| [ Total Views: 1131 | Total Replies: 19 | Thread Id: 98814 ] |
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 butch97
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| posted on September 15th, 2012 at 03:36 PM |
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Clutch cable keeps breaking: 67 Beetle
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
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68AutoBug
A.k.a.: Lee Noonan
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| posted on September 15th, 2012 at 08:55 PM |
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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
- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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 vw54
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| posted on September 15th, 2012 at 09:03 PM |
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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
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68AutoBug
A.k.a.: Lee Noonan
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| posted on September 16th, 2012 at 10:20 AM |
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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
- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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barls
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| posted on September 16th, 2012 at 10:26 AM |
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try these guys
http://jaydeeautocables.com.au/
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whathaveidone
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| posted on September 16th, 2012 at 10:53 AM |
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[maybe stainless steel??
Shouldnt use stainless steel!!! It will work harden and break quicker than gal!!
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OZ Towdster
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| posted on September 16th, 2012 at 06:56 PM |
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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
Don't let body work get in the way of real suspension travel
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68AutoBug
A.k.a.: Lee Noonan
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| posted on September 16th, 2012 at 10:14 PM |
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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
- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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donn
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| posted on September 16th, 2012 at 11:35 PM |
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| Quote: | Originally
posted by whathaveidone
[maybe stainless steel??
Shouldnt use stainless steel!!! It will work harden and break quicker than gal!!
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Second that, tried it and failed in 3 months.
I dream of a day when a chicken can cross a road without being asked for it's motive!
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vlad01
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| posted on September 17th, 2012 at 09:44 AM |
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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 
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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butch97
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| posted on September 17th, 2012 at 01:44 PM |
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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
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vlad01
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| posted on September 17th, 2012 at 01:57 PM |
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sounds like the clutch tube inside the tunnel is worn through at that point.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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 Bizarre
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| posted on September 17th, 2012 at 02:35 PM |
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| Quote: | Originally
posted by butch97
I'm constantly breaking clutch cables, averaging about 1 or 2 per year in my last couple of bugs.
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Are you saying the same thing happens in different cars??
if so - then that is REALLY weird
In 30 years of driving bugs I reckon I could count on one hand the number of cables that have broken and still have fingers left over.
If it is just one car - then I would be laying out the cable beside the tunnel, taking a deep breath, and cutting an access hole to have an
explore.
If it is multiple cars - I would be looking at the way you adjust, install and set up your clutches
Keep us updated on what you find out
Futue te ipsum!!!
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vwo60
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| posted on September 17th, 2012 at 02:42 PM |
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http://jaydeeautocables.com.au/
By the catalog they sell automotive electricial cable not clutch cables.
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vlad01
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| posted on September 17th, 2012 at 03:54 PM |
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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.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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vlad01
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| posted on September 17th, 2012 at 03:57 PM |
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wait what??
https://vault2.secured-url.com/ShopSecure/autocables/results1.asp?CategoryID=...
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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68AutoBug
A.k.a.: Lee Noonan
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| posted on September 18th, 2012 at 11:58 AM |
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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
- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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barls
A.k.a.: Mr indestructible
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| posted on September 18th, 2012 at 12:04 PM |
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right late night and got the wrong link. my bad
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butch97
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| posted on September 18th, 2012 at 01:44 PM |
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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
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68AutoBug
A.k.a.: Lee Noonan
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| posted on September 18th, 2012 at 06:28 PM |
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Good news...
so, maybe Now You will get a few years worth of wear..
cheers
LEE
- [size=4]Helping keep Air Cooled VWs on the road - location: SCONE in the Upper Hunter Valley - Northern NSW 320 kms NNW of SYDNEY--- [/size]
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