How much of the thread should show on the adjustor cable....

on the clutch? Fitted a new one this morning and can't seem to get the adjustment right. its either not engaging or it won't go into gear easily…. mine is a 1.8gti, anyone who knows and can help much appreciated. Really i should have checked the old one before i took it off but bloody forgot!

Cheers

Paul

Its not done by the amount of thread, its by how much free play is in the pedal before it starts clutch engagement. It should be 15-25mm according to the Haynes manual.

If its not behaving as it should, then its probably a different problem like one or more of the fittings on the clutch cable is missing or the bulkhead is flexing (too much). Another thing I've noticed is, the clutch feel can be improved if the cable is secured (eg with cable ties to any handy brackets etc) so it can't move around too much as it takes up tension.

There does seem to be a fiar bit of flex in the bulkhead which looks to have been repaired before. I've tried adjusting the thread between those settings which feels right in terms of the give in the pedal… only thing is it won't go into second very easily and won't go into 4th/5th at all. Am a bit stumped as to what i may have missed to be fair :?

I reckon the flex in the bulkhead is the root cause of the problem. It can be solved by welding a repair, or by securing a big plate with a hole. The plate would need to be secure. When the clutch pedal is pressed, the plate would be pulled against the bulkhead (if you fitted it engine bay side), so you're not actually stressing the fasteners, but you'd want them tight to reduce the 'slack in the clutch mechanism, which is somehow dragging your clutch and making gearchanges awkward.

There's a possibility its a cracked release bearing/actuating lever too - but that's for another day!

10mm of free play when you lift the cable up at the gearbox end is the easiest way to set it.

lots of info on cable setup, pushrod, finger, bearing etc here:
Welcome to BrokeVW.com

the bulkhead may be flexing due to damage, or it may just be your clutch is too old and heavy which is putting strain on it. 1st thing to do is check the bulkhead, if its cracked or rusty get the repair plate from GSF and stick it on. Ive seen people use 2 plates to beef it up even more