Project D2 S8 (FL) 01E Conversion.

[Goran]

I was not convinced that machining the pedal box casting to fit the master cylinder, and needing a custom over centre spring was the best solution so I thought of an alternative.

I simply rotated the entire master cylinder assembly out of the pedal box casting so it would sit on top, and re-shaped the clutch pedal design to fit.
Inspiration is mainly from Audi A3 / Golf clutch pedal assembly, I bought one of these for £20 off ebay, and it came with a over-centre spring too.

In up position the clevis meets the pedal at 85 degrees, this seems to be how the stock LHD clutch pedal is set up. Master cylinder moves through 30mm, and is 75mm from clutch pedal mounting centre, so I made the over-centre spring arm 75mm too. This is how the A3 pedal was set up too, master cylinder mounting point was 58mm from pedal pivot point, and that was more or less the lenght of the lever arm going to the over-centre spring.

New list of requirements: custom clutch pedal (with polybush bushing), custom aluminium mounting bracket for master cylinder and over-centre spring (welded or bolted to pedal box), move brake pedal spring mounting to right side of well, custom mirror image brake pedal spring, ebay M8 clevis.

A few potential issues:
1) over centre spring is just underneath the master cylinder, may need to machine the pedal box casting a little so it can move freely.

2) over centre spring is 30mm wide, it will fit between the brake booster piston boot but with only a couple of mm clearance.

3) the re-designed clutch pedal reaches up 11mm above the height of the sensor bracket. I have had a look in the car without removing the trim and it seems like there is enough space up there, but not much.

Here are some pictures of a wooden test pedal, A3 over-centre spring and S8 stock clutch master cylinder.

[Dezzy]

nice work goran but 71camaro wouldn't need to manufature / modify a pedal box just get hold of a pedal box and assoiciated bits from a left hooker eh? as he won't have the starter motor bulge to get over.

It's easy for the guys already sat over on that side, like a 20 min job or something

[ainarssems]

starter motor bulge to get over

That's not starter motor bulge, it's where front diff is on side of gearbox/bellhousing. Starter motor is more towards front on side of engine and neatly tucked in not protruding at all. Must be pain in the @s# to change.

[Goran]

Hi 71camaro,

I went to the Audi dealer again today for a aircon service, whilst I was there I asked a different guy for some part numbers and prices. This time round they found a price for the cluch pedal, its not too bad. These prices are excluding VAT.
Here is the list of parts from last time with some new prices added.

Part number-----Description-----------------------Price £
4D1721401-------master cylinder----------------£231
811907343B-----clutch pedal sensor----------£16.01
4D1721465M----metal hose from master cylinder to slave cylinder---£71.50
857721453-------rubber hose supply to master cylinder-------------£10.96
4D1721485-------slave cylinder to gearbox bracket-----------------£11.24
4D1721316A-----LHD clutch pedal---------------------------------£45.85
4D1721450A-----clutch pedal spring-------------------------------£3.91
4D0721196-------spring bearing bush------------------------------£0.84
4A0721261-------slave cylinder (several different part no)---------£85

[71camaro]

That isn't bad at all. I assume that would be all parts needed? Also, I assume that "clutch pedal sensor" would be what we call the clutch safety switch? Thanks

[Goran]

I think thats most of the parts. There are a few minor bits that cost next to nothing that I forgot to ask for, they are those metal crimp pieces that hold the clutch sensor and brake pedal sensor in place.
Oh and that the other thing I forgot the brake pedal sensor.
I think you are right, the clutch pedal sensor is the clutch safety switch, I dont know what else it could be.

[71camaro]

I wouldn't need a slave. I'll shoot you a PM shortly.