Disassembling and assembling pedals
Includes: removing and installing pedals Important note
Remove the pedals together with the clutch master cylinder.
To do so, slacken the hydraulic lines on the clutch master cylinder. Release servo spring partially (move clutch pedal into de-clutched position).
Plug the hydraulic lines or clamp off the supply line using a commercially available hose clamp. Also plug the connecting bores of the clutch master cylinder.
Disassembling pedals
1. Mount brake pedal of pedal system onto a vise - using protective jaws -.
2. Turn adjustment screw for the servo spring to the left (counter-clockwise), until the leg of the servo spring fits closely to the rocker (arrow).
- 2358-30
3. Remove clutch master cylinder. Then lock rocker / servo spring. To do so, move clutch pedal into de-clutched position. In this position, operate clutch pedal (by pulling it backwards), until an auxiliary tool (steel pin with 8 mm 0) can be inserted from the side into the bore of the rocker.
- 2357-30
4. Release servo spring in two steps. Use an appropriate spring tensioning tool, e.g. brake spring pincers by Hazet (Hazet no. 797) to load and release the servo spring.To protect the mounting block, use a liner when applying the pincers.
First step:
Remove the support pin (arrow) on lever no. 9 using a screw driver. Caution: Do not get into the operating range of the rocker, the servo spring or the levers with your fingers or hands.
- 2370-30
Second step:
First load the servo spring through the rocker until the auxiliary tool (steel pin with 8 mm 0) can be removed easily from the bore of the rocker. Then release the servo spring by opening the pincers.
- 2366-30
5. On vehicles with cruise control: Mark position of microswitch. Remove microswitch.
6. Slacken fastening nut no. 28 on operating lever no. 9.
Remove lever from clutch pedal shaft -through the lateral bore on the mounting block - using a copper or brass mandrel. If lever can be removed, continue with item 8.
Important note
If lever no. 9 cannot be removed from the clutch pedal shaft without damaging the clutch pedal shaft (which may occur due to tolerances), continue with item 7.
If the lever cannot be removed with a puller, the clutch pedal shaft must be destroyed. To do so, separate clutch pedal from pedal shaft (by sawing) with bearing tube no. 11 slackened (screw no. 10 removed).
7. If lever no. 9 cannot be removed from the clutch pedal shaft without damaging the clutch pedal shaft (which may occur due to tolerances), part of the mounting block must be sawed off (arrow / dotted line). Then remove the lever using a commercially available two-claw puller.
If the lever cannot be removed with a puller, the clutch pedal shaft must be destroyed. To do so, separate clutch pedal from pedal shaft (by sawing) with bearing tube no. 11 slackened (screw no. 10 removed).
If lever no. 9 can be reused (see - Note - on page 30-18), remove the lever from the pedal To do so, use plate VW 401 and an appropriate bushing, e.g. Matra 40-503.
2359-30
8. Lift out clutch pedal shaft with clutch pedal
Note
If the pedals were disassembled because of the complaint - sometimes the clutch pedal does not return fully -, replace lever no. 9 (fig. 2348-30 / new, modified version with optimized kinematics).
> Distinguishing old and new levers Part number on part.
> Previous version:
Part no. 993 423 519 00 or
993 423 519 01 (gold-colored).
> Modified I new version:
In the beginning, the modified, new levers were golden as well.
9. Remove shaft no. 7 from mounting block. Remove bearing sleeve no. 5, servo spring no. 6 and the assembly of lever no. 9 and rocker no. 16.
- 2365-30
10. Remove bearing pipe no. 11 and brake pedal.
- 2363-30
Assembling pedals
1. Check all parts, replace any parts, if required.
If the bushings must be replaced, use an appropriate mandrel for removal or installation. Coat all bearings and slide faces with a Teflon-compatible low temperature grease - e.g. Glissando by DEA (Texaco).
- 2348-30
Note
Check the mounting block for deformations (might stem from removal of lever no. 9). If necessary, remove the mounting block.
2. Insert brake pedal into mounting block. If necessary, fit a shim (arrow) between the brake pedal and the mounting biock (to compensate for the axial play). The shim is not always present.
When replacing the mounting block or the brake pedal, determine the thickness of the shim (if present and/or required):
With the brake pedal installed, determine by trial and error which shim can be inserted. There are shims with two different thicknesses available. Insert bearing tube no. 11. Insert screw no. 10, but do not tighten it yet. Important: Tighten screw no. 10 only after installing the pedals.
- 2363/1-30
3. Preassemble lever no. 9, rocker no. 16 and connecting pieces no. 13. If necessary (after installaton of a new rocker), turn adjustment screw no. 17 until the leg of the servo spring fits closely to the rocker (arrow). Install only levers no. 9 with optimized kinematics. See note on p. 30-18.
- 2364-30
4. Insert bearing sleeve no. 5, servo spring no. 6 and the assembly of lever no. 9 and rocker no. 16 into the mounting block. Insert and fasten shaft no. 7.
2365/1-30
5. To preload the servo spring, mount the brake pedal of the completed pedal system onto a vise - using protective jaws.
6. Preload servo spring as follows:
Use an appropriate spring tensioning tool, e.g. brake spring pincers by Hazet (Hazet no. 797), to preload the servo spring until an auxiliary tool (steel pin with 8 mm 0) can be inserted into the bore of the rocker from the side.To protect the mounting block, use a liner when applying the pincers.
- 2366/1-30
7. Insert clutch pedal shaft with clutch pedal no. 2.
Fit lever no. 9 in its correct position to the clutch pedal shaft (notch on lever must face tooth gap of shaft).
Fit fastening nut no. 28.
Do not tighten fastening nut yet, (see next item).
2365/1-30
8. Remove auxiliary tool (steel pin to preload servo spring) from rocker. To do so, move clutch pedal backwards (towards clutch posi tion) carefully and only slightly. Remove the steel pin as soon as it is no longer under load.
Then tighten fastening nut no. 28, tightening torque 34 Nm.
Note
If the auxiliary tool (steel pin) is not removed with utmost care or if the fastening nut is tightened with the auxiliary tool still inserted, the rocker may get damaged in the area of the bore.
9. On vehicles with cruise control, install the microswitch.
10. Install the clutch master cylinder.
On vehicles with cruise control, adjust the microswitch by sliding it into the proper position.
The microswitch must be triggered (clicking sound) on the first few milimeters of pedal travel.
If the clutch master cylinder does not fit closely to the mounting block, rework the mounting block's contact surface using a plastic hammer.
11. When replacing the mounting block, re-install those parts of the old mounting block that are required.
12. Set adjustment screw of servo spring (no. 17) to the dimension of 6 mm (see page 30-13).
13. Install pedals with the servo spring released partially (clutch pedal in de-clutched position).
Important note
Then tighten screw of bearing tube (see item 2 on page 30-19).
14. Connect lines of hydraulic clutch system to clutch master cylinder. Bleed clutch
Note
Carry out adjustments, e.g. adjusting brake light switch, and inspections, e.g. limiting / adjusting pedal travel.
The adjustment jobs are described on pages 30-13 and 30-14.
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