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Firat

Clutch problem or pedal box?

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Firat

Hi all,

I recently bought a polo 6n2 1.4 8v with 40,000 on the clock so not been used much for its age and I'm having the following problems:

1) after a few minutes of driving, clutch pedal starts making a noise.

2) clutch is very heavy and the biting point is very high.

3) trouble selecting gear 1 mainly, other gears are normally fine. Sometimes it will suddenly get very smooth and the car drives amazing, then "it" happens and I have trouble getting into first.

I'm aware of this pedal box issue but I'm not sure if my pedal box is going, clutch pedal is at the same level as the brake pedal and as mentioned above biting point is very high, there is about 4 mm flex of the clutch pedal either side.

Could it be the clutch cable? I heard they can squeak.

Video link:

It's my first car so not sure what it could be, any insight would be greatly appreciated!

Regards

Firat

Edited by Firat

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Firat

Any ideas?

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infinitelivez

Does the clutch pedal sound like that? If so it's definitely the pedal box.

If the clutch is heavy then the pedal box will go, sooner rather than later as well.

The welds on it are just that weak.

I was/am in the same boat. I bought a 6n2 that had a heavy clutch and within a month the pedal box went. I've now fixed the pedal box but the clutch is still really stiff so I've got to change that ASAP or this new pedal box will go as well.

So your pedal box may not have gone yet but it will do if you don't the clutch sorted. Take it to a garage as soon as you can and get it checked out.

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Koop

My first Lupo had a heavy clutch & high bite, the clutch cable hadn't been set correctly when the clutch was replaced under its previous ownership. Local garage reset it for me & it was lovely after, best 20 quid I ever spent so worth looking into. Clutch release bearing is another possibility.

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Firat

Thanks for the replies, the link below takes you to a video of my clutch pedal and associated noise:

Have a look and tell me what you think

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infinitelivez
Thanks for the replies, the link below takes you to a video of my clutch pedal and associated noise:

Have a look and tell me what you think

It does sound a bit like the welds are creaking but I can't see that much movement up there. On mine the creaking was a lot louder but it does sound like the same noise. You could see the bracket bending right out when I pushed the clutch on mine as well.

Unhook the clutch cable from the pedal(loosen it off and unhook it in the engine bay first) and push it up and down, if there is no resistance/noise then you know the stiffness is coming from the actual clutch and the noise is coming from the bracket on the peddle box. I don't think a gummed up cable could cause enough resistance to break the welds on your pedal box, but you could always take the cable off and spray some spray lube down the ends of it to see if that makes any difference at all.

Firstly I would head down to a garage and get that stiff clutch sorted. It may just be the release bearing thats gone but it makes sense to get the whole thing changed while they're down there. The clutch kit will cost £70-90 and it's a 3-4 hour job. According to google the average labour rates now days are £65 an hour, so you're probably looking at roughly £350 - £450 for the kit and fitting. Shop around to try and find the best deal.

Once that's done and you have a nice light clutch your pedal box might be ok, but you'll probably need to get that done as well because if the welds are split it will go eventually and it can be pretty dangerous. That could cost you anything up to £500 to get sorted. If you wanted to try and do that yourself there are plenty of guides out there(google "polo pedal box guide"), you'll only have to pay for the parts(about £50) but it is a real pig of a job.

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Firat
Thanks for the replies, the link below takes you to a video of my clutch pedal and associated noise:

Have a look and tell me what you think

It does sound a bit like the welds are creaking but I can't see that much movement up there. On mine the creaking was a lot louder but it does sound like the same noise. You could see the bracket bending right out when I pushed the clutch on mine as well.

Unhook the clutch cable from the pedal(loosen it off and unhook it in the engine bay first) and push it up and down, if there is no resistance/noise then you know the stiffness is coming from the actual clutch and the noise is coming from the bracket on the peddle box. I don't think a gummed up cable could cause enough resistance to break the welds on your pedal box, but you could always take the cable off and spray some spray lube down the ends of it to see if that makes any difference at all.

Firstly I would head down to a garage and get that stiff clutch sorted. It may just be the release bearing thats gone but it makes sense to get the whole thing changed while they're down there. The clutch kit will cost £70-90 and it's a 3-4 hour job. According to google the average labour rates now days are £65 an hour, so you're probably looking at roughly £350 - £450 for the kit and fitting. Shop around to try and find the best deal.

Once that's done and you have a nice light clutch your pedal box might be ok, but you'll probably need to get that done as well because if the welds are split it will go eventually and it can be pretty dangerous. That could cost you anything up to £500 to get sorted. If you wanted to try and do that yourself there are plenty of guides out there(google "polo pedal box guide"), you'll only have to pay for the parts(about £50) but it is a real pig of a job.

Thanks for your input mate,

You can see in the video there is a tiny bit of flex at the moment but it isn't going to get better as you said with the heavy clutch, I got a labour quote of £240 for the clutch fitting and I'm going to get a Sachs kit from gsf for £105 (I'm assuming its sach as it says premium part) so ill get that done for £350 basically.

As I just got the car, I'm doing its timing belt and water pump (£280 all in, it's a gates kit and water pump p) at a garage in the coming week so this is going to have to wait till the end of the month unfortunately being a student and all, I just hope it doesn't get worse!!!!

Regards,

Firat

Edited by Firat

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Firat

Update:

My car is booked in for its timing belt & water pump change this coming Friday, and also getting a new clutch cable, my mechanic knew a lot about this pedal box issue surprisingly (not a vw specialist) and he told me that the pedal box replacements from vw are modified and are meant to be much better, hopefully I wount need one but its good to know that if I do it will be better!!

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Firat

Update:

New clutch cable definitely improve things, less squeaking! But clutch will be changed

Asap.

Timing belt & water pump kit installed, but I'm getting hissing noises that are dependant on rpm, sounds like its coming from the alternator - started after Cambelt change, anyone know what it could be?

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Firat

So I got the clutch kit fitted today, the garage said the friction plate was down to its rivets :o and the release bearing was extremely noisy and bad.

The clutch feels very light now and the clutch pedal doesn't make the noise anymore yay!

So I'm happy I didn't have to do the pedal box aswell!

Problem solved!

Edited by Firat

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