Re: clutch cable shattered

[DNK006@aol.com]

Wow man, you should write VW manuals!  I didn't need to loosen the tention at 
all.  Straight forward job, thats the VW spirit!  $18 for a fix...  My 
truck's clutch cylinder went out a week ago ($35) in the same parking lot!!! 
whats up with that???


In a message dated 1/31/2000 09:37:29 GMT Standard Time, 
drew@dyermaker.cs.uoguelph.ca writes:

> The clutch cable is pretty easy to change, especially if the adjuster
>  still works.  The following applies to manually adjusted cables:
>  
>  If possible, tun the adjuster to shorten the outer housing (lengthen the
>  cable) until there is enough slack in the cable to remove the clip and
>  rubber bushing form the clutch lever on the side of the transaxle (working
>  from the top of the engine compartment).  Pay attention to the orientation
>  of the parts - there's a rubber bushing that fits into the oblong hole on
>  the clutch lever, a metal spacer that the bushing fits into, then a
>  slotted clip that has a dent that fits the end of the clutch cable and
>  holds it against the lever.
>  
>  If you're definitely junking a FUBAR cable, cut the cable between the
>  adjuster and the clutch lever with a pair of cutters, paying attention to
>  where the retaining clip, spacer and bushing fall... :)  If the adjuster
>  is siezed but you're hoping to save the cable for an emergency spare, use
>  a jack to actuate the clutch lever to provide enough cable slack to remove
>  the retaining clip.
>  
>  Inside the car, remove the lower dash shelf, or tray for access to the top
>  of the clutch pedal linkage.  Often you can push the clutch cable from the
>  transmission end to unhook the eye from the hook on the clutch pedal.  If
>  not, then actuate the pedal while holding the cable end to unhook it.
>  
>  Remove the clutch cable from the engine compartment.  Install the new
>  cable (some anti-sieze or grease around the bushing that goes through the
>  firewall will aid future removal, if required).
>  
>  Working inside the car, hook the new cable's eye over the hook on the
>  clutch pedal lever.
>  
>  Working from the engine compartment, install the transmission end of the
>  cable down through the rubber bushing and the clutch lever on the
>  transmission.  With maximum cable length you should be able to install the
>  rubber bushing and retaining clip with nothing more than light hand
>  pressure lifting on the lever.  If you haven't done this before you'll
>  probably find it easier to do from underneath the car.
>  
>  Adjust the cable using the large white plastic knob to achieve a distance
>  of 12mm between the cable adjuster and the casting on the side of the
>  trasnmission where the clutch cable goes through.  Lock the adjuster with
>  the 15mm or 17mm nut.
>  
>  Re-install the under-dash tray or shelf (you may wish to apply some
>  lithium grease to the hook on the clutch pedal and the bushings if you
>  have a squeaking pedal.)
>  
>  Hope you find this info helpful.
>  
>  Drew  (84 Wolfsburg Ed.)

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