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Would just like to add to this, seeing as I have been faced with the broken pedal box issue lately. We have a 2000 SDI with 127000 miles and the pedal box went last week. I knew straight away what it was as my Mums Polo did the exact same thing a year ago. So, knowing the situation and that there was no point in chasing any dealerships, along with the costs of using a garage, I decided to tackle the job myself. After a long afternoon of swearing and agro, the pedal box is out. I am going to my mates tomorrow and we are going to weld it up around the entire bracket to strengthen it. The only thing I have bought is the plastic retainer that clips into the rear of the brake pedal (confirming what everyone else has stated about it being impossible to remove without breaking). I will also write up my method statement as it may be useful for anyone else facing this job. It's certainly helped me having all the info posted on this thread. - Disconnect battery negative terminal - 10mm nut - Remove driver seat (essential imo for work space) 2 x 13mm nuts at front center and remove 2 x plastic trim pieces that are fixed with 2 x phillips screws that are covered with blanking caps. Seat then slides back and out of the runners - Remove steering cowling and other bits of plastic interior trim to expose steering column and fuses - a hole host of torx bolts - Disconnect all electrics from steering column and tie to one side (so they dont drape in your face while you work). Pretty simple automotive connectors (one is covered in grey sponge!?) The black connector morphes into the plastic ring that surrounds the ignition barrel. I found this popped off with two small flat head screw drivers. - Ah, now the fun bit.... SHEER BOLTS!!! I never understood why car companies use these to fix steering columns. Security bull****! Anyuway, some people on here mentioned using a sharp chisel and hammer to get them off. Well, this didn't work for me. Firstly they aren't small bolts (there is a lot of metal to chisel), secondly to room you have to hammer a chisel up there is very restricted. Even if you were to chisel a flat head "slot" into the bolts, it's still a nightmare. So, I opted to drill them out. I used a corded drill and some high speed steel drill bits, building up from about 2mm up to 15mm. This was still a pain and took me a long time. You have to drill your first pilot hole exactly in the center of the bolts or the job becomes harder (trust me I know). I also trimmed a little of the plastic either side of the column (won't be seen when it's all back) so that I could get the drill up there. I found it long, hard work on my back getting metal swarf in my eyes (wear glasses) but after some persistance they fall out. To me this was the hardest bit of the removal. - Once that is done the steering column can be unbolted from the spline shaft in the footwell (covered by a piece of plastic trim with one small torx strew). Don't forget to maek with tippex the position for re-fitting, although mine actually came apart further up the joins???. The column then just pulls out. - Now it's on to the pedal box itself. I first un-bolted the clutch pedal (13mm nut) and popped it off along with the nipple adjuster on top of it. Naturally the broken piece of metal in question followed... I think there was a connector or two to remove from here also. - Now the brake pedal. If you remove to brake light switch (disconnect, twist and out) you can pull the pedal forward. Now the plastic clip that holds the pedal onto the servo rod. Yes you have to brake it, but I decided to weaken to retainers by drilling them on the left hand side using an angle/small drill. I then yanked the pedal forward and it popped off. - Finally, undo 7 x 13mm nuts to get the pedal box out (+ one or two more electrical connectors). I had to push the servo out a bit for clearance. So, thats where I'm up to. Took me ages really, though the sheer bolts really took up most of the time. Would love to know an easier way of removing them. Tomorrow Im getting it repaired and will put it all back... Hopefully in time for tea. Martin :thumbup: