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    Thread: Clutch Cable Carrier Tube breaky....

    1. Member teknikALLEN's Avatar
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      07-11-2013 10:24 PM #1
      My carrier tube breaky for me today!



      Well... it actually looks like it broke a while ago and catastro****ly failed today to be teknikly correct.

      I stuck a washer on and let the cable adjuster all the way out for the roadside fix.... when I got home I noticed the cable was cutting the plastic cable end.





      So I rigged up a couple bottle tops as spacers:




      Trimmed the smaller cap to compensate for the angle of the dangle:




      Fits together at the angle with a nub to fit through the firewall:




      It's a little spongy but the cable is not binding or cutting the cable end nor firewall and all the slack is taken up.



      How bad is it to remove the pedal cluster??

      Are these pedal clusters universal through the cabby run? ( i.e. will a 1992 fit a 1985)?

      Last edited by teknikALLEN; 07-13-2013 at 08:31 PM.
      Quote Originally Posted by briano1234 View Post
      I would rather do a 3 rear cables than a passenger side motor mount.
      020ld for this stuff... a clutch and 5th gear conversation with Broke VW

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    3. Member tolusina's Avatar
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      07-11-2013 10:41 PM #2
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    4. Member teknikALLEN's Avatar
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      07-11-2013 10:51 PM #3
      Ron, thanks to the link to the fix.... checked it from a previous thread in the Mk1 section.... will likely cut a piece of the tube and make a spacer for the washer.

      Was looking for some experience with actually removing the whole thing-a-ma-jigger and replacing it with one from say... a 1992...

      That is if it fits....

      Does it entail removing the entire dash?

      ... just the kneeboard?

      .... or can I remove my seat and pull it upside down?


      For some reason it doesn't seem to be a step by step in my Bentley...

      (but my eyesight has gotten bad in my advanced age and I could have missed it....).
      Quote Originally Posted by briano1234 View Post
      I would rather do a 3 rear cables than a passenger side motor mount.
      020ld for this stuff... a clutch and 5th gear conversation with Broke VW

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    5. Member CajunSpike's Avatar
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      07-12-2013 10:04 AM #4
      I've done the repair in ron's link. works fine, no disassembly required other than removing the clutch cable end from the pedal cluster.
      Save yourself some major work and just go with it.

    6. Member tolusina's Avatar
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      07-12-2013 10:45 AM #5
      I have changed the complete bracket a couple of times, it's a whole lot of work.
      The knee bar will have to come out for access, the dash stays in place.
      The steering column tube has to be wrestled with, there's one spring clip that's particularly tedious.
      Nuts on the engine compartment side, best I recall, attach the booster bracket, those are tedious too. I don't recall if the master and/or the brake lines need to be dealt with.
      ---
      As far as compatibility, best I can offer is that you make sure the replacement has provisions for two brake and one clutch switch if the target car has cruise control, otherwise I'd expect a direct bolt up.
      Don't expect a replacement bracket to be any stronger than the original. If you weld on any sort of stiffener brackets or gussets, you'll just be moving the weakest link deeper into the bracket. Best I recall, A2 brackets didn't suffer tube failures, the main bracket structure cracked in multiple places instead.

      It's a lot of work. Expect at least three to four hours if you are real good with tools, a day or more if you have to muddle through.
      The cheap easy fix can be done and driving again in about a half an hour.
      ---
      Whichever way you go, do use a new cable, lube it with some sort of light silicone grease that will last a long time without freezing in cold temperatures, or caking up over extended use.
      To prevent future failures, any time the pedal starts getting stiff, fix the cause of the stiffness.





      .





      .
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    7. Member teknikALLEN's Avatar
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      07-13-2013 08:37 PM #6
      I have decided to fabricate a piece using a large washer welded to the original tube at the angle of the fully intact rubber fire wall seal.
      Last edited by teknikALLEN; 07-13-2013 at 08:45 PM.
      Quote Originally Posted by briano1234 View Post
      I would rather do a 3 rear cables than a passenger side motor mount.
      020ld for this stuff... a clutch and 5th gear conversation with Broke VW

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    8. Senior Member briano1234's Avatar
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      07-13-2013 09:00 PM #7
      Quote Originally Posted by tolusina View Post
      I have changed the complete bracket a couple of times, it's a whole lot of work.
      The knee bar will have to come out for access, the dash stays in place.
      The steering column tube has to be wrestled with, there's one spring clip that's particularly tedious.
      Nuts on the engine compartment side, best I recall, attach the booster bracket, those are tedious too. I don't recall if the master and/or the brake lines need to be dealt with.
      ---
      As far as compatibility, best I can offer is that you make sure the replacement has provisions for two brake and one clutch switch if the target car has cruise control, otherwise I'd expect a direct bolt up.
      Don't expect a replacement bracket to be any stronger than the original. If you weld on any sort of stiffener brackets or gussets, you'll just be moving the weakest link deeper into the bracket. Best I recall, A2 brackets didn't suffer tube failures, the main bracket structure cracked in multiple places instead.

      It's a lot of work. Expect at least three to four hours if you are real good with tools, a day or more if you have to muddle through.
      The cheap easy fix can be done and driving again in about a half an hour.
      ---
      Whichever way you go, do use a new cable, lube it with some sort of light silicone grease that will last a long time without freezing in cold temperatures, or caking up over extended use.
      To prevent future failures, any time the pedal starts getting stiff, fix the cause of the stiffness.
      Is this Ron's technospeak for PAIN IN THE ARSE?

    9. Member teknikALLEN's Avatar
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      07-14-2013 09:43 AM #8
      Quote Originally Posted by briano1234 View Post
      Is this Ron's technospeak for PAIN IN THE ARSE?
      I forced the issue by asking for a few details....

      my bad.
      Quote Originally Posted by briano1234 View Post
      I would rather do a 3 rear cables than a passenger side motor mount.
      020ld for this stuff... a clutch and 5th gear conversation with Broke VW

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    10. Member teknikALLEN's Avatar
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      07-16-2013 01:46 PM #9
      I just came across this repair panel on ebay designed just for this situation! It is designed for RHD, but it looks to be good for LHD as well.



      Any of you have an opinion? It is asymmetrical in the contours....
      Last edited by teknikALLEN; 07-16-2013 at 02:16 PM.
      Quote Originally Posted by briano1234 View Post
      I would rather do a 3 rear cables than a passenger side motor mount.
      020ld for this stuff... a clutch and 5th gear conversation with Broke VW

      My MkI & Cabby WTB Wish List
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    11. 11-03-2013 08:57 AM #10
      Looks like the domain to the link on the easy fix has expired anybody have a copy of the write up?

    12. Senior Member briano1234's Avatar
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      11-03-2013 03:50 PM #11
      Email Tolusina, and he will send it to you...

    13. Member tolusina's Avatar
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      11-03-2013 03:53 PM #12
      Quote Originally Posted by briano1234 View Post
      Email Tolusina, and he will send it to you...
      Sorry, he can't because he can't find it........
      Text of the original is apparently gone, photos are coming right up.




      .
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    14. Member tolusina's Avatar
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      11-03-2013 04:18 PM #13
      teknikALLEN has posted this excellent photo of the part that breaks off in it's broken off state......


      Here's a pic of the same part, repaired one of the hard and somewhat hazardous ways, welding in place....

      Can't say I recommend this method except for skilled and cautious welders.
      ---
      Head off to your local hardware store's plumbing department. It's been a while and I no longer have the car, best I recall, we'll be working with 3/4" pipe, might be 1/2", if you take your busted piece or clutch cable, size will be readily apparent.
      All you need to buy there are a floor flange and a 1" or 2" long nipple.

      Floor flange.....


      Nipple......


      Here is the end result installed........


      Odd shaped cut, the flange protrusion fits nicely into the hole in the firewall........


      Pipe nipple screwed into the bottom side of the flange, reverse of normal plumbing use, thread tapers are bass-ackwards, parts go together just fine......


      Length of the cut down pipe nipple is not critical, here is what worked fine on my car.......

      Plus or minus 1/2" from this will likely work just fine.

      The odd shaped cuts i made to the floor flange need explanation.
      I had limited tools on hand, I just cut until the flange would fit up flush to the firewall and work.
      If you've got more tools and time than I had when I made this repair, you should be able to produce a much more aesthetically pleasing result.
      The version shown looks like a hack job, I've seen a few versions elsewhere that took this idea and refined it nicely.

      Here's what the clutch arm normally looks like while operating........







      ,
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    15. Member bugsy98nb's Avatar
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      11-03-2013 05:24 PM #14
      Quote Originally Posted by tolusina View Post
      teknikALLEN has posted this excellent photo of the part that breaks off in it's broken off state......


      Here's a pic of the same part, repaired one of the hard and somewhat hazardous ways, welding in place....

      Can't say I recommend this method except for skilled and cautious welders.
      ---
      Head off to your local hardware store's plumbing department. It's been a while and I no longer have the car, best I recall, we'll be working with 3/4" pipe, might be 1/2", if you take your busted piece or clutch cable, size will be readily apparent.
      All you need to buy there are a floor flange and a 1" or 2" long nipple.

      Floor flange.....


      Nipple......


      Here is the end result installed........


      Odd shaped cut, the flange protrusion fits nicely into the hole in the firewall........


      Pipe nipple screwed into the bottom side of the flange, reverse of normal plumbing use, thread tapers are bass-ackwards, parts go together just fine......


      Length of the cut down pipe nipple is not critical, here is what worked fine on my car.......

      Plus or minus 1/2" from this will likely work just fine.

      The odd shaped cuts i made to the floor flange need explanation.
      I had limited tools on hand, I just cut until the flange would fit up flush to the firewall and work.
      If you've got more tools and time than I had when I made this repair, you should be able to produce a much more aesthetically pleasing result.
      The version shown looks like a hack job, I've seen a few versions elsewhere that took this idea and refined it nicely.

      Here's what the clutch arm normally looks like while operating........







      ,
      this is what the Prior owner to my cabby did same as above I've had the cabby for a year with ZERO problems from it , http://www.golfmkv.com/forums/showpo...ostcount=22985
      ~ Jay (o\ | /o)

    16. Senior Member briano1234's Avatar
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      11-03-2013 05:25 PM #15
      Well no one else said it, THANK YOU RON....

    17. Member tolusina's Avatar
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      11-03-2013 06:05 PM #16
      Quote Originally Posted by briano1234 View Post
      Well no one else said it, THANK YOU RON....
      Thanks for the thanks Brian, but this fix won't be needed on your automatics.
      Lot of broken links to the152.com on the neoBentley+ that need to get fixed, one at a time as they come up I guess.........





      .
      Quote Originally Posted by kamzcab86
      I hate reading: "But I bought this car for $500 and don't want to put another dime into it."
      ____(hey, it's VW AND it's electrical, what's not to fail?) neoBentley+



    18. Member flying_oliver's Avatar
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      11-03-2013 06:42 PM #17
      Any

    19. Member flying_oliver's Avatar
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      11-03-2013 06:43 PM #18
      Any info/idea on when the 152 will be up again? I just checked and it still said its down.

    20. 11-04-2013 11:39 AM #19
      Thanks for the pictures, I ended up browsing the local hardware store and coming up with a random half inch bracket to a window fixture and using an inch long spacer, kinda ghetto but functional for now, eventually I'll go with the floor flange method seems a lot less sketchy then mine haha.

    21. Member teknikALLEN's Avatar
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      04-29-2014 10:08 AM #20
      Thanks Ron.

      I think I should post a repost to a post with a link to this post retitled "Ron's missing the152 clutch tube fix."
      Quote Originally Posted by briano1234 View Post
      I would rather do a 3 rear cables than a passenger side motor mount.
      020ld for this stuff... a clutch and 5th gear conversation with Broke VW

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    22. Member rabbitnothopper's Avatar
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      10-12-2014 09:37 PM #21
      just broke mine on friday.....

      i had noticed the cable was going through the firewall at a rather sharp angle

      this angle problem is probally why it wore out the metal bracket tube

      when it went it just said POP and that was it.

      ...next step i suppose is to get the flange and go from there
      until i can remove the steering column assembly to weld in the cracked piece

    23. Senior Member briano1234's Avatar
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      10-12-2014 11:09 PM #22
      Quote Originally Posted by rabbitnothopper View Post
      just broke mine on friday.....

      i had noticed the cable was going through the firewall at a rather sharp angle

      this angle problem is probally why it wore out the metal bracket tube

      when it went it just said POP and that was it.

      ...next step i suppose is to get the flange and go from there
      until i can remove the steering column assembly to weld in the cracked piece
      Don't need to remove the steering column with Ron's fix nor welding required.

    24. Member rabbitnothopper's Avatar
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      10-15-2014 09:19 PM #23
      got mine replaced today

      removing the push nut on the tube was the hardest part! it really didnt want to give up


      mine apparently broke all the way back to the flat metal of the steering column itself
      irrelevant...


      my solution at home depot for $3 was:


      1inch to 1/2inch reducing washer X2


      1/2inch chase nipple


      1/2inch lock washer (i have dozens in my bag)


      thats it

      also it fits perfectly into that recess on the firewall


      if you wanted a little stronger material than 2x reducing washers
      you can cut this:

      http://www.homedepot.com/p/Steel-Cit...-25R/202515995

      its a 3-1/2 octagon box cover with 1/2inch knockout



      also the side facing into the engine bay
      if you use something with more height it reduces the slack on the clutch cable
      similar to oem would be about 1/8th inch from the firewall metal itself

    25. Member tolusina's Avatar
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      10-16-2014 10:04 PM #24
      Quote Originally Posted by rabbitnothopper View Post
      got mine replaced today

      removing the push nut on the tube was the hardest part! it really didnt want to give up


      mine apparently broke all the way back to the flat metal of the steering column itself
      irrelevant...


      my solution at home depot for $3 was:


      1inch to 1/2inch reducing washer X2


      1/2inch chase nipple


      1/2inch lock washer (i have dozens in my bag)


      thats it

      also it fits perfectly into that recess on the firewall


      if you wanted a little stronger material than 2x reducing washers
      you can cut this:

      http://www.homedepot.com/p/Steel-Cit...-25R/202515995

      its a 3-1/2 octagon box cover with 1/2inch knockout



      also the side facing into the engine bay
      if you use something with more height it reduces the slack on the clutch cable
      similar to oem would be about 1/8th inch from the firewall metal itself
      I pretty much like this!
      Your parts appear selected by an electrician, mine by a plumber.

      Can you post a pic of the completed assembly?






      .

    26. n00b
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      Today 08:20 AM #25
      Sorry guys In having to reinitialize this post. I have a 89 cabby and like others the tube ended up cutting my cable wire and snapfu. My tube broke off like many others has. I have built RONS pipe detail for the firewall fix, but this is my current problem. I have my slack adjuster set to the MIN setting and seems the cable is just a bit to short. Yes I have ordered the correct cable. I ordered the Pioneer cable. My clutch is tight the second i step on it. Its not fully releasing. I went up a pretty good grade in 2nd and she started to slip. I dont how else to get the slack needed to get the throw out bearing away from the plate to allow the full pressure to rest.. I almost need another 1 1/2" of cable it seems. Any ideas guys?
      Thanks in advance.

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