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Does anyone know a trick how to install a new clutch cable? The eleven year old cable finally broke in my 2006 Vintage speedster because it unraveled at the front of the tube. I obtained a new correct length cable from Kirk but I can't get it started because I can't really feel the tube-not a lot of feeling in my hands. I took off  the Bowden tube and I reversed the cable and it slides completely to the front fairly easy. The tube doesn't feel loose or broken. When I look in the pedal opening I can see the fuel line on the bottom of the tunnel. I  have  tried rubber tubing ,needle nose pliers, and small vice grips to no avail. The length of the threaded section is the same as the previous one. Thanks for any  ideas.

Joel

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The front of the clutch tube is at about 2:30 o'clock as you look straight at the pedal cluster hole in the tunnel.  If you stick a finger in there you should be able to feel it, even with poorer touch sensitivity.  If you have a small mirror and can stick it in the pedal cluster opening and look towards the rear, you should be able to see the tube, but the front of the tube should be very slightly higher than mid-high on the hole, and about 1" behind the rear of the opening.  It is welded to a bracket that is part of the bottom of the tunnel and holds the tube up off the deck about 2"-3".  That should give you a bead on where it's at.

That said, VW never made it especially easy to get the stud started into the tube.  You have to get a feel for where the tube starts, then get the stud end started in the end of the tube and then PUSH to get it started.  Once it's started, the cable is smaller diameter than the stud and should form a nice bend and just follow along.  Getting the stud in there and started on its way in the tube is the hardest part.   Grease the stud, find the tube opening and get the stud in it, then try to pull the tip of the stud toward you (to straighten it in the tube) while pushing the cable end of the stud with your left hand to force it into the tube.  When it gets in there, the pressure will release and it will continue into the tube, but that first couple of inches is a bitch.

Good luck, Joel.   Grease, grease, grease.......

Don't forget to grease the rest of the cable on the way through.  I wear some vinyl gloves, get a walnut-size glob of grease in one hand and then slide the cable through the grease glob while pushing it into the tube.  That gets the entire cable greased with minimum fuss in the cockpit.  

Last edited by Gordon Nichols

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