VW Polo 16V, 1999. How to remove pedal box? - SV650.org

MrMessy · 27-05-06, 08:02 PM

I am removing the pedal box on my wife's car to repair the clutch cable bracket that has sheared off again (common problem apparently, last done under warranty). I have undone steering column and the pedal box is unbolted, but I cannot get the brake pedal actuating rod that goes into the servo out! The rod appears to be part of the brake pedal, no clevis pin etc to undo. It will not pull out of the back of the servo and I cannot see any clips etc to undo? Has anybody any experiance of removing these? Do I have to unbolt the master cyllinder and unclip it from the engine bay side? Any help would be appreciated.

Speedy · 28-05-06, 01:05 AM

NO!

There should be a white plastic retainer that the servo push-rod clips into! They are a git to remove in situ,and infact there is a special tool for doing this!

Sometimes the retainer will stay on the push-rod,and on re-installation,it just clips back into the pedal.Otherwise,you'll have to just pop the rod back in to the retainer whilst its in the pedal itself!

Main cause of the pedal-box failing is either worn clutch,worn cable,or both!

When we change them,we add weld to the 'box as it IS weak anyway,we seam weld both sides of that part of the 'box before re-fitting them.
Also I've welded them in situ,can be done,but FIRE caution is required as the carpets and underlay/sound deadening burn easily.

Good luck,they're a pig of a job!

If you need anymore help,just ask and I'll do my best!

MrMessy · 28-05-06, 04:59 AM

Thanks Speedy,
I will have a look when I get home, seem to remember a white plastic piece but could not see behind the pedal. Was only going on feel!
I am going to weld the piece back in place and fit some strenghtening plates! A VW specialist who was going to do the job said it was a common fault on these Polo's.
Thanks for your help, upto getting stuck with the brake pedal the rest of the job was relatively straight forward.
Mr Messy

Speedy · 28-05-06, 03:52 PM

No probs!

Yeah the Polo's are a TAD easier than the SEATs that I have to work on. Mainly because of the Dash design.

Try doing one on a Lupo/Arosa! They are particularly awkward!

MrMessy · 28-05-06, 07:12 PM

Hi Speedy,
What a job, struggled with it this afternoon, but got no where! Tried to prise the whole block out but it would not move. Do you prise the "clips" open to release the arm or do you prise the whole block out? I am looking at making a tool to push the 6 "tongues" in to release the whole block. Any further advice appreciated.
Derek

27-05-06, 08:02 PM	#1
MrMessy Member Join Date: Sep 2004 Posts: 557	VW Polo 16V, 1999. How to remove pedal box? I am removing the pedal box on my wife's car to repair the clutch cable bracket that has sheared off again (common problem apparently, last done under warranty). I have undone steering column and the pedal box is unbolted, but I cannot get the brake pedal actuating rod that goes into the servo out! The rod appears to be part of the brake pedal, no clevis pin etc to undo. It will not pull out of the back of the servo and I cannot see any clips etc to undo? Has anybody any experiance of removing these? Do I have to unbolt the master cyllinder and unclip it from the engine bay side? Any help would be appreciated.

28-05-06, 04:59 AM	#3
MrMessy Member Join Date: Sep 2004 Posts: 557	polo Thanks Speedy, I will have a look when I get home, seem to remember a white plastic piece but could not see behind the pedal. Was only going on feel! I am going to weld the piece back in place and fit some strenghtening plates! A VW specialist who was going to do the job said it was a common fault on these Polo's. Thanks for your help, upto getting stuck with the brake pedal the rest of the job was relatively straight forward. Mr Messy

28-05-06, 07:12 PM	#5
MrMessy Member Join Date: Sep 2004 Posts: 557	Polo: Hi Speedy, What a job, struggled with it this afternoon, but got no where! Tried to prise the whole block out but it would not move. Do you prise the "clips" open to release the arm or do you prise the whole block out? I am looking at making a tool to push the 6 "tongues" in to release the whole block. Any further advice appreciated. Derek

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28-05-06, 01:05 AM	#2
Speedy Member Mega Poster Join Date: Apr 2006 Location: Biggin Hill,Kent Posts: 1,074	NO! There should be a white plastic retainer that the servo push-rod clips into! They are a git to remove in situ,and infact there is a special tool for doing this! Sometimes the retainer will stay on the push-rod,and on re-installation,it just clips back into the pedal.Otherwise,you'll have to just pop the rod back in to the retainer whilst its in the pedal itself! Main cause of the pedal-box failing is either worn clutch,worn cable,or both! When we change them,we add weld to the 'box as it IS weak anyway,we seam weld both sides of that part of the 'box before re-fitting them. Also I've welded them in situ,can be done,but FIRE caution is required as the carpets and underlay/sound deadening burn easily. Good luck,they're a pig of a job! If you need anymore help,just ask and I'll do my best!

28-05-06, 03:52 PM	#4
Speedy Member Mega Poster Join Date: Apr 2006 Location: Biggin Hill,Kent Posts: 1,074	No probs! Yeah the Polo's are a TAD easier than the SEATs that I have to work on. Mainly because of the Dash design. Try doing one on a Lupo/Arosa! They are particularly awkward!