight away and wants to move off and almost stalls then it's okay. If you reach almost fully off and the car doesn't even move then it's worn down and will need to be changed. A lot of sellers will just adjust the cable and say that they changed the clutch.

Also Changing the oil in the gearbox for nice new stuff would also make a nice difference when changing gears.

HTH

Also, if the pedal is lower than the brake pedal, the pedal box has probably gone..

You can adjust the bite point / pedal height by twisting the little wheel one the end of the clutch cable under the bonne.

If you look to the right side of the engine you will see the top of the gearbox and there will be a cable which goes to the drivers side of the bulkhead. You should also check the clutch by parking the car and pulling the handbrake all the way up donut won't move. Then select forth gear and gently ease off the clutch, if it bites straight away and wants to move off and almost stalls then it's okay. If you reach almost fully off and the car doesn't even move then it's worn down and will need to be changed. A lot of sellers will just adjust the cable and say that they changed the clutch.

Also Changing the oil in the gearbox for nice new stuff would also make a nice difference when changing gears.

HTH

Donut won't move?

Yeah adjusting the clutch cable should sort you out, unless it's got an auto adjust cable (won't have the nut on the end), in which case you'll need a new one.

Lol. The donut wont move because its full of jam.

Its tHat bloody auto correct again, I really should turn it off...

donut ism't even a word.I think what I was trying to say was SO IT WON'T MOVE, haha

Edited 23 March, 201214 yr by dixy

Thanks guys I thought there'd be a similar cable to find, but the clutter of the engine bay puts an amateur like me off delving much further than the ignition cables.

Anyway, just taken a few photos first to highlight my Clutch position

And then I think I found what looks, with my limited knowledge, like the clutch cable but thats not all that accessible. Is this screw the sign of an automatic adjusting cable? Or is that the limit screw & I need to get at a bit between the two photos to make an adjustment?

Certainly doesn't look as easy as it is on our Corsa (which you can see here)

Edited 23 March, 201214 yr by Joe_90

Yeah, that's it. Don't see how that's harder than the Corsa though?..

It's even easier cause there's an actual nut you can get a spanner on, not just, pull the arm and turn the head (which will only give you so much movement)..

If you've got strong fingers, you can even turn the plastic knurled bit..

Yeah, that's it. Don't see how that's harder than the Corsa though?

Because I've got massive (clumsy) hands & theres cables & all sorts around. That area of the corsa is pretty open.

I'll have another look at it then. Thanks :)

Haha, even with chubby hands it's not too bad man. If that doesn't do it though, get on your back and look underneath the clutch pedal.

Where it joins onto the box it might have a fracture - the weld breaks and that's why it might be sitting low..

Common problem on the 6n2's.

Well comparing to my 6N2 and having experience of a failed pedal box - that's definitely what it looks like, a failed pedal box, as the last poster pretty much said. I put a bolt through mine and ran it for about 6 years like that before getting a new clutch and pedal box this year. To keep the cost down I went to Mr Clutch for the clutch and got a VW dealer to do the pedal box. I think the dealer did me a favour cos they know I'm a good customer and they did the pedal box for £150. Normal cost is anywhere from £300 to £400. Remove the underside of the dash and that might cut a bit on the labour charge. My clutch is still not quite as light as I'd like it but the only thing I can change now is the cable.

The new pedal box - although supposedly modified in both 2003 and 2007 - looks just as naff as the first. When the clutch starts to go heavy (for whatever reason - internal diaphragm springs etc) the pedal box will probably fail again. Most people in the know buy a new box (around £30 to £40 I think) and then weld it up really strong to compensate for the 3 measly spot welds.

As said already - a very common fault on this model.

Hope this helps.

Simon.