Recent content by deeeeps

I think I may have found why the original clutch cable bracket gave up in the first place. I may be wrong but……………. Read on: I placed an entry a bit further back up this string, where I had THE problem with the clutch cable mounting breaking off. I managed a repair using some angled...

Hi All, Well, after doing the repair using a bit of old bedstead and some plastic tubing, I am pleased to say (touching wood and whistling) that the clutch operation is still fine - indeed it is nicer to operate than ever before, which means the defecting metalwork had been around for quite a...

Hi All, I am sorry, I am being a bit thick with this forum from a posting point of view. I uploaded a bunch of pictures and promptly couldn't find them anywhere, even after I had added words. Sooooo, having already run a blog on wordpress, I simply wrote up a new one called...

At the top of the picture is the L cross-section bracket bolted in place between the existing pedal mount plate.<br>The other bolt was the existing pedal mount plate bolt. Once tightened, it assisted by 'pinching' the new bracket, helping prevent any lateral movement.

Like others, I took my trusty Polo into our local garage. They had serviced the Polo regularly and I trusted them. They replaced the clutch, swearing blind that it was worn out (at 33000 miles? AND my dad owned her before me!) I took her back a couple of days later and this is what they did...

The cable end can be seen to the left and the securing bolt to the right. This bracket was made longer, to allow more 'meat' of the bracket to press against the plate it was bolted to.

I used the grey plastic pipe (conveniently exactly the same diameters (inside and outside) as the cable sleeve. The blue pipe I cut a slit longitudinally and slipped over the grey pipe and the cable sleeve to keep them aligned.

This was made using mild steel L section plate cut from an old bedstead with a hacksaw. The reason it as replaced was because I wanted more length on the opposite side of the mounting bolt, plus the correct position for the bolt hole was exactly mid-way between the two holes shown here. (A...

Once the spot welds had given way, this small stretch of metal bent back and forth with every clutch pedal operation. It eventually cracked.

2 spot welds that eventually gave out, leaving all the stresses on a very small stretch of metal.

Looking at the right protrusion and the bottom, these were where this bracket connected to the rest of the support. continuous movement caused it to break.

VW Polo Lupo and Golf apparently have this problem, where the metal bracket supporting the clutch cable is not strong enough. This results in the bracket bending at its weakest point and then breaking at a most inopportune moment. These are pictures of the repair I did, using mild steel L bar...

Hi All, Managed to repair the problem with the clutch cable support. I manufactured a bracket using some L section mild steel cut from an old bedstead. I drilled/filed/ground out the bolt hole on the bedstead to take the plastic clutch cable sleeve, then added a short length of plastic...

Hi All, Good informative information, thanks. I have a bit to add, as I have had a problem which I am told is a standard issue with Polo, Golf and Lupo. There is a plate, down in the footwell above the pedal, that holds the clutch cable outer sleeve in place. This allows the inner cable to...