TheSamba.com :: View topic

Wed Jul 24, 2019 12:52 pm

OK, my 1967 VW Beetle needed a clutch cable replaced. Why not replace what I can when everything is disassembled. Clutch cable, bowden tube, wing nut and clutch hook lever at the pedal assembly. I ran into a problem with the bowden tube. I'm looking to see if anyone else has this problem. Everywhere I've seen that the end of the bowden tube at the very end goes into a bracket that can be removed by undoing 2 nuts on the transmission. My problem is my bracket is cast into the transmission housing and can't be removed. I ran into problems with the cable installed in the bowden tube then trying to bend the tube in place and I can't bend the bowden tube into both housings with the cable in it. I was able to install the tube but with the bend, then the threaded end gets to the bend in the tube and refuses to go through, even with a ton of grease in the tube. Anyone have this problem?
Thanks,
Dave

Wed Jul 24, 2019 12:56 pm

A pic would really help here.

Wed Jul 24, 2019 1:34 pm

davidyat wrote: Everywhere I've seen that the end of the bowden tube at the very end goes into a bracket that can be removed by undoing 2 nuts on the transmission. My problem is my bracket is cast into the transmission housing and can't be removed.
The older transmissions had the bowden tube holder cast into the transmission side cover; I know this because I broke one off while trying to get the bowden tube out of a customer's VW in 1974.

The fix was to bolt on one of the later brackets, went right on two of the studs which held the side plate on. No, I didn't tell the customer that I b roke off her bowden mount.

Wed Jul 24, 2019 1:52 pm

Cusser wrote: No, I didn't tell the customer that I broke off her bowden mount.

:lol: Good times....

Feed the cable through the Bowden tube just to end with it out of the bracket.. then.. place the tube back down to the pan cable conduit, feed the cable through the mount, .. then fit the Bowden tube in its mount.. ..
Sometimes it can fight you.. use pliers if necessary

Or.. if that isnt working..

Maybe it has the wrong Bowden tube.

There are different lengths. Check it.

VOLKSWAGNUT wrote:

Yes there are 3 different lengths.

Found while surfing so cant take credit for accuracy.

the interweb wrote: Lengths are overall, tip-to-tip:

111 721 361E 13 -1/4 inches short tip
211 721 361D (or A) 14-1/4 inches long tip
311 721 361 = 13-1/8 inches long tip

CIP also now states lengths ... I assume mount to mount lengths.

111-721-361 = 12 - 1/2 inches
211-721-361D = 12 - 5/8 inches
311-721-361 = 11 - 3/4 inches

111 has a short tip
211 and 311 have long tips to allow more adjustment and more fit for older cast tube bracket trans axles.

https://www2.cip1.com/searchresults.asp?Search=bowden+tube

.

Example : Cast tube bracket

.

Wed Jul 24, 2019 2:09 pm

What work'd for me was the following:

1. Run the cable thru cable tube from pedal end to rear
2. Push boden tube onto cable at rear end
3. Seat boden tube to end of cable tube, now the hard part..
4. Carefully bend boden enough to go in rear end holder/bracket

If you bend too much, outer skin of boden will break. So you may need to reverse 3rd & 4th steps (above). The extra piece of rubber hose can be located where it may help. Of course, you need to thread cable end thru holder/bracket before you can get boden tube end thru. It ain't easy, requires good forearm strength.

Wed Jul 24, 2019 3:11 pm

Inspect the clutch pedal shaft cable hook for wear. they can wear down from the cable rubbing action, thinning down the hook metal so much that the hook folds over on itself, or breaks.

file any sharp protruding edges of the hook or cable end that may accelerate wear between the two,parts, clean and lubricate with thick grease Running dry accelerates wear!

bent hook from my Bug. approx. 350k miles of use.

Bug On!

Wed Jul 24, 2019 5:20 pm

For Volkswagnut,

Thanks for your input. First of all, I saved the old Bowden tube and it matches exactly the new one I purchased from Wolfsburg West in CA. Your picture of the bracket on VW transmission is exactly what I have. I guess I'll have to take your advice on how to mount the Bowden tube. I was even thinking of taking a pot of boiling water out to the garage, soaking the Bowden tube, put on some heat preventing gloves and seeing if that might work. If not, I hope my 73 year old arms have the strength to muscle it in.
Thanks,
David

Thu Jul 25, 2019 5:34 am

Its a pain in the ass, but you have to install the cable as mentioned before trying to get the tube into the retainer. I have actually damaged a bowden tube because I kinked it too much and the inner metal sleeve broke.

I get the tube seated on the pan clutch tube and then work it into the retainer with the threaded end almost through the bowden tube as mentioned. Good luck.

Thu Jul 25, 2019 7:22 am

Success with my Bowden Tube. And some advice for anyone who has a Bowden Tube bracket cast into the transmission case and can't be removed. What I did was take a 3/4 inch by 3/4 inch, 18 inch long oak stick I had laying around from a woodworking project. Use whatever you can to make a 1/2 inch half round notch at one end. Feed your clutch cable through the Bowden Tube with about 1/2 inch sticking out the end. Slide the tube to fit into the frame pan end. Manipulate the other end with the 1/2 inch cable end sticking out to the bracket end with the tube looped downward and the tube end at about a 45 degree angle pointing upward towards the bracket. Yes, it will look all cockeyed and not installed. Then take your stick and work the tube up and you'll see the end starting to straighten out in relation to the bracket. You might have to bend the tube, hold it with your hand and re position your stick for better leverage. When you get it right, you will hear it snap or pop into the bracket. I found this method much easier than working with pliers, screwdrivers or your hands. Here are some photos of my stick. Really, it did make it much easier.
David

Wed Jul 19, 2023 2:28 pm

Related Bowden tube replacement question:

I am replacing the rubber grommet that the accelerator cable and clutch cable go through when exiting the interior. It seems really flimsy. Can anyone describe what this side of the Bowden tube is supposed to push off of to get a sufficient bend? I’m scared it will just pop through the robber and won’t have a bend. Picture below with end/grommet circled in red.

Wed Jul 19, 2023 2:46 pm

The bowden tube butts up against the end of the clutch cable tube in the chassis at the front end and up against the bracket on the transaxle at the other. The rubber grommet in question slides over and seals around the outside of the clutch and throttle cable tubes, so essentially the tubes just pass through the grommet.