clutch cable

73BAY · Post by **73BAY** » Mon Mar 25, 2002 1:26 pm

my clutch cable came appart where it connects to the pedal. The cable is in fine shape but i cannot get it to stay connected to the pedal. The flimsy metal pice in the linkage spread appart, i tried to fix it by attaching a clamp around the cable end+the linkange, but it crapped out pretty fast.

any suggestions would help. and is this a common thing to happen? and is there any reason the hanes manual says to take the left rear wheel off other than ease of access because i found i had to crawl under the van anyway, taking the wheel off was just a pain.

Thanks,
the Brian

Hank Winning · Post by **Hank Winning** » Mon Mar 25, 2002 8:39 pm

taking the tire off if you have long arms it is easier than brushing the dirt out of your eyes.
solid jackstands on the torsion bar housing

does your cable end have the metal clevis pin
that locks it to the clutch pedal arm?

hank

Derek May · Post by **Derek May** » Mon Mar 25, 2002 9:58 pm

Get a new cable. Sounds like its bagged. Make sure you also get a new clevis pin, and grease the cable well before you slide it in.

I think busdepot.com has cables with clevis pins.

VeeDoubleU · Post by **VeeDoubleU** » Tue Mar 26, 2002 2:39 pm

This is a common effect from "riding" your clutch or it being too tight...or a combination of the 2. If your rest your foot on the pedal it will cause the tension of the cable to become too tight and the vibrations will wear out the small aluminum hook that attaches to the pedal assembly.

vwbusman215 · Post by **vwbusman215** » Tue Mar 26, 2002 3:32 pm

Speaking of clutch cables... I have a question.

I put a new clutch in the bus in Jan '01 and this problem was present before and after the new clutch. Whenever I adjust my clutch cable it is all the way adj and there is still too much freeplay in the pedal. Not just tons of freeplay but more than bentley calls for. I am as tight as the wingnut will allow me to go even with a new cable that I bought from RMMW for my year bus, '76. Could this maybe caused by something being worn in the transaxle or something else possibly. Anyone ever have this problem?

Any input appreciated.

------------------
Casey
www.angelfire.com/tx5/76vwbus

VeeDoubleU · Post by **VeeDoubleU** » Tue Mar 26, 2002 3:55 pm

Sounds like the issue I had when I put my first cable in.

I think what may be happening is your preload is not being tightened enough. There is a preload spring on your clutch lever that is connected to you tranny. If you pull on this lever it moves a few inches and seems to stop. this is where your freeplay is. Now if you pull on this lever to where it seems to stop then tighten your wing nut and let the lever go..that is your freeplay. When i did my first clutch cable I thought the preload that I could pull with my hand was the clutch being released....but you cant engage the clutch lever with your hand, its too hard...at least for me

thanks to the great invention of the lever.

What I do is put a block under my clutch pedal so I dont have to keep yankin on it. Pull the lever on the tranny to where it stops, then tighten the wing nut. Then go check the freeplay of the pedal with my hand. If its too tight..then loosen the wing nut...too loose ....then pull lever and tighten wing nut some more.

hope this helps!

vwbusman215 · Post by **vwbusman215** » Tue Mar 26, 2002 4:28 pm

I think I understand what you are talking about but I'm not sure if it is exactly what my problem is. My wingnut is tightened as tight as it goes, meaning no more threads on the cable left to tighten anymore. Sorry if I wasn't clear about that previously. Maybe I didn't understand correctly, but it almost seems as if the clutch cable is too long...?

Thanks

------------------
Casey
www.angelfire.com/tx5/76vwbus

VeeDoubleU · Post by **VeeDoubleU** » Tue Mar 26, 2002 5:26 pm

oh..i see

u may want to check your manual (if u have one) for the correct length....

according to motorworks.com and bus-boys.com, for your year, it should be 3215mm/126.57"

as far as something else being wrong...thats beyond me

vwbusman215 · Post by **vwbusman215** » Tue Mar 26, 2002 5:55 pm

Hey VeeDoubleU,
Thanks for the advice. I am curious if there is anything inside the trans that can wear to present me with my situation or if I just don't have something correct on the outside somewhere?

------------------
Casey
www.angelfire.com/tx5/76vwbus

vgonman · Post by **vgonman** » Wed Mar 27, 2002 2:09 am

Sometimes the Bowden tube is wong for the year, and or the solid tube it connects too has been bent "up", You can put a few large washers on the end of the tube right before it connects to the bracket on the trans...This can give you a little more distance to tighten the wing nut.

vwbusman215 · Post by **vwbusman215** » Wed Mar 27, 2002 9:36 am

I've got a new rubber tube with metal end that I will install when I get everything back together. The other tube had a plastic end and already had about 5-6 washers hooked up to it. Maybe this new tube will help some. I'll know in about 2 wks.

Thanks

------------------
Casey
www.angelfire.com/tx5/76vwbus

Pillow · Post by **Pillow** » Wed Mar 27, 2002 12:19 pm

Casey,

In all my years in VWs I have not seen the inner fork bend inside the bell housing. I have seen the tensioner spring break though, but that is not your issue here.

I think your cable is too long and the wrong PN. Given that the bowden tube is correctly situated.

I alwaus have a hell ov a time with the bays because the clutch pedal is too soft! Grrr, no feel at all.

------------------
Adrian Pillow
'66 VW Westfalia - "Biscuit"
'79 Porsche 911 SC - "Cochese"