Clutch Cable & Conduit

ims101 · Post by **ims101** » Wed Feb 23, 2011 11:13 am

Hi All,
My clutch cable snapped the other morning (as I said in the Dubfreeze thread) this seams to happen on a regular basis (well 2000m since the last time). I don't think the Beetle cable is strong enough for the 911 clutch? When I've got it all built up and back together I'll get a bigger/stronger one custom made for the job with the right ends and the right length. But what I need to know is does the standard Beetle cable goes through the conduit where it comes out of the chassis/centre tunnel with the threaded end on it? Because the cable (with the threaded end on) won't go through conduit on my car!! But if I cut the cable and try to thread it through it will probably fray, see me dilemma?

Any advice or help welcomed

Nige · Post by **Nige** » Wed Feb 23, 2011 11:27 am

http://www.deimosaircooled.com/products/cables/beetle
http://www.justkampers.com/shop/clutch- ... 14423.html

As it exist the chassis I'm also sure it goes through a metal tube that has a bend in it to smooth out the clutch action, this help reduce the clutch/bite snatch. I certainly seen this on one of my aircooleds in the past but can't remember which one.

speedstars · Post by **speedstars** » Wed Feb 23, 2011 11:45 am

Do you mean you`ve got a shortened cable with the threaded end already crimped on, and you can only feed it through from the clutch pedal end so far and then in gets stuck? If so you`ve got a bend in the conduit, that is longer than the threaded section, hence it won`t go around the bend. I`ve always used a shortening kit. wrap the end with tap and cut off the threaded end, poke through with plenty of grease and then fit the shortening kit. It looks Heath Robinson, but they work. If your cable keeps breaking in the same place, usually the front, it`s rubbing on the entrance to the conduit. File smooth if rough, or bend the conduit to the right angle. It`s fiddly, because you can only access it through the pedal assembly opening. If not cut a hole in the tunnel.

speedstars · Post by **speedstars** » Wed Feb 23, 2011 11:55 am

Sorry, my bad, Iv`e just re-read your post. You mean the plastic coated conduit between the chassis and the mount on the gearbox. Pull the end off the gearbox mount, poke the cable through, with the conduit stretched straight poke the cable through the gearbox mount, bend the conduit and push the end through the hole in the gearbox mount. If the threaded end wont go through at all, use the shortening kit. But it should do, unless you`ve got an M8 thread on it!

ims101 · Post by **ims101** » Wed Feb 23, 2011 12:22 pm

This is my conduit

it has a threaded end for adjustment at one end and the other fits onto the chassis

the inside diameter is only wide enough for the cable and not the threaded end fitted to the cable it is also 9cm longer than a VW Beetle one.

this is where the threaded end goes into the gearbox

and this is the leaver that the cable has to attach to on the clutch

looking from the back of the car forwards

speedstars · Post by **speedstars** » Wed Feb 23, 2011 12:48 pm

sorry, didn`t realise it was a 911 set up. Principles the same, but I`ll leave it to the 911 boys now

Bruce M · Post by **Bruce M** » Wed Feb 23, 2011 2:09 pm

Your cable tube doesn't look standard to me. Is it a normal conduit with a threaded fitting shoved in the end?

Don't know much about the your car but does it use a standard length or shortened beetle cable?

Depending on the answers to above, some german conversion parts (for a 901 box in a beetle) may help.

Firstly, a new mounting point for the cable tube. Bolts to the side cover and allows a std beetle tube/conduit to fit. Easy one to make to be honest.

Also a threaded connector for the std beetle cable into a 901 clutch arm. Solves the problem with the cable being too short (in a beetle).

See www.bugat5speed.de for details (clicking the UK flag will translate some pages).

As per above. Clean up the conduit where it enters/exits the chassis and burrs chew through a cable pretty quick. Also if the car uses a shortened bug chassis, how did they fix the cut clutch conduit inside the tunnel?

Bruce M · Post by **Bruce M** » Wed Feb 23, 2011 2:29 pm

oh ................

wait.

Is that a 915 box?

In which case the post above is probably useless....

ims101 · Post by **ims101** » Wed Feb 23, 2011 3:34 pm

It's a standard Beetle clutch cable but it has to be shortened by about 135mm (this is the threaded end on the cable that won't go through the conduit!)

and when its been cut down I'm going to use this to finish off the shortened cable (it's a bit crude but there doesn't seem to be anything else?)

This end of the conduit does look a bit knackered so I'll file it down and make it better.

also this tubing was inside it any ideas? The numbers are 430 320 38 07 or 09 at the end

ims101 · Post by **ims101** » Wed Feb 23, 2011 3:37 pm

Bruce M wrote:oh ................

wait.

Is that a 915 box?

In which case the post above is probably useless....

Yeah it is sorry I thought I said in the first post it's a 911 3L engine and a 915 box

mdmax72 · Post by **mdmax72** » Wed Feb 23, 2011 6:50 pm

Ian

the threaded end should go through the conduit. The conduit should be around 10mm in diameter, allowing the thread end to pass through. What is proberly happening is that when the chassis was shortend you have to cut a section out, when it gets put back together the 2 conduit ends get tacked together. Sometimes more than a blob of weld gets used which is properly causing an obstruction in your passage

. Bit of a bugger which is why some people buy the standard beetle cable and chop it up without the threaded end so it passes through aliitle easier. If you do this put some tape on the chopped end to stop it binding/fraying in the conduit...

Just out of interest were does it keep snaping?? cos on you threaded section with the x2 nuts you can see it binding on the side, the plastic sleeve fits into that but must be to short which it is rubbing metal to metal. Is this were it snaps???

mdmax72 · Post by **mdmax72** » Wed Feb 23, 2011 6:53 pm

Ps the mrs in the background said you got nice fingers for a bloke but need to sort those cuticles out

mdmax72 · Post by **mdmax72** » Wed Feb 23, 2011 6:54 pm

Ps the mrs in the background said you got nice fingers for a bloke but need to sort those cuticles out

ims101 · Post by **ims101** » Wed Feb 23, 2011 7:44 pm

There hairdressers fingers

I'm normally running them through someones hair

but that don't get my clutch fixed

Nige · Post by **Nige** » Wed Feb 23, 2011 8:08 pm

I was thinking that earlier, when you say would you like some product through your hair after a cut, do you use LM grease?