Clutch cable length issues

Hi Guys,

Please can someone advise me about clutch cables.

I replaced the clutch cable on my carb/non GTI Mk1.

The one I got from Heritage was considerably longer than the old one.

The old one was 121cm
Whereas the new one from Heritage is 161.5cm.

Did I have the wrong cable to begin with and is the Heritage cable the correct one?

I ask because the Heritage cable is over a foot longer and I’m lucky if I don’t get smacked in the face with the slack when I open the bonnet.

Also, the guidance is that you need to leave 10 -12mm play at the clutch end, but when I do this, I struggle to get it into 1^st and it crunches when I put it in reverse. So, I have had to reduce the play considerably, I’m not sure what it’s at but it’s probably around 5mm. Is this this OK or is the Heritage cable just the wrong cable?

Heritage says that a GTI clutch cable is 147cm which is considerably shorter than the 161.5cm one they sent me but still longer than the one I removed which was 121cm. Should I give the GTI cable a go? What’s the difference anyway?

Thanks in advance for your wisdom.

Which engine/gearbox is it?

Hi,

It's a 1.8 carb engine, code: EX with the corresponding 5 speed G.box, code: 7G.

Both were taken from a post 83 Clipper (convertible) and fitted into my 83, 4 door tin top.

Thanks, hope you can help.

Hi,
The correct part number for 1.8 Carb RHD is 154721335, which is 1615mm long according to here.

Best place to buy it from is Mark at Classic-VW - You also get 5% discount if you become a paid member of the club - see here.

Thanks Ade,

It seems that the one I fitted is the right one then ie 161.5cm.

But why is it so long, why is there so much slack?

Also, why when I set the play to around 10mm at the gearbox end does it resist going into 1st and crunch when I put it into reverse?

Would I be better off with the GTI clutch cable? Apart from the shorter length is there any difference?

Thanks again

I guess it depends on how you route it, should come straight out past the timing cover, turn and run by the rocker cover and then down.

Not sure on the carb versus GTI cable as only ever had GTI's.

Sounds like the clutch is not disengaging, perhaps the clutch diaphragm, release bearing or internal rod/lever is worn. The internal levers are prone to splitting.
When you press the pedal is the clutch external lever getting full travel?

Could also be that you gear lever is not adjusted properly underneath.

Surely the GTI cable is longer because it has to go around the inlet manifold, my opinion for what it's worth is you need to get a cable the same length as the one you took off.
You don't need 10-12mm slack at the clutch end, I just set it up so there is some play there, probably about 3mm.

cedar said

Surely the GTI cable is longer because it has to go around the inlet manifold, my opinion for what it's worth is you need to get a cable the same length as the one you took off.
You don't need 10-12mm slack at the clutch end, I just set it up so there is some play there, probably about 3mm.

I would go with that clearance too as 10-12 is far too much.

Thank you all for your help and apologies for the late follow up.

It's too late for me now I've already put in the longer cable because that was the only one that was available quickly enough at the time.

However, I would recommend to everyone with a standard carb engine to get the shorter GTI clutch cable,  there is no difference in the fittings and you will have less cable to try and tame.

I don't know why they make 2 different cable lengths in the first place and charge more for the shorter one.

By the way, Daytona and Cedar, you were right I had to reduce the free play considerably. Not sure what it is, I just kept reducing it until it stopped crunching and started going into gear smoothly, but it's probably around 5mm or less.

And lhasadreams, you have given me a lot to consider when it's time for a new clutch.