Clutch cable - again!

[Radorocco]

What is it about my car and clutch cables?

I've just had another one snap and its getting tedious

Again its at the clutch pedal end. There's maybe about 3 or 4 inches left.

Wondering if its rubbing against something but it seems like a fairly straight route for the cable.

Now to source another cable

Cheers
Jeff

[james butler]

i had the same problem.
solved it by straitening out the kink that's in the outer cable under the bonnet to a less severe angle. putting 3in 1 oil down the cable before fitting also helps.
i found out at a later date that the hole in the bulkhead doesnt really line up with the pedal that well so i made a new bulkhead clutch patch out of steel plate and repositioned the hole for the outer cable to line up properly and bolted it instead using undersized bolts in oversized holes to allow for movement.

[james butler]

viewtopic.php?f=10&t=8298&start=15
i knew it were on here somewhere lol

[Radorocco]

Any tips on fitting a clutch cable or is Haines fairly reliable on this point?

Had to get a 1660 mm cable, garage had fitted an FK1193 before - same length. Seemed to route through OK though

Thanks
Jeff

[DT1]

Had to get a 1660 mm cable...

Are you talking about the GTX? Clutch cable length for a K-Jet engine is 1,470 mm.

[Radorocco]

Thought it was 1490 but can't find one anywhere.

Is there any reason why a slightly longer one wouldn't be suitable?

Cheers
Jeff

[DT1]

Think the 1,490 mm is for the carb.

532721335J clutch cable F >> 53-F-060 000 1.8ltr. rhd 1490 mm
172721335H clutch cable F >> 53-F-060 000 rhd 1470MM K-JETRONIC

Clutch-Cable-1470mm-for-Mk1-Golf-Scirocco-Jetta-for-RHD-K-J-172721335H - reproduction, or you can pay twice as much for an original.

All I can say is that the fact that the longer one keeps snapping indicates that it isn't suitable. If you have the cable routed so that it is clipped to the rocker cover then there is tighter curve where the cable goes around the cam cover compared to the shorter cable which just goes over the cam cover, which probably means you have to push harder on the pedal.

[ianaudia4]

A 1470mm clutch cable is for a 1.6 GTi! The 1.8 injection cars need a 1490mm cable.

Give Volkspares a call on 0208 683 7442, last time I spoke with them they had 29 clutch cables of the correct length.

[ThomasD]

A 1470mm clutch cable is for a 1.6 GTi! The 1.8 injection cars need a 1490mm cable.

Give Volkspares a call on 0208 683 7442, last time I spoke with them they had 29 clutch cables of the correct length.

Ian's right - the longer cable is correct for the 1.8L injection cars. I've replaced the cable on my 84 Storm, and both the cable I removed and the cable I installed were the same length as the 532721335J part. The routing is neither too tight nor too loose.

These numbers are all the longer cable (1487mm cable):

532 721 335J (VW)
FKC1236
GEMO 434930
GEMO 434370

All of the above seem to be very good quality, and pretty close to identical.

I've had luck finding these cables new on eBay - they come up periodically. Currently someone on there has two new OEM cables for sale, but he's asking a lot of money for them (http://www.ebay.co.uk/itm/Clutch-cable- ... 1c3eb8eb31) so you may be better off with Volkspares as Ian suggests.

[ianaudia4]

Fifty quid! That is excessive, I think I paid £20 for the last one I bought.
A tip with fitting clutch cables, before fitting on the car get loads of oil (such as 3 in one) down the inside of the cable to prevent it rusting from the inside out. Also ensure that it is routed correctly in the engine bay and is verticle on the lever, seen loads that are at an angle which "saws" into the lever and gives the cable a hard time.

[Radorocco]

Thanks for the tip off Ian, £24 quid-ish in the post!

Apprently they have plenty in stock. I nearly got a spare one to be on the safe side!

Cheers
Jeff

[ianaudia4]

Thanks for the tip off Ian, £24 quid-ish in the post!

Apprently they have plenty in stock. I nearly got a spare one to be on the safe side!

Cheers
Jeff

You're welcome mate, and if I was you get a spare to keep in the boot!

[p in phcas]

Does anyone have a pic of the correct routing for the 18i from bulkhead to clutch? I'm mine isn't correct as the pedal is heavy and the outer sheath rubs on the rocker cover.

[ThomasD]

Does anyone have a pic of the correct routing for the 18i from bulkhead to clutch? I'm mine isn't correct as the pedal is heavy and the outer sheath rubs on the rocker cover.

You can see a picture of the cable in my engine bay on Richie's site:

http://website.lineone.net/~dr.dub/mk2ext.htm

I think the routing is correct. The cable passes over the top of the cambelt cover - but not so low that it gets wrapped around it (I added a zip tie to help that). There is a metal clip on the rocker cover which helps to locate the cable. Also, there is a plastic clip on the brake master cylinder which tries to keep the cable vertical. I say "tries" because I find that plastic clip always moves a bit.

All that said, when I first got the car, I found the clutch a bit heavy. But as I had not owned a VW with a clutch cable in many years, I think I had just forgotten what it was like

[ianaudia4]

I would post you a picture but Photobucket is being a feckin pain in the harris!
Have you a picture of yours? If so I could take a look and see if there is anything obvious.