Early Pedal Assembly Rebuild:

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How to Replace VW Clutch and Accelerator Cables and Pedal Assembly: A Complete Guide

Introduction:

While we were replacing the clutch and accelerator cables in our 1963 Beetle we noticed the clutch pedal cross shaft was worn. This gave us an opportunity to show you how to rebuild the pedal assembly. Today, we’re going to walk through the steps of replacing and upgrading the clutch and accelerator cables, as well as the pedal assembly, for your Volkswagen. While we were at it, we swap out the accelerator pedal for a roller pedal.

Tools Needed:

10mm Wrench
11mm Wrench
14mm Wrench
15mm Wrench
Vice Grips
3/8" Ratchet
6" Extension
17mm Socket
6mm Allen Wrench
Flathead Screwdrivers
Hammer
Punch
Chisel

Before You Begin

• Ensure the front wheels are chocked.
• Lift the back end of the car onto jack stands.

Adjusting and Removing the Clutch Cable

• Loosen the clutch cable adjustment nut from the cable with a wrench. Use pliers or vice grips to prevent the cable from twisting while you remove the nut.

Disassembling the Pedal Assembly Inside the Car

• Remove the two 17mm bolts holding the pedal assembly in place.
• Pull the accelerator cable off the linkage end.
• Pry up the brake pedal push rod clip with a flathead screwdriver to remove the push rod pin.
• Remove the push rod from the master cylinder and brake pedal.
• Pull the pedal assembly forward slightly to detach the clutch cable from the pedal hook.
• emove the pedal assembly from the car.

Preparing for a Roller Pedal

• If upgrading to a roller pedal, remove the stock accelerator pedal from the floor pan by pulling the pivot pin loose.

Disassembling the Pedal Assembly at the Workbench

• Remove the accelerator cable lever by pushing the pin out.
• Secure the pedal assembly in a bench vise and tap out the clutch pedal cross shaft pin using a hammer and punch.
• Reposition the assembly in the vise to remove the clutch pedal by tapping it off at the cross shaft.
• Take the assembly out of the vise and remove the cross shaft.
• Place the pedal base back in the vise to remove the snap ring from the brake pedal. Ideally, use snap ring pliers, but flathead screwdrivers can work as an alternative.
• Remove the brake pedal and return spring.

Reassembling the Pedal Assembly

• Clean and degrease all components before reassembly.
• Begin reassembly by placing the brake pedal return spring on the brake pedal and sliding it onto the pedal base.
• Secure the snap ring with the screwdrivers.
• Grease and insert a new clutch pedal cross shaft.
• Align the clutch pedal and hook to point in the same direction and secure with the pedal pin.

For Stock Pedal Setup

• Reinstall the stock accelerator lever and secure with the pivot pin.
• Slide the washer onto the push rod and connect it to the pedal lever.
• Mount the accelerator pedal to the floor pan with the pedal pivot pin.
• Place another washer on the push rod and install it into the pedal.
• Secure with the spring clip.

For Roller Pedal Installation

• Remove the stock linkage and install the roller pedal with the pivot pin, adding washers as needed to reduce wobble.
• Attach the clutch cable to the pedal hook.
• Push the pedal assembly base into the tunnel while holding the clutch pedal forward.
• Push the brake pedal return spring forward to position the pedal away from the firewall.

Final Steps

• Loosely bolt the pedal assembly to the tunnel, ensuring the clutch pedal stays up.
• An assistant guides the clutch cable end through the transmission clutch arm.
• Tighten the clutch cable adjustment nut to remove slack.
• Fully tighten the pedal assembly bolts.
• Grease and insert the brake pedal push rod into the master cylinder.
• Install the brake pedal push rod pin and secure with the clip.
• Connect the accelerator cable to the new roller pedal.
• If using a heavy-duty cable, secure it with a small bolt and nuts.
• For stock pedals and cables, attach accordingly.

Conclusion

Replacing your Volkswagen's clutch and accelerator cables, along with the pedal assembly, ensures reliable and responsive control of your vehicle. Regular maintenance and timely replacement of these components keep your Volkswagen in top driving condition.