Bad clutch cable

[OldRic]

I replaced the clutch cable on my MK1 cab about two weeks ago.
I then got a vibrating noise when I backed off the accelarator, re-adjusted the clutch cable last Saturday and the vibrating went away however I went to check it again today but found that the cable was at maximum adjustment. I checked the cable and found that the rubber mounting through the bulk head had broken. This was an after market one from EuroCarParts, anybody had a similar problem, going to order a genuine VW one tomorrow.

[raferackstraw]

check the bulkhead where cable goes thru these are prone to rusting away and maybe the cause, they are not self adjusting iirc

[OldRic]

It doesn't look as if its been cut by the bulk head, it actually looks like the cable has been pulled through the side of the rubber. As I said this cable is only two weeks old, the old cable was fine, no damage to the bulk head rubber, I only replaced it because it was the original cable and it was feeling a bit stiff.
I now its not self adjusting, but it had been adjust to the max because the bulk head rubber was broken and had moved.

I saw on a realier feed that someone had mentioned a repair plate from GSF, does anyone know about this. What exactly is it?

[rubjonny]

basically it is there to fix that hole in the bulkhead, the vw cabvles can end up cutting thru the bulkhead and/or they rust out. if the hole is still the right shape you dont need the repair panel. its kinda square at the top, with a round bottom if that makes sence 

the cable can even start hacksawing thru the gearbox mount as well, MK2 golfs have a clutch cable retaining arm to prevent this problem, well worth fitting one if you can find.

the real problem could be your clutch is well worn and very stiff, this puts pressure on the cable and bulkhead which leads to this issue

[OldRic]

The hole is the right shape. no sign of rust, no sharp edges.

Went to VW dealer, cable no longer available. Had new clutch fitted by TSR last year.

Will have to get another from eurocarparts

[Snoopy]

I have had to try a few different cables in the past as they seemed to go stiff after a short time. I put this down to how they are routed round the engine bay and there inferior quality ment they dried up or were just rubbish to start with.

[OldRic]

I got a replacement from euroCarParts for the cable that I only fitted two/three weeks ago.
I also got the repair plate from them (£13). Put the new cable in, haven't yet put the plate in as the whole looks fine.
Adjusted the cable and it's right near is maximum adjustment? Also the clutch pedal is really stiff and I'm having trouble actually getting the car in gear. It going back to the people who rebuilt the gearbox about 5 weeks ago so that they can check it and sort out a leak from the diff.

Does anybody know where you can still get an OEM (or decent) clutch cable?

[raferackstraw]

id say its something to do with the box and clutch fitting mate, a brand new cable should not be at max adjustment straight away.
did it do it before box rebuilding?
there should be 15mm of free play in pedal before it starts to operate clutch, difficulty getting into gear could be gear linkages and bushes,
i had my box rebuilt and still had 2nd gear crunch, changed linkages and bushes and felt like a factory fresh box.
have a look at the clutch pedal asssembly and the pivot pin and see id there is anything obvious wrong there to cause the stiffness.
but as rj said if the cable is pulling out of the bulk head it must be something to do with the clutch requiring excessive pressure to operate if that makes sense?
the leak from the diff is most probably the drive flange seal where its not been fitted properly or has been fitted in the original position on the wear on the flange, if they fit the seal 2mm towards the flange it will make the correct seal. hope this info helps

[rubjonny]

I'd go with a clutch or box issue as well. i did try a cable once that made the clutch far heavier than the one I took off, but it was a cheapo make. the gemo(?) ones gsf sell are ok.

i had the same issue as you with the adjustment and no clutch action, which turned out to be a damaged release plate. i think this was caused by a bent pushrod which made it hit the release plate off-centre. could have been a worn brass pushrod bush, but it had no play in it as far as I could see when it 1st went in

[Lee_dub]

I bought one from my local motor factors and it was awfull, really stiff an horrid so i took it strait back off.  Im sure the GSF/ECP ones are normally fine tho