I'm trying to get the pedal cluster out of my '59 bug (so I can replace a broken cable) but I'm stuck:
The brake push rod is attached to the brake pedal by a big fat pin (which in turn was held in place with a small circlip - I have removed the circlip). The big fat pin is supposed to just slide out, but it is rusted in place and I can't get it to budge! How can I get the pin out?
1959 red & white Beetle
1975 Kombi camper
Soak it with something like wd 40 or penertrine, be carefull you do not damage the end of the pin by directly hitting it with a steel hammer, us a brass hammer or dolly after you have allowed the WD 40 to soak in.
You should be able to manipulate the clutch pedal to allow the rod to slide off if not undo the pushrod and separate it..
Hi
I might not be reading what your saying correctly, but the pin is fixed in the pedal, the pushrod has a round end that should slip off easily once you back off the adjustment.
Steve
It is seized in the pedal.
As Steve said you slide plunger rod off pedal if it was seized the brakes wouldn't work
grumble wrote:You should be able to manipulate the clutch pedal to allow the rod to slide off if not undo the pushrod and separate it..
x2
I'm in real trouble here :-(
As well as the pin being rusted into the brake pedal (even after soaking with penetrating oil for a few days), the two bolts holding the pedal cluster to the pan are also stuck. Now I really don't know how I'll ever change the clutch cable.
p.s.
Steve and Klaus, you must be thinking of a different model, because yes the pin is supposed to slide out of the brake pedal. Take off the circlip first (which I've done), then the big fat pin attaching the pushrod to the brake pedal should slide straight out towards the tunnel... but it is stuck.
1959 red & white Beetle
1975 Kombi camper
Hi
Do you have an oxy set? A little heat might help. I was at a plumbing shop the other day and they had oxy kits with disposable bottles and it was very reasonably priced.
Can you take a photo of the pin?
Is this a RHD car?
Steve
It is a early pedal set were you take the circlip of and push the pin through the pedal, unscrew the the push rod and push the brake pedal back far enough to get the pin out.
Here is a pic of it. I have highlighted in red the pin which is stuck in the brake pedal.
Yes it is a RHD car. I have already removed the circlip from the right-hand end of the pin. The pin is supposed to slide out leftwards, towards the tunnel, but it is rusted stuck.
I don't want to use oxy or any other blowtorch because I'm the clumsy type who will just burn the car to the ground.
I can't see how I can unscrew the pushrod: there is a locknut, but no way to turn the part which goes forward through the bulkhead into the master cylinder?
Anyway, with the two bolts holding pedal cluster to pan also rusted tight, the entire situation seems hopeless anyway 😢
1959 red & white Beetle
1975 Kombi camper
Removing the two bolts that secure the end of the pedal shaft and the pedal stop plate to the floor is your best chance.
Even if you have to break those two bolts, you can drill out the old bolts and tap the threads from underneath the car.
With the bolts removed from the left hand side of the tunnel and the pedal stop (adjustment) plate, you can lay the brake and clutch pedal
back and twist the assembly enough to get the cable into the clutch tube and the hook the cable back onto the pedal.
Much easy to demonstrate than describe. Hope this helps!
Dave
ragged wrote:Removing the two bolts that secure the end of the pedal shaft and the pedal stop plate to the floor is your best chance.
Even if you have to break those two bolts, you can drill out the old bolts and tap the threads from underneath the car.
With the bolts removed from the left hand side of the tunnel and the pedal stop (adjustment) plate, you can lay the brake and clutch pedal
back and twist the assembly enough to get the cable into the clutch tube and the hook the cable back onto the pedal.
Much easy to demonstrate than describe. Hope this helps!
Dave
As Dave says removing the bolts is probably the easiest,you are probably better off to put it on stands and drill the bolts on centre from underneath as there isn't a lot of room inside behind the cluster. centre punch and drill a pilot hole first then progressively drill larger to around 6.5mm then turn the heads off the bolts,remove the cluster,tap the holes for the bolts. or take it to a mechanic who can do the work.
It does not look very rusted, if you have a copper hammer it would probaly move with a couple of good hits.
If you don't want to use a oxy or torch, a heat gun with a small outlet on it will put out a fair bit of heat, is there enough material on the other side of the pedal to use a two leg puller?
It will all be OK in the end, if it's not OK it's not the end!
Have you managed to give it a good hit with anything? A couple of ggod whacks on the surrounding area and then on the end of the pin. use a sturdy lever and hold it onto the pin and hit as close to the pin as possible. It souldnt be that stuck just needs some leverage.
Unscrew the pin on the other end so that you have more movement and something to move back and forth/ side to side.
Oxy should sort that and use a sharp screw driver as a wedge to push apart ..gently with a big hammer
Be carefull what you hit it with, you could end up damaging the end of the pin and then it will not fit through hole in the pedal. use a copper hammer or a brass drift.
Update:
I started thinking about maybe cutting an access hole in the tunnel. When I removed the rest of the insulating foam over the tunnel, to my horror/delight I discovered a previous owner had already cut an access hole. This allowed me to change the clutch cable, so problem solved.
1959 red & white Beetle
1975 Kombi camper
😂👍
