I thought I'd be productive yesterday after getting home from work and that I'd go ahead and swap my speedometer cable out since the new cable and gasket had been beckoning from the backseat for several weeks... The project turned into a bit of an abortion since I am now in the market (again) for a new dash trim surround and I've also set myself up for a LOT of additional and unnecessary work thanks to loosing my patience while reassembling everything. No one but myself to blame, of course, but if this prevents even one person from rushing a tedious project and creating more work for themself, then telling on myself will serve a good purpose!
In all honesty, it's not as bad as it appears but I am back to riding sans radio and with an open dash for the moment. I was going to swap in the excellent dash from my other '89 parts car anyway so this simply forces the issue and ensures there won't be too much procrastination involved. It will also afford the opportunity to use the intact portions of the wiring harness from the parts car (after careful scrutiny, of course) since many of the leads in my existing harness had been cut and spliced (and thereby shortened, leading to some frustrations themselves) by a previous owner. I'll also be bundling the different harness sections to alleviate the rat nest effect that the former owner left behind. I'll document and share the swap in another thread when the time arrives.
Back to the original problem! I removed the speedometer cable thinking that it was broken but found that the gear that one is supposed to swap from their old cable to their replacement cable had been stripped on one side. I'm not sure what would cause the gear damage (it wasn't like that when I pulled it last year while replacing the clutch) but it's obvious that it needs to be replaced now. It should be rather obvious in this photo:
Does anyone have an idea where I might find one, aside from the dealer (if it's dealer-only, I'll have to order it from an out-of-town dealer since I refuse to deal with the local one)? I've yet to find any compatible manual transmission VW's in the region's salvage yards so that's not really an option, either. I haven't pulled the one from my parts car to look at it but since it's an automatic, I have a feeling it's an entirely different set-up since the Bentley mentions nothing about gear replacement when swapping the auto cables and the mounting system/location is different, as well.
Just for the record, I went ahead and installed the new cable into the rear of my cluster (great fun) and left it out of the way in the engine bay while I used the old cable (sans gear) to cover the mounting hole on the transmission until I can obtain a new gear. Whoever did the Fox 1.8 engine swap in years past had substituted duct tape wrapped around the cable instead of the firewall grommet so at least now both the firewall and the raintray grommets are in place and I imagine it will cut down on some dust and noise behind the dash, as well. It also dawned on me that they didn't use a gasket at the transmission (I remember thinking that it just didn't look like the best seal in the world when I reinstalled it while doing the clutch... Go figure!) so that will be corrected now, too.
Thanks in advance for any ideas!
Modified by native-texan_in_tn at 8:25 AM 4-20-2008