Brake Pedal Assembly Problem

Maxoceanblue · Posted: Sat Jul 06, 2013 2:00 pm Post subject: Brake Pedal Assembly Problem

Please help,

Got a problem with my brakes. The bolt that connects the brake pedal to the rod that enters the master cylinder (silver in picture) will wiggle it's way out, fall out and then the pedal is no longer connected to the master cylinder, then no brakes!!! I just bought the car and I lost my brakes, found the bolt put it back in thinking it would stay but has wiggled it's way out again within a week. The bolt isn't threaded, it enters the brake base into a dead end hole, it doesn't go all the way through, there doesn't seem to be a way to lock it in place. I have a zip tie holding it in now just to be safe on my way home but don't want to drive around with it like this.

Does anyone know what the solution short of buying a new assembly is? The car is a '64 Beetle, although not sure if the brake assembly is the same age.

The view below is looking toward the driver side, up over the tunnel behind the gas pedal.

Image may have been reduced in size. Click image to view fullscreen.

luis · Posted: Sat Jul 06, 2013 2:08 pm Post subject:

Its supposed to have a metal clip that holds it in place. Kind of like a metal tab that bends from the bushing over and up over the brake pedal assembly to hold it firmly in place. Hard to explain and trying to find a picture for you. But what you need is a Brake Pedal to Master Cylinder Push Rod Retaining Lock Plate / Clip. VW Part Number 113721221

Scroll down to see the image

http://www.bughaus.com/beetle85.htm

Maxoceanblue · Posted: Sat Jul 06, 2013 2:13 pm Post subject:

Ok, I just found the part on Wolfburg West. It looks just like the one I have but how does it say in without wiggling out???

http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=113721219A

glutamodo · Posted: Sat Jul 06, 2013 2:15 pm Post subject:

Easier to show than describe:

Miklo · Posted: Sat Jul 06, 2013 2:15 pm Post subject:

http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=113721221

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Maxoceanblue · Posted: Sat Jul 06, 2013 2:19 pm Post subject:

I think I found it:

http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=113721221

But how does it work?

Maxoceanblue · Posted: Sat Jul 06, 2013 2:21 pm Post subject:

Thanks a lot, what a simple solution. I guess the owner before me failed to replace it.

I could have been in a bad accident.

Thanks.

wayne1230cars · Posted: Sat Jul 06, 2013 2:30 pm Post subject:

glutamodo · Posted: Sat Jul 06, 2013 2:36 pm Post subject:

Maxoceanblue · Posted: Sat Jul 06, 2013 3:07 pm Post subject:

Yea, I had to use the e-brake too. Thank God I wasn't in a bad spot. Do you bend the thing around by hand after you install it or before? I guess I'll just figure it out when I get it. I looked around my garage, I thought I had some sheet metal I could just cut myself a piece.

Wild Bill · Posted: Sat Jul 06, 2013 4:00 pm Post subject:

Max, That is the beauty of the Samba! The later models use a different device(Clip). Glad that mystery is solved! Thanks for coming by the Tech Session today. From that close up of the zip tie there is some Brake fluid seen. Might start looking for a replacement master cylinder just in case it fails completely. Wink

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wayne1230cars · Posted: Sat Jul 06, 2013 5:11 pm Post subject:

Install the pin first and then bend the clip. You might tap it with a small hammer. It's easy.
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presto · Posted: Sat Jul 06, 2013 5:23 pm Post subject:

Love the Samba .... I had that pin wiggle out and slam .... right between 2 cars .... not bad but it happened .... now i gotta find the clip and replace it .... i thought id have to redo the whole assembly ....

Maxoceanblue · Posted: Sun Jul 07, 2013 7:49 am Post subject:

Fixed it with a piece of sheet metal I had.

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Eric&Barb · Posted: Sun Jul 07, 2013 8:08 am Post subject:

You need to order one of these today.

http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=BOOK1
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skapunkfoo · Posted: Mon Jul 08, 2013 12:37 pm Post subject:

Just the other week I had the same problem and rolled through a stop sign. Put the pin back in and now check it every couple miles. Hasnt fallen out or wiggled out at all but now I can get the correct part to fix it. Thanks to all of you.
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skapunkfoo · Posted: Mon Jul 08, 2013 12:38 pm Post subject:

Just the other week I had the same problem and rolled through a stop sign. Put the pin back in and now check it every couple miles. Hasnt fallen out or wiggled out at all but now I can get the correct part to fix it. Thanks to all of you.
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slalombuggy · Posted: Mon Jul 08, 2013 2:42 pm Post subject:

There's a flower bed at a local mall that hasn't been the same since that happened to me Shocked

I was cleaning shrubberies out of the car till the day I scrapped it.......... Embarassed

brad

emperormoto · Samba Member Joined: December 26, 2014 Posts: 1

Mechanical engineer and designer here -

I had this happen on Friday in a '63 Ghia. I'd just been bombing down a long hill and using the brakes heavily. Turned into a neighborhood going 15 mph and the pin fell out. Got it stopped but was really lucky it didn't happen earlier. The retainer clip was old and had been re-bent many times.

If the pin had fallen out on the downhill I WOULD BE DEAD.

The sheet metal tab should be installed and bent ONCE ONLY. Re-bending the clip work hardens it (like when you bend a paper clip too many times and it breaks) and makes it brittle. Eventually it will break.

The part costs 75 cents. If you order one, order five, because when you bend the tab back to work on the brakes you need to take it out and REPLACE THE CLIP EVERY TIME.

You can also replace the pedal cluster from a '67 and later VW and though the design is not perfect it is much less prone to coming apart.

Thanks.

Maxoceanblue · Posted: Sun Aug 06, 2017 5:44 am Post subject: Re: Brake Pedal Assembly Problem

I should replace my homemade piece with the one that's been sitting in my tool box all this time. I think I've pushed my luck long enough with my homemade sheet metal replacement.

Thanks.
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1964 Beetle Sedan/1600cc DP 12v converted


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