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Clutch Pedal fell off today
#1
Our Berlingo is terrific but it has had a disproportionate number of faults in the 3 years we have owned it. Repairs have cost loads more than we paid for it.
Today's issue:- Clutch pedal broke off where it fits over the shaft.

Metal fractured both sides. :-(

Any experiences of fixing/tips to share please?
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#2
       
I thought about sourcing second hand until I realised there were 15 different types of clutch pedal fitted to the Berlingo so I have had to bit the bullet and buy a new Citroen one for £45. The part number is 2127W1 and the car is a 1.6HDI Multispace 55plate.

Looking at the job, access seems to be the issue. Possibly best to open door and sit on ground outside car. Any hints/tips/do/don't do will be appreciated.
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#3
I changed the cable and pin a few months ago, so here's what I remember:
First thing to do (and the most important!) is to press the clutch pedal, or what's left of it, as far in as possible, then take a belt and tighten it around the clutch actuator on the transmission. Then you won't have any issues with the cable tension. After that it's pretty direct - loosen the bolt holding the clutch pedal and pull it down, then slide the pin to the side and remove the cable from the pedal, insert the new pedal and put it all back together. You will want to work from outside the car, otherwise you won't be able to see anything.

Here's the link between the cable and the pedal - helps to see what you'll be dealing with:
[Image: KWOTlK1.jpg?1]

Good luck!
[+] 2 users say Thank You to cbeck113 for this post
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#4
Thanks cbeck.

I am still now sure why it broke. There doesn't seem to be any indication why it broke.
One theory is that I did not find the retaining clip for the pin that goes through the pedal and end of the clutch cable. Perhaps the clip was lost (as happened previously x 2) and the operation of the clutch with the pin partially removed may have caused the pedal to twist outside its normal operating range causing it to break-off.
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#5
If you don't know why it broke, then I'd think about changing the cable and the link, which includes the pin (I paid 7 €). The pin was worn on mine and caused the pedal to swing around pretty badly, afterwards it was like new.

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#6
How did you get on with replacing your clutch pedal? The clutch pedal on mine wobbles and no doubt will need replacing at some point but access is awful & so far I've not found anything in the Haynes Manual that covers removal and refitting so it's something I've put off for now.

Does yours have a cable controlled clutch? I thought all 1.6HDi's had a hydraulic clutch (mine does). :-S

Edit: Just found it in the Haynes manual, but no pics to assist. It suggests removal of the dashboard is helpful for better access (though it's a big job) and on models with a hydraulic clutch removal of the brake pedal is also helpful.
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#7
(10-02-2014, 11:47 AM)stuartinlancashire Wrote:  How did you get on with replacing your clutch pedal? The clutch pedal on mine wobbles and no doubt will need replacing at some point but access is awful & so far I've not found anything in the Haynes Manual that covers removal and refitting so it's something I've put off for now.

Does yours have a cable controlled clutch? I thought all 1.6HDi's had a hydraulic clutch (mine does). :-S

Edit: Just found it in the Haynes manual, but no pics to assist. It suggests removal of the dashboard is helpful for better access (though it's a big job) and on models with a hydraulic clutch removal of the brake pedal is also helpful.

Directly to the right of my thumb in the picture above is a white pin; wear to this plastic pin caused my pedal to wobble, and replacing the link with the pin solved this problem completely. I can imagine that the hydraulic clutch has the same or a similar mechanism.
A hydraulic clutch would be nice for those back-pain days...and I saw a thread describing how to replace it here...http://www.berlingoforum.co.uk/showthread.php?tid=8779
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#8
Thanks for that advice Check113. I'll take another look once the weather gets a bit warmer, it's a bit too cold at the moment for sticking my head in the footwell to have a look whist the rest of me remains outdoors!

I managed to track down this not too brilliant diagram of the pedal assembly for the hydraulic clutch.

[Image: 23js8cx.jpg]

I don't think it has the plastic white pin you mentioned, item 7 on the diagram is the bolt that the pedal pivots on, item 8 is some kind of plastic sleeve (is this what you mean?) and item 71 is a nut. If you look at the pivot point on the pedal it is tubular where the bolt passes through and that plastic sleeve fits over the tube. My guess is that on mine either that tubular section is damaged, or the bolt has worn down over time which is allowing the pedal to wobble about.
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#9
1.6 HDi has a hydraulic clutch....No cable!
[fon‌t=Tahoma, Calibri, Verdana, Geneva, sans-serif]The Older I get the Better I Was!  Cool [/font]
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#10
Sorry Ol'Jeffers, but that is not true...my 1.6HDi has a cable, which I changed last year - and it wasn't difficult to find the parts, so I don't think that that is a rare configuration. BTW, it was built in December 2007.
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