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The definitive Pedal Box Thread

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Pretty sure the two odd brackets are not vw , they look like the dual control linkages used on learner driver cars

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Hi there club lupo users i was just wondering would this problem be fixed at any vw dealer or will i have to find which dealer my lupo was originally purchased from ? I would like to address this problem before it totally packs in on me.

many thanks sam

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Hi there club lupo users i was just wondering would this problem be fixed at any vw dealer or will i have to find which dealer my lupo was originally purchased from ? I would like to address this problem before it totally packs in on me.

many thanks sam

Maybe if you get a time machine . . . . . . .

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After 117k miles of gear changes and what not, my pedal box started creaking last month. At first, I thought it was just the clutch cable, but it turns out I too, was suffering from the pedal box issue. Anyway, they can be welded, but I decided to buy a new one instead. I think welding it is a good shout but you should see the quality of a new one compared to the old one. Far better quality metal, and just better made on the whole. Less flexing. Makes you wonder why VW didn't put that kind of quality into the original design. Anyway, I've been told the new pedal boxes are designed to last over a million miles so should be okay. Here's hoping :D

I've got some photos I'll put them up tomorrow :)

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Guys,

In my opinion, dont get it welded. I am now £200 lighter, it cracked with in two days of getting it welded. Got it welded again and cracked within 3 days. Cant get my under goodwill because it is too old. Im gonna change the pedal box myself. Just trying to work out the best technique to get the shear bolts out! wish me luck!

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Guys,

In my opinion, dont get it welded. I am now £200 lighter, it cracked with in two days of getting it welded. Got it welded again and cracked within 3 days. Cant get my under goodwill because it is too old. Im gonna change the pedal box myself. Just trying to work out the best technique to get the shear bolts out! wish me luck!

It's the hardest part of the job. Drilling them is really the only way.

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It's the hardest part of the job. Drilling them is really the only way.

So do you drill directly where the centre of the bolt head would of been? Do you have any more info on this, ie, technique, drills type and sizes? Thanks.

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So do you drill directly where the centre of the bolt head would of been? Do you have any more info on this, ie, technique, drills type and sizes? Thanks.

Can't remember sizes. Yes, drill the centre head of the bolt and then work your way out, eventually they sort of crumble and fall out. You need to be careful not to use a drill bit too big though. Just be patient and work from the inside out if you get me. They took a fairly long time to get off, so don't be put off if it takes you more than an hour, even two.

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hi :wave:

i run a company called clutch and gearbox in wolverhampton and we keep the pedal box kits in stock

we can supply and fit a new modified pedal box,new shear bolts and brake cylinder locking clip for 120 pounds all in

we offer a while you wait service if neccesary and the job takes around 2 hrs to complete

for anymore info/advice please call 07854 07854 9 or http://www.clutchandgearbox.webs.com

thanks for looking

Edited by clutchandgearbox

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hi :wave:

i run a company called clutch and gearbox in wolverhampton and we keep the pedal box kits in stock

we can supply and fit a new modified pedal box,new shear bolts and brake cylinder locking clip for 120 pounds all in

we offer a while you wait service if neccesary and the job takes around 2 hrs to complete

for anymore info/advice please call 07854 07854 9 or http://www.clutchandgearbox.webs.com

thanks for looking

Is this OEM? If so that is bloody cheap £120!!!

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I've been known to install repaired pedalboxes for £60.

I don't replace the brake pedal clip, I don't install shearbolts and I have a personal record of around 40 minutes.

Drilling shearbolts takes too long, I couldn't be arsed going that route.

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I've been known to install repaired pedalboxes for £60.

I don't replace the brake pedal clip, I don't install shearbolts and I have a personal record of around 40 minutes.

Drilling shearbolts takes too long, I couldn't be arsed going that route.

I wish I hadn't put new shearbolts in hindsight. Total waste of ****ing time.

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I wish I hadn't put new shearbolts in hindsight. Total waste of ****ing time.

Yup.

I did a repair on one about three weeks ago where some idiot hadn't repositioned the bracket and had just welded it bent, idiot had still installed some shear bolts.

That was five minutes I won't get back.

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I had my pedal box done roughly 3 to 4 years ago along with a new clutch and gearbox rebuild to boot. The beginning of december my clutch cable snapped and ever since replacing it, the change hasn't been right. It was ok for all of a few days and now after a little while of driving it just gets harder to get into gear. Could this be the cable needs adjusting? there is obviously the thread and 2 nuts to adjust. Or could it be a pedal box again? Pretty sure the new pedal box would have been a revised one. Just after some advice before throwing more money at a 16 year old 115000 mile lupo which to be fair isn't worth that much any more. Was going to get the clutch done as was told the springs were weak and worn but the clutch 3 to 4 years ago has covered less than 40k.

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Hardly ever posted on here but just want to say a big Thank You to Alex @alex1916v and Martin @Phatbwoy  (+ Sir smudge) on here for giving me the confidence to get on with it - have some health/memory issues so to see someone took the trouble to describe the work that's needed is invaluable to me :)

Edited by pond

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1 hour ago, pond said:

Hardly ever posted on here but just want to say a big Thank You to Alex @alex1916v and Martin @Phatbwoy  (+ Sir smudge) on here for giving me the confidence to get on with it - have some health/memory issues so to see someone took the trouble to describe the work that's needed is invaluable to me :)

pond, any tips for others on here. I should have taken more photos than I did, and it's now too long ago that I can remember much of anything :D

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 Alex and Martin said most of it Skezza in page 6 and 8 of this thread I think? Just about to start drilling as big drift and sledgehammer wouldn't shift shear bolts. Used to do them on Fiat/Lancia all the time but those were easy/i was much younger :rolleyes:

Edited by pond

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Ahh, sheer bolts as I said, you need drill them. Start with a smallish piece and work out. It took me ages, but Rich probably has a better solution than me

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all finished now, thanks again to all the helpful posters :) I left the fuse box and the main one-piece dash panel in place but this did make it hard to locate new pedalbox without damaging anything. I found this the most difficult part after removing the shear bolts of course. The brake light switch is a separate case of it's own of course as many already know. I cant believe the stupidity shown here in converting something that was once the simplest item to fit on a car to something so complicated. I hope there is a thread on this Forum to explain this in full but meanwhile - if you can't remove the switch without force then get advice on here. Basically, you need to depress the plunger while swivelling to remove but there are at least two designs now and not sure how this might differ.

Edited by pond

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Hi. I've posted the below reply I got from the DVSA regarding pedal box issues (in my case a 2000 Polo MK3) for interest. I bought the car at 49K (2 prev owners), and at around 55500 miles the pedal box went. Apparently the DVSA have investigated this fault before and found that it doesn't count as a safety defect because it doesn't fail completely in one go on the cars with a lower spec than the GTI that got the recall. Frankly I find the penultimate sentence in the letter to be just plain wrong 'It was therefore determined that the driver would receive sufficient warning of  the issue before it affected the operation of the clutch and gear selection.' Simply not true, the first time it breaks, there's absolutely no warning at all, none! So how is that safe?! If the driver is used to one biting point and the clutch pedal suddenly drops as mine did then you aren't going to push it down far enough & therefore won't be able to change gear until you realise what on earth's happened. Draw your own conclusions, but I'm of the opinion it's clearly a design fault and VW should have done a much better job designing it to last (which would also mean I wouldn't be down £400). From what I can tell looking on the VAG part finder it's the same part that failed on the GTI, but it's been deemed safe by the DVSA on all versions but the GTI. When I was dealing with them I just got excuses similar to those on the first page of this thread, and no admission that there was any issue with the design. Not impressed with VW.

ReplyfromDVSA.jpg

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amusingly the gti and tdi suffer a different clutch pedal fault

 

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I thought all polos were eligible for the recall.... I know quite a few people and have read online a lot of times how they had it done for free. I'd like to have my 2nd SDI sorted too, but it's not creaking yet. Anyone know a cheap place to buy a new pedal box? Vw quoted me £112 plus vat just for the box!

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just weld a reinforcing bracket and start swapping it out.

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