Club 80-90 Forums

The part of the pedal box that the clutch master attaches to has snapped clean off on my RHD 2.0L air-cooled 1983 Devon.
First, can someone confirm the bad news ? I assume the whole dash has got to come out to remove the old pedal box ? Is that correct ?
If anyone knows of a step-by-step, that would be immensely helpful.
Does the whole brake/clutch pipework etc have to be removed/disconnected ?
Is this a common problem ? If so, should I weld/reinforce any replacement before fitting ?
I was wondering about attaching some kind of replacement bracket to the crash beam instead, to save the pain that lies ahead. Is that as bad an idea as it sounds ?

From the lack of replies I'm assuming this is not a common issue, so I won't bother strengthening the replacement bracket.
Trouble is now, I cannot get the dash out. The screws along the top under the windscreen just won't budge.
I've tried one set of screw removal bits which were useless (rolson brand, made of chocolate I think, from halfords).
I'm awaiting delivery of another (hopefully better) set, but don't hold out much hope.
Looking like I'm going to have to drill the screws out, but I'm hoping this will not make it hard to re-attach the dash.
Any tips or experience on this most welcome.

Not something I have heard of (but common on some Polos), a quick search took me to this

https://www.thesamba.com/vw/forum/viewt ... p?t=500810

No need to remove the dash, I suggest you read the thread linked to in the first post

MagicWagon wrote:From the lack of replies I'm assuming this is not a common issue, so I won't bother strengthening the replacement bracket.
Trouble is now, I cannot get the dash out. The screws along the top under the windscreen just won't budge.
I've tried one set of screw removal bits which were useless (rolson brand, made of chocolate I think, from halfords).
I'm awaiting delivery of another (hopefully better) set, but don't hold out much hope.
Looking like I'm going to have to drill the screws out, but I'm hoping this will not make it hard to re-attach the dash.
Any tips or experience on this most welcome.

Impact driver got mine turning - careful in there there's a big piece of glass near the lump hammer!

A pic of what has snapped would help - link above appears to be concerning the clevis pin etc not the pedal box.
I have done the clevis - have a spare good clutch pedal available if needed.

Here's a picture of what is broken (not my actual one), with the red line showing where it broke

I have a nasty feeling that it is a dash out job to access all of it. Hopefully someone who has done it comes along with good info.
I wonder if it is possible to just bolt in a new piece of angle to make a repair - how on earth has that broken there is the question though.

Your guess is as good as mine as to why it snapped. Clutch pedal was fairly easy to depress. Can only imagine it is 36 years of fatigue, but it's fairly low mileage AFAIK.
Yes I'm pretty sure it's going to need the dash out, if I can get the screws undone. I did wonder about bolting on some kind of replacement bracket, but I think it would need to be fairly accurate with regards to angle and position, and my fabrication skills and available facilities are pretty non-existant.

Yep impact driver got the windscreen screws put on mine - the type you hit with a hammer, not the powered ones useful on lots of screws - front brake shields, petrol cap too

I had this on one of ours a few years back, I think we didn’t take the dash out , although the memory is a little foggy ......
I seem to think you can wiggle it free by just removing all the bits off it that come off ...

Finally got the dash out. Bought an impact driver (halfords advanced range - good bit of kit) which got most of the screws out, except the one that I mashed up with the rolson screw "extractor" (rubbish bit of kit), so I had to drill that one out.
Pedal box came out compete with pedals. servo, brake master, without too much problem, so just got to wait for the 2nd hand replacement pedal box now.
Thanks for all the advice.