clutch cable tube replacement?

warrenbaity · Post by **warrenbaity** » Fri Mar 31, 2006 1:29 pm

I have finally gotten around to the home stretch on my complete buildup of my 66 bug. I started to get the pedals and cables installed and I found out that I have no clutch cable tube. Actually I have about 4 or 5 inches at the very front and then it just stops and dumps the cable into the tunnel. I just want to know what I should use as a replacement? I have also been thinking of only using 10 or 12 inches of tubing just where it exits the tunnel? This way itll be way easier to install? Any thoughts or opinions about this? Thanks

MedicTed · Post by **MedicTed** » Fri Mar 31, 2006 5:38 pm

You need the tube to maintain the proper flexion and adjustment. You probably will need to find a used tube and get it installed.

warrenbaity · Post by **warrenbaity** » Fri Mar 31, 2006 9:10 pm

I am not talking about the bowden tube. I know what that is for and I understand the function of it. I am talking about the tube that the clutch cable goes through in the tunnel. I can not use the bowden tube unless I have the tube that goes through the tunnel. And I need that unless I want to run solid mounts, which I do not. So I was just wondering what I should use as a replacement for my missing tube, and if I can run with just about a foot of it where if exits the tunnel and connects to the bowden tube? I really hope someone can help as I dont want solid mounts or a hydraulic setup. Thanks again for any help

Buggin_74 · Post by **Buggin_74** » Fri Mar 31, 2006 11:29 pm

u will definatley need the entire guide tube through the tunnel otherwise when u release the clutch the cable will get caught up on all the other things in there like shift rod, handbrake+heater cables fuel lines etc
i did a semi auto to manual conversion a few years ago and i got a lenght of 1/2" thin walled tube just a tad over 5 feet long
u will also need the middle bracket to weld it to
its a horrible job but is fairly straight forward
email or msn me if need any help

good luck
Joel

warrenbaity · Post by **warrenbaity** » Fri Mar 31, 2006 11:41 pm

Well the reason that I thought of only using a small length of tube was that I read an old post where that was talked about. I dont have the heater cables in the car, and the gas line runs along the bottom of the tunnel. I dont really see how the the clutch cable could interfer with anything else as long as it is routed correctly to begin with? I would appriciate some more input into this. Also buggin, did you take any pictures while you did the job? If so could you post them? Thanks

Buggin_74 · Post by **Buggin_74** » Sat Apr 01, 2006 2:39 am

do u know why ur bug hasnt got a full guide tube?
i dont know how u'd get a new cable fed through the 2 peices if it wasnt joined
the guide tube is welded to 2 mounts one just behind the pedals and the other just below the handbrake
heres some pics of them in a pan that was cut open

Joel

Gabe · Post by **Gabe** » Sat Apr 01, 2006 7:28 am

Thanks Buggin for those great pictures. Like they say " . . . worth a thousand words." I've always wanted to see what the tunnel looks like inside, and those cross-section pics are super. I'm definitely going to copy those to my computer for future reference.

MikeVW · Post by **MikeVW** » Sat Apr 01, 2006 9:22 am

How does your clutch tube disappear like that? The 2 pieces of tube might work but what happens if your cable breaks? It would be a hassle to replace it.

Mike

warrenbaity · Post by **warrenbaity** » Sat Apr 01, 2006 9:32 am

I didnt understand how it wasnt there either. I figure that if I only use the small rear piece Ill be able to push the cable to the rear of the tunnel and then feed it through that piece through the rear access hole.

MedicTed · Post by **MedicTed** » Sat Apr 01, 2006 5:39 pm

warrenbaity wrote:I didnt understand how it wasnt there either. I figure that if I only use the small rear piece Ill be able to push the cable to the rear of the tunnel and then feed it through that piece through the rear access hole.

You can try, but it won't work.

Post by **Marc** » Sun Apr 02, 2006 7:44 pm

The only part of the cable conduit that's vitally important is the rear section that the Bowden tube connects to - as you realize, it has to be welded in solidly in order to be able to establish proper Bowden tube preload.
It WILL work with only this short piece of tube present. Getting the cable routed through the first time is slightly challenging; if you need to replace it later on all you have to do is tie a wire to the old one before you pull it out, and use the wire to pull the new one back through. Oh, and the cable may act a little long, you may have to use a slightly shorter one or make a "longer nut" by drilling the threads out of one wing nut and welding another one on top of it.
Would it be better to weld in a complete tube? Of course. But it isn't mandatory.

Buggin_74 · Post by **Buggin_74** » Mon Apr 03, 2006 3:15 am

hi all,
if anyones interested the entire car was cross setctioned lol
u can see the rest of it and various other VW parts cross sectioned on the queensland vw drivers club website
http://www.vwdcqinc.org.au/insideabug.html

Joel