I was originally thinking about making new clutch pedals for the C4 chassis as many are prone to failure with the use of stiffer pressure plates, however they are cheap enough to buy used and I wanted to see if there was an underlying issue causing the failure beyond the added stresses. So I made these clutch pedal bushings, to replace the old worn out and cracked stuff in hopes of keeping slop out of the pivot point. Audi had cast the pedals in aluminum, and to avoid post op machining, they stuck the pedal assembly into a mold for the plastic bushing - to mold it directly to the casting, which surrounds the sleeve feature both inside and outside making it a non-serviceable part. Fantastic idea in terms of manufacturing efficiency, but as we all know Audi's plastic tends to get brittle and crack. Being a non-serviceable part, the fix would have been to replace the entire pedal - which is not expensive, but nowadays they're used units which may also have cracked bushings.
The bushings that I made are a two-piece design machined from Delrin, which once the old bushing is removed, press in from either side of the pedal with the help of a small amount of grease. Once pressed in, the ID of the bushings need to be drilled out to the final diameter due to Audi not conducting post op machining on the inside bore to give it a consistent diameter (better to have too much material than a loose fit right out of the gate, right?) - this can be achieved using a 15/32" (0.46875") drill bit, and just running it through the installed bushings prior to climbing back under the dash. It then gets installed onto the pedal bracket with a small amount of grease on the post.
While I do not have pictures of this installed on the car, I have the pedal assembly out of the car with the pedal and bushings installed.
I also did a short video on this explaining exactly what I just typed above
I have these listed for sale for $35 plus shipping at george-vanburen.com
https://youtu.be/HMd3rn7Ti30
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