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Clutch Cable replacement success

DaveOBrienDaveOBrien
Well last week the day before the San Diego C&C my clutch cable broke. I sent off to VS for a new shortened clutch cable. My old one had been the looped and clamped style and the hose clamps had loosened up last summer (I just reclamped it).

Looked at my manuals and did some online research http://www.superbeetles.com/Tech_talk/sep.htm
this was the best besides the Samba.

Hah, realised that the old wing nut was larger than the new cable end so I had to go to the local VW parts store and just for kicks I bought a standard bug clutch cable.

I must have some blockage or deformed tube in my pan because I could not get the cable end through the tube got about 2/3's the way. And Yes I did remove the bowden tube so it wasn't that. Maybe from when the frame was shortened?
Solution was to cut the longer cable and it sailed through, and I spliced the cable by overlapping and clamping with two 1/8" u-clamps. Worked like a charm and I'm back on the road again.
1959 Intermeccanica(Convertible D)
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DaveOBrienDaveOBrien
Well last week the day before the San Diego C&C my clutch cable broke. I sent off to VS for a new shortened clutch cable. My old one had been the looped and clamped style and the hose clamps had loosened up last summer (I just reclamped it).

Looked at my manuals and did some online research http://www.superbeetles.com/Tech_talk/sep.htm
this was the best besides the Samba.

Hah, realised that the old wing nut was larger than the new cable end so I had to go to the local VW parts store and just for kicks I bought a standard bug clutch cable.

I must have some blockage or deformed tube in my pan because I could not get the cable end through the tube got about 2/3's the way. And Yes I did remove the bowden tube so it wasn't that. Maybe from when the frame was shortened?
Solution was to cut the longer cable and it sailed through, and I spliced the cable by overlapping and clamping with two 1/8" u-clamps. Worked like a charm and I'm back on the road again.
FM Former Member
Hey Dave O,
Sounds like you did the same "cable clamp" solution that I did, 'cept I used three cable clamps. I also liberally lubed the cable during assembly. Result was a clutch action was WAY lighter than before - which may explain why I had to replace the cable in the first place. Glad you're in motion again.
DaveOBrienDaveOBrien
Thanks Ernie and David,

I had to cut the longer standard VW cable, I suspect that the VS one would have worked but there was an obstruction in the tube. The threaded part would not go through but the cut cable end did. And man was that cable tough to cut!

I only had two U clamps so I will get another one and slap it on. Would hate to have it slip.

Working on these cars does wonders for your flexibility not to mention just climbing in and out of them. Happy the job is done and when I removed the pedal assembly I was hoping it would go back together easy. Luckily I put it back together quickly (same day) otherwise I would have forgotten something I'm sure. Reminds me of my youth where if I didn't fix it I walked.

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Alan MerklinAlan MerklinDrclock - Elkins, West Virginia Supporting Member
Obstruction solution:
With the Accelerator, heat or clutch cable out, I use a 5'piece of metal electrician's snake. Grind a taper on one end to form a cutter edge and chuck the other into a cordless drill.
Spray some WD 40 or similar lube into the cable tube, insert the snake. Push the metal snake gently into the tube as you power up the cordless drill ON SLOW speed and work it through...too much speed and you'll twist the snake into a pretzel and wrench your wrist all at the same instant. ~Alan
FM Former Member
Hey Dave O, I store CRZNTUB on a KWIK LIFT (see product review tab) in my garage. It's amazing what gettig down and up off a creeper 30 or 40 times in one day will do for someone with arthritis. For sure I don't get started as early in the morning as I use to.

Here is some zen: Felixibility is like the Bowden tube on your clutch cable, no bend is bad, just a little bend is good, too much bend is invite to a failure. I resemble that remark!
Jack CrosbyJack CrosbyHot Springs, AR, VS RabyTypeIV

Dave---congrats on getting the new clutch cable installed and working well. You know, these cars are a blast to drive but many never know the satisfaction of FIXING something on the car either to repair it or to make it better. I'm no mechanic but like you I have had some
little victories that to me were major ones. I don't want to face changing out a clutch cable but when the day comes I have the info in the Knowledge section plus your new post and the other great tips from our "brain trust". Hell---it almost makes me want my clutch cable to snap!! Not really, but I'm ready for the challenge now.

Lane---same temps here---64 degrees today and lots of tinkering going on here as I plan the installation of my shiny new Marchals.
I blame Marty for showing me his nice fog lights that gave me the itch!

---Jack
DaveOBrienDaveOBrien
Thanks Jack,

I'm of the "if it isn't broke, don't fix it" school but it was kinda fun. So far Ive swapped the muffler a couple of times, adjusted the valves, oil, fixed lights, horn button, added a third brake light and power source.
Still to do is the fog lights w/switch, armrests and swapping out my 914 seats with some Miata seats I bought (just need to dye the seats) my family thinks I'm crazy but you guys understand.

Lane, as David K will confirm we had clear sky's today with a high of 66. David, I really hate those sudden aches, my buddies at work have a theory that the long 4 day xmas holiday ending with the Chargers crushing of the Broncos did not help with the older bones. I bet David was jumping out of his chair Sunday night!

Cheers
Dave

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