Pedal Box Replacement

[EyExR]

Okay. So my pedal box has a small crack in it -which, I believe, may be causing a low clutch pedal.

I have a manual, airbag car. What's the story on replacing it? Do I have to pull the dash? Any details would be VERY helpful. I'm hesitant to even start this job.

[jlevie]

Depending on where the crack is, it might be possible to weld the crack w/o removing the pedal box.

[EyExR]

Yes, I thought of this but think it best to replace entirely. I don't trust myself with a welder up in there... nor would I trust anyone else at this point.

Also, I think once the box has cracked it'll never be right. I have a brand new one on hand....

So, anyway, what's involved?

[FredK]

I just removed an airbag pedal box yesterday in a car that had no dash.

I am 99% certain it can be done with the dash in place.

The vanity covers first need to be removed, as well as the lower steering column panel. You then have to lower the steering column by removing the two anti-tamper M8 fasteners that secure the column to the sheetmetal bracket of the car. This will likely require slotting with a Dremel or similar tool, then removal using a screwdriver. Beyond that, there's a single M8 bolt that secures the column to the pedal box.

You will have to then remove the pedals from the bracket. This is held in place with a long M10 bolt. You must also remove the brake pedal from booster clevis. The booster nuts must be removed (4x M8). You then need to remove the four M8 bolts that secure the pedal box to the sheetmetal of the car.

You should be able to remove the box now.

[jlevie]

Yes, I thought of this but think it best to replace entirely. I don't trust myself with a welder up in there... nor would I trust anyone else at this point.

I would not hesitate to have a pro weld up the crack. A real pro will tell you "no problem" and take the precautions needed to avoid damage to other things. Or they'll decline the job.

[bmwm42]

You do NOT have to mess with the steering column. I've done this plenty of times

[FredK]

Oh, yeah I guess if it's possible to remove the two rear-most M8 bolts, you don't have to necessarily drop the column. I just didn't see a way to get a wrench in there.

[roznic]

Definitely can do it without touching the dash!! just gotta have the right extensions and swivel extension will help.

[EyExR]

This helps a lot! Thanks!!

I'm assuming this would be the same on an iX with airbag..

[SmokeE30]

Don't assume anything with an IX but I know the clutch pedal itself is interchangeable on them when adding the clutch pedal to 5spd swap an IX so they are probably pretty damn close if not the same

[EyExR]

I'm mostly concerned with airbag vs. non-airbag.....