On Thu, Mar 5, 2009 at 8:55 AM, mark drillock <mdrillock@cox.net> wrote:
> http://images.thesamba.com/vw/gallery/pix/530767.jpg
>
> http://images.thesamba.com/vw/gallery/pix/530766.jpg
>
> If you have clutch problems you may want to consider this as a possible
> factor. The clutch pedal has a short linkage between it and the clutch
> master cylinder. This linkage connects to a hole in the pedal lever and
> that hole can suffer extreme wear. So can the pin that goes in the hole.
> Eventually the hole can wear into a long oval and break through
> entirely. The 2 levers in the photos are both from 100,000+ mile
> Vanagons. The pin on the right is a new one for comparison. When the
> wear occurs you lose some of the travel of the clutch cylinders since
> the pedal will move a ways before it does anything. You can likely
> detect the wear if you push the clutch pedal with your hand. Right at
> the top of the travel you may feel a clicking or clunking as the pedal
> moves in the wear gap.
>

When I rebuilt stuff behind the dash, I found that hole in my clutch
pedal had worn a lot, but not all the way through. Just to show that
it's possible to do at home, here's how I repaired it:

http://tubaneil.googlepages.com/clutchpedalrepair

Neil.

--
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines