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MK2 Ibiza / Cordoba Pedal box replacement

Discussion in 'Mk2 Ibiza/Cordoba FAQ's (6K) 1993-1999' started by ibiza_95, Jul 16, 2009.

  1. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    A big thank-you to Alpinewhite for actually making the guide, i just put it into more simplistic form and also Fl@pper

    Useful part numbers

    S6K2721335H Clutch Cable £27.62
    S1H0721169A Bracket £3.33
    S411417549 Shear Bolt £1.82 ea, x2 = £3.64
    S6K2721115D Bracket £62.38

    Net £96.97
    VAT £17.97
    Total £113.94

    1. Access to the pedals

    remove the driver's side glovebox (just pull it upwards and outwards) and the plastic tray underneath it. It's held in by two screws (arrowed).

    [​IMG]

    take out the driver's seat. It's only held in by one bolt at the front after which point it lifts out.

    2. Remove the steering wheel

    Firstly the airbag has to come out (the battery must be disconnected for this). It's held together by two allen head screws at the back of the wheel.

    [​IMG]

    Once these are undone the airbag unit is loose. It comes away from the steering wheel but there's an electrical connector which just pulls out. The airbag should be stored with the padded side up, according to the manual.

    At this point the steering wheel nut (24mm) must be removed. Also, there was another connector from the airbag that has to be unclipped. This was hidden in some foam padding:

    [​IMG]

    3. Remove the stalks

    There are three black screws which hold the stalks on. Then, make sure all the connectors are undone - i kept finding more of them! Once they are undone the stalks just slide off the steering column and you will be left with something like this:

    [​IMG]

    4. Remove the steering column

    At the base of the steering column is a rubber guard, held in by two plastic nuts. Take these out:

    [​IMG]

    You'll then have clear access to a plate with two nuts on it. Undo these, being careful not to drop them into the hole where the steering column disappears into....

    [​IMG]

    Once the nuts are undone, the plate comes away with the two bolts.

    5. remove the shear bolts that hold the steering column frame in

    Shear bolts are now out. I tried the method of driving them around with a chisel but it wasn't working for me. I ended up using a dremel to cut the heads off. The washers then fall out with a knock and the rest of the bolt is very easy to remove.

    Then the steering colum will drop down, but I couldn't remove it completely because of the wires going up into the column.
     
    #1 ibiza_95, Jul 16, 2009
    Last edited: Oct 25, 2009
  2. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    6. Remove the brake shaft from the pedal

    The Haynes manual talks about a special tool fabricated from an exhaust bracket, so this should be interesting!!

    Stuck with getting the pedals off the pedal box itself. It's only a retaining clip that needs to come off but it's got me foxed.

    [​IMG]

    on the one in the pic, try lifting the left hand side of it (away from the shaft) and then slide the clip towards you away from the pedal box.
    Got that one off, next is the brake pedal. It's another retaining clip:

    [​IMG]

    Not a great photo I know.

    The pedal box was also stopped by a little plastic tie that tidies up the wiring - shown below. This can be pushed out with fingers or a screwdriver.

    [​IMG]

    7. Box removal

    The pedal box can, as written elsewhere, be removed without taking off the brake pedal connector. I carefully pulled the brake pedal through the large hole in the pedal box.

    And it's out

    [​IMG]

    Side by side with the new pedal box:

    [​IMG]

    Note that the design is the same, except for the tab that holds those wired mentioned earlier in this post. I'll have the new pedal box reinforced before putting the new one in.

    Failures on the main body:

    [​IMG]

    The 'bolt hole' is from where i'd previously bolted the two parts together.

    And the corresponding bit that broke off!

    [​IMG]
     
  3. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    8. Pedal Box Reinforcing

    As supplied by SEAT

    From above:

    [​IMG]

    From below:

    [​IMG]

    As modified

    From above:

    [​IMG]

    From below:

    [​IMG]

    9. Clutch Over-Centre Spring

    1. Position the pedal end of the spring onto the pedal
    2. Use an open-ended spanner (I used 12mm) to compress it slightly and push it up the metal wall towards the pedal box. It will get stuck in a gap between the two.
    3. Use a screwdriver to lever the spring end onto the pedal box. By positioning the end of the screwdriver on the pedal box, it almost acts as a rail when you pull on the screwdriver.

    The correct orientation is shown below:

    [​IMG]

    10. New shear bolts in

    [​IMG]

    And all back together, except for the plastic cowling:

    [​IMG]


    A big thank-you to Alpinewhite for actually making the guide, i just put it into more simplistic form and also Fl@pper
     
    #3 ibiza_95, Jul 16, 2009
    Last edited: Sep 26, 2009
  4. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    as an extra note: i managed to do it without removing the steering column and thus didnt fight the shear bolts... you may also be able to too
     
  5. AlpineWhite

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    Ah, just found this. Good work chap :)

    As mentioned above, big thanks to Fl@pper, couldn't have done it without him.
     
  6. jibs666

    jibs666 Love my car man

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    i am doing this now but the steering column is in my way how did you manage to do it without fighting shear bolts
     
  7. old 'uns

    old 'uns Modern Life is Rubbish...

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    did mine as well without removing shear bolts.
    i pulled the uni joint out of steering column ( single bolt i think?), watch for spring falling out & orientation, this gave me enough room to get pedalbox around & back in.
    this may not work if you don't have an adjustable stering column though
     
  8. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    i just left it in and worked it out that way?
    obviously i undied the mount for the lower part of the column... then just jiggled it around it
     
  9. charless

    charless Guest

    Thanks to Alpine white as well. a big help.
    Hi from NZ. I have been removing my friends Cordoba pedal box.
    I found it better to take the steering column out. Instead of grinding the sheer bolts off I drilled the centre and used an eze out. As long as you drill straight, the bolts come out quite easily. Also the bolt is quite easy to drill.
    My question is,...I wish to remove the brake pedal. I have pushed in each side of the clip but the pedal still wont come free.... is there a trick to it.? If I forcefully remove the pedal am I at risk of damaging the brake servo?
     
  10. old 'uns

    old 'uns Modern Life is Rubbish...

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    just give it a sharp yank, bit frightening as you do it!
    clip is a 'one time' item
     
  11. Mk2Ibiza

    Mk2Ibiza Active Member

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    Hi guys, realise this thread is fairly old, but, whats the best way to remove the brake shaft pin/ and the nut that is behind the right of the steering column? much help, more advice would be appreciated. As i havent opted to remove the steering column.
     
  12. Mk2Ibiza

    Mk2Ibiza Active Member

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    Anyone out there?
     
  13. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    if you mean the white clip that stops the brake pedal from coming off, youre best bet is to buy a new one and just break it off and replace...
     
  14. Mk2Ibiza

    Mk2Ibiza Active Member

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    I'll admit im really new to fiddling about with the pedal box and all of that, umm the best way i can explain this would be the pin that retains the brake and clutch pedal, which goes through the pedal box.

    Would it help if i could take a picture? If so, i'll have to get my post's up so i can post some pics.
     
  15. Mk2Ibiza

    Mk2Ibiza Active Member

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    Forgot to say thankyou ;) All the help you can give will be much appreciated, as im trying to do this on a budget and in a rush because my beeza is a daily runner to and from college.
     
  16. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    [​IMG]

    thats what youre looking at...
    the big rod that everything pivots on is removed by taking the clips off either end, and sliding it out the passenger side of the box
     
  17. Mk2Ibiza

    Mk2Ibiza Active Member

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    Thanks for that ibiza_95 really appreciated, looks like there are a few bits on that exploded diagram that i might lose :| Again thanks for that im gonna give it a shot tomorrow got work in a bit, hope you don't mind me asking for any more help along the way? I think ive reached my 15 post's aswell so I will be uploading a pic of my beeza soon :D Thanks alot
     
  18. ibiza_95

    ibiza_95 1.8T MK2 Conversion

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    sure, theres loads of helpful people on here that have done this so im sure you wont go too wrong
     
  19. Mk2Ibiza

    Mk2Ibiza Active Member

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    This is what i thought was causing my clutch problems...

    [​IMG]

    This is my beeza guys....

    [​IMG]

    [​IMG]

    HOWEVER ITS MY PEDAL BOX...PICTURES TO FOLLOW
     
  20. vngtx

    vngtx Guest

    that clutch has loads left compared to my old one. although even with my pedal box gone the car still drives perfectly and pedals are all equal height.
     

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