Hi Guys

I'm constantly breaking clutch cables, averaging about 1 or 2 per year in my last couple of bugs.
Does anybody know where I can get one that will last me longer? Something a bit more heavy duty.
I'm getting sick of replacing them, it's not a fun job.

Cheers
Dave

wHERE ARE THEY BREAKING?

if its near either end it means the cable is bending

You could try a later clutch arm on the gearbox as they were longer [not sure when they changed them?]
Supers?

Do You grease the cable as You put it IN?

heaps of lithium based grease?

You would never want to touch an old cable after that.. lol

LEE

Its not the cable or maybe if its cheap chinese

I would be looking at other things like pre tension, the outer tube and angle onto the clutch arm

also get an OEM cable from VVDS in Sydney

Many Years ago I found a company in the USA that made and sold unbreakable clutch and accelerator cables, but they wouldn't post them overseas...
they were not that expensive either..maybe stainless steel??

LEE

try these guys
http://jaydeeautocables.com.au/ 

[maybe stainless steel??

Shouldnt use stainless steel!!! It will work harden and break quicker than gal!!

As said above , whre are they breaking as if it's the same spot each time it could be something as simple as a brocken hard tube that constantly chaffes the cable or a buggered bowden tube that also chaffs the cable
And finally is it a stock clutch pressure plate or a high poundage kennedy etc

I was thinking also of the pedal end too
if the cable end doesn't pivot like it should
the cable would break near that end...

otherwise as said... wherever its bending at

Bowden cable or tube etc

its NOT normal

LEE

sounds like someone need to develop pedal clusters with integrated hydraulic clutch. Been done on so many of the popular aussie cars already. Guess the vw is too cheap of a market to invest in

Hi Guys

Thanks for the replies.
The cables seem to break about 3/4 of the length, down towards the rear of the car.
The clutch tube is firmly attached at either end, im using a stock 1300 with a stock clutch too.
I do put as much grease as I can when replacing them, and you are right Lee I certainly dont wan't to touch them after that.
A friend has suggested that my height may have something to do with it, im 6 foot 5 and tend to depress the clutch pedal pretty close the the floor which could be stretching the cable.
Ill check out Jaydee auto cables, they are just around the corner from my house.
Cheers
Dave

sounds like the clutch tube inside the tunnel is worn through at that point.

http://jaydeeautocables.com.au/ 
By the catalog they sell automotive electricial cable not clutch cables.

ummm I think you guys are look for this mob.

http://www.autocables.com.au/ 


they make custom cables and what not. I have been recommended them to do my handbrake able to suit my skyline calipers.

wait what??

https://vault2.secured-url.com/ShopSecure/autocables/results1.asp?CategoryID=...

I thought that is where many do break [from a very old memory]

so, You may be correct...

You need to re adjust Your cable so the clutch is always depressed when You push the cable in [no grinding]
so I would suggest You unscrew the adjuster slightly until it crunches and then about 1 turn tighter..

You may be adjusting the clutch cable so it actually works a few mms 10-20mm] before it hits the body.. ??

hope that helps

LEE

Hi Guys

Thanks for all the help and sugggestions.
Ill clarify a little bit, in my previous bug i was going through 1 -2 per year, no worries at all.
I bought a new Beetle in Feb this year and broke my first cable on the weekend, continuing my track record of busting one every 6 months or so.
Anyhow, i dropped it off at the mechanics cos I couldn't bear to do it myself, and the good news is that the cable was bone dry, not a bit of grease on it.
I now have a new cable, plenty of grease and the difference in the clutch is amazing.
It feels so light now, and makes me realise there must have been something wrong with my previous Beetle.
Thanks again

Good news...

so, maybe Now You will get a few years worth of wear..

cheers

LEE