Technical Plastic clutch pedal snapped

[CeriR]

The plastic clutch pedal on our 2001 1.9td Ducatto has snapped off at the top. This is the second time that this has happened!!! Has this happened to anyone else and
Is there a more reliable fix for the same thing?

TIA

 

[bugsymike]

The plastic clutch pedal on our 2001 1.9td Ducatto has snapped off at the top. This is the second time that this has happened!!! Has this happened to anyone else and
Is there a more reliable fix for the same thing?

TIA

You may end up needing a new clutch assembly
Reason being if the clutch operation is so heavy it is breaking the pedal or putting extreme load on the cable a wear ridge caused by owners resting the foot on the pedal makes a groove on the clutch pressure plate that the release bearing has to force it's self over to release the clutch.
I assume a recent or good clutch cable has been tried first, but in general if a person cannot reach in and press the clutch pedal to the floor with their hand it may point to what I said.
Some years ago a mobile mechanic called me for help as he had fitted two clutch cables and every time he pressed the pedal the plastic eye snapped.
As a temporary fix I sprayed oil into the bell housing at the release bearing/pressure plate area and used a bar to assist the clutch lever at the gearbox a few times so he was able to get the clutch to operate, but basically the problem would only be properly fixed by a new clutch assembly.
If you can get an endoscopy inspection camera into bell housing (many garages use them these days) it may be possible to see the wear ridge I am talking about.

 

[Erikd]

We’re stranded with the same issue here. Same car, same year 160.000km.
A new pedal has been ordered and will be here in a day and it should be an easy fix.
I’m trying to figure if it is just the plastic that got old and gave away, or that there is more to it.
We bought the camper last year and have driven about 10.000 km since then. I’m definitely not a foot-on-the-clutch driver.
I tried to move the metal clutch lever that sticks out of the gearbox by hand, but this is impossible. It does move when I apply a more leverage (used the old clutch pedal as a lever). Is it normal for this lever to go this heavy? Also trying to operate the clutch by pulling the cable with an extension made from zippties from the driver seat (as tried by the tow truck guy) is impossible. Pre-clutch pedal issue the shifting and everything went fine. Also the force required to press the pedal was not heavy in my opinion.
So my main question is: is it normal that the clutch lever at the engine side requires much force to operate? Any ideas?

 

[bugsymike]

We’re stranded with the same issue here. Same car, same year 160.000km.
A new pedal has been ordered and will be here in a day and it should be an easy fix.
I’m trying to figure if it is just the plastic that got old and gave away, or that there is more to it.
We bought the camper last year and have driven about 10.000 km since then. I’m definitely not a foot-on-the-clutch driver.
I tried to move the metal clutch lever that sticks out of the gearbox by hand, but this is impossible. It does move when I apply a more leverage (used the old clutch pedal as a lever). Is it normal for this lever to go this heavy? Also trying to operate the clutch by pulling the cable with an extension made from zippties from the driver seat (as tried by the tow truck guy) is impossible. Pre-clutch pedal issue the shifting and everything went fine. Also the force required to press the pedal was not heavy in my opinion.
So my main question is: is it normal that the clutch lever at the engine side requires much force to operate? Any ideas?

If clutch has a wear ridge for what ever reason, where the release bearing rests against the pressure plate then the diaphragm spring plate developes a groove which had the affect of making the intial release of clutch at begining of travel quite hard to overcome.
In some cases a new clucth kit is the only answer, which apart from no wear ridge being new it operates much easier.
Not relevant to you as cable operated, but recently a friend of mine has had to fit a hydraulic servo to the clutch system on several Land Rovers to ease the pedal pressure a bit.
In the old days clutch pedal was metal and although it would wear it rarely broke unlike plastic which is less forgiving, but obviously cheaper to manufacture.

 

[Erikd]

Thanks for your quick reply.
At least an inspection of the clutch is on the to do list for when I get back. I understand things will go smoother when all parts are new.
What isn’t clear to me yet is if everything is new and nice and ok, should it then be possible to operate the clutch lever by simply pushing down by hand the metal lever at the clutch housing, or is this something that should not be possible in any case? I can understand that you have to compress the clutch which are very stiff.

 

[bugsymike]

Thanks for your quick reply.
At least an inspection of the clutch is on the to do list for when I get back. I understand things will go smoother when all parts are new.
What isn’t clear to me yet is if everything is new and nice and ok, should it then be possible to operate the clutch lever by simply pushing down the metal lever at the clutch housing, or is this something that should not be possible in any case?

No that is never possible by hand, it is only with possible with a long lever if you can do so without damage.
Generally speaking with modern clutches after fitting a new one, to me they almost feel too soft an action.

 

[Erikd]

No that is never possible by hand, it is only with possible with a long lever if you can do so without damage.
Generally speaking with modern clutches after fitting a new one, to me they almost feel too soft an action.

Great, thank you so much. That gives me some comfort that fitting a new clutch pedal will at least get me home.
Stupid idea then to make such a highly loaded section out of plastic.
A metal hook on a plastic pedal would work much better, but as you mentioned, would cost a few euros more…

 

[bugsymike]

Great, thank you so much. That gives me some comfort that fitting a new clutch pedal will at least get me home.
Stupid idea then to make such a highly loaded section out of plastic.
A metal hook on a plastic pedal would work much better, but as you mentioned, would cost a few euros more…

Fingers crossed Eh!
If pedal feels very stiff it may still break the new plastic pedal, for the the reason I mentioned at #2 earlier so try to not have to use it too much.