[s-cars] Clutch pedal broke

[tedebearp at yahoo.com]

I've removed the clip attaching the broken piece of the pedal to the clutch master cylinder, as well as the clip for the pedal pivot.  I couldn't figure out how to compress the overcentering spring and was just going to let it come off like you did.  However, I can't get the pedal to come off the pivot.  There's not much room to work in with the fiberboard right up against the pedal pivot.

How did you get the fiberboard off?

Sent from my iPad

On Oct 17, 2013, at 7:39 AM, "McCall, Randy" <rmccall at nexant.com> wrote:

> For removal, I don't recall what I did - I believe I just pulled the pedal off the post and let the spring and end caps do their thing. It wasn't under much tension as I recall and didn't try to put my eye out with unguided heat seeking missile velocity. :-)  It seems hard to imagine even getting something on there in place to help on the removal though - it's a really tough spot to access.
> 
> For reinstallation I tried using zip ties at first, but I just couldn't make them work as they wouldn't stay in place on one side of the plastic fork ends, or they interfered with getting the assembly back in place when I crossed them.  The c-clamps I made from bicycle spokes solved those problems, and were easy to make and then remove once the assembly was in place with the new pedal back on the pivots.
> 
> -Randy
> 
> -----Original Message-----
> From: tedebearp at yahoo.com [mailto:tedebearp at yahoo.com] 
> Sent: Thursday, October 17, 2013 1:35 AM
> To: chris chambers
> Cc: McCall, Randy; s-car-list at audifans.com
> Subject: Re: [s-cars] Clutch pedal broke
> 
> Did you use the ties to keep the spring compressed while removing it?
> 
> Thanks, I'm going to try tackling the job.  Worst case is I have the car towed to the shop, which I'd have to do anyway.
> 
> Sent from my iPad
> 
> On Oct 12, 2013, at 11:42 AM, chris chambers <fastscirocco_2000 at yahoo.com> wrote:
> 
>> 
>> Ditto to PITA but doable task.
>> I used a vise and plastic cable ties to keep the spring compressed.
>> I simply cut the ties after assemblying.
>> 
>> HTH
>> 
>> Chris
>> 
>> 
>> 
>> ------------------------------
>> On Sat, Oct 12, 2013 11:12 AM EDT McCall, Randy wrote:
>> 
>>> 
>>> Message: 1
>>> Date: Thu, 10 Oct 2013 14:05:51 -0700 (PDT)
>>> From: Theodore Chen <tedebearp at yahoo.com>
>>> To: s-cars <s-car-list at audifans.com>
>>> Subject: [s-cars] Clutch pedal broke
>>> Message-ID:
>>>   <1381439151.76695.YahooMailIosMobile at web124905.mail.ne1.yahoo.com>
>>> Content-Type: text/plain; charset=us-ascii
>>> 
>>> '92 S4, 183k miles. At 174k, the clutch was replaced, along with pressure plate, flywheel, master cylinder, slave cylinder, etc.  I looked under the dash and the pedal is definitely broken. <br/><br/>The pedal effort didn't seem any higher than usual so I'm attributing the failure to fatigue cracking in the cast aluminum pedal rather than high clutch effort. <br/><br/>I'm debating whether to do this replacement myself or have the car towed to the shop. How long does it take and how annoying is it?  I've looked at a couple of writeups on Audiworld and it sounds like the spring is a pain to deal with.<a href="http://overview.mail.yahoo.com?.src=iOS"><br/><br/>Sent from Yahoo Mail for iPhone</a>
>>> 
>>> Ted- I had to do this repair two years ago at about 150K.  I happened to have a spare pedal from my wrecked S-6 parts bin, so tackled it on my own - a pain in the butt repair due to the location, and the over-center spring assembly was definitely the hardest part of the process.  I took the front seat out to get my old fat body some room to work, and most importantly, made some two custom "C"-clips out of some heavier gauge spare bicycle spokes I had to keep the spring and end cap holders compressed.  I'm not sure if I could have done this job without something like that.  I put the spring and two plastic keepers in my vice, compressed them, and put the two "C-clips"s that I had made on the outside of the plastic caps and then relaxed the vice.  That kept the assembly short enough to fit the plastic forks into the pivot points once the new pedal was back in there.  Once in place I just levered the C-spring clips off and it was like magic.
>>> 
>>> Hope that helps!
>>> 
>>> 
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