Hi All I thought I would just pass on a the details of a strange clutch problem I have just figured out.

A few months ago, with great plans to head to Harry's in Sydney on the Friday night I jumped in my beetle, started up, put the clutch down, into reverse.. The clutch pedal never can back up.

I thought it was a cable problem (broken?). Hoping I wouldn't have to pull the engine.

So got sorted to do a stack of stuff while I'm investigating, rod bushings, overhaul the pedal assemble and replace the clutch cable.

Got in there, pedal assembly out, had trouble getting to the clutch cable, so took the shift rod out. Still couldn't see anything unusual (using my phone to look in the passenger side inspection hole). As the shift rod banged its way out there was a "clunk". So something just gave.. And there it was - the clutch pedal was back. Even with the shift rod out, nothing appeared wrong. I scratched my head for a while and decided the cable better come out anyway.

We cut a 3 sided hole in the tunnel to pull a temporary access hole up. eventually got the clutch cable out. Cable was in great condition so I cleaned it re-greased it and put it back in. Put the pedal assembly back in etc and were testing the clutch again. With the space to move and see we noticed the bracket in the tunnel that holds the clutch tube (directly behind where the pedal assembly mounts) was crooked. And when we pressed on the clutch the drivers side of the bracket had come away from the tunnel. There appears to be 3 big spot welds (you can see them from the outside of the tunnel by the clutch pedal). Sooooo, long story short ..

The bracket was moving, changing the angle of the tube, and the head (with the hook eye) of the clutch cable was catching on the top of the tube... So this was the bang I heard, as the shift rod must have knocked it on the way passed.

I don't have a welder that would do the job and I thought a rivet might be too obstructuve.. And possibly too weak? So we got two little roofing self tapping screws and drilled them into the bracket (through the tunnel). Worked perfectly and won't be seen under the carpet.

So there you go. Damn thing ! What a mission.

Yup, If Hans hadn't set the spot welder up properly that morning then probably plenty of weak spot welds out in the world

Don't know about 'Hans' - it would have been welded in Melbourne. More chance of being an Italian 'New Australian' on the Clayton lines than a German in the 1960s.

https://www.youtube.com/watch?v=yNRBfy8ay4E 

rare event
seems like u enjoyed it...lol

Didn't enjoy it being off the road. Didn't enjoy spending an hour getting that wing nut off either!!

Enjoyed finally solving the mystery though. Satisfying, that's what this hobby is all about eh. Learning stuff.

Thought I better pass it on, as there is a good chance Hans, or Pietro or maybe even Wayne (?) welded more than one tunnel.

small rag soaked in oil wrapped around the wing nut for an hour or three will help