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Yelempi Samba Member
Joined: September 13, 2022 Posts: 6 Location: Yuma AZ
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Posted: Tue Dec 20, 2022 3:53 pm Post subject: Clutch tube help |
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Replacing the clutch cable on the Sportster, it never had a Bowden tube and the cable was starting to cut into the trans eyelet where the Bowden fits.
The clutch tube extended out from the chassis about six inches, way to long for the Bowden to fit.
So I cut it off, figuring the p.o. never cut it after shortening the chassis.
After cutting it to the right length, I found it loose, sticking my finger in the pedal opening I couldn’t find the tube. Getting pliers on the stub and twisting I find the tube is broke loose from the mounts. Trying to pull it out thru the back, it jams up with part of the middle bracket.
Any suggestions on how to capture this tube and pull out thru the front to replace the tube?
Or should I try to braze/ weld and reattach the cut off piece and and repair the mountings. |
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jeffrey8164 Samba Member
Joined: January 06, 2018 Posts: 3815 Location: Georgia
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Posted: Wed Dec 21, 2022 3:42 pm Post subject: Re: Clutch tube help |
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There are 3 points where the clutch tube attaches inside the tunnel. One just aft of the hole the pedal assembly passes through one just in front of the e-brake and another in the rear near the shift coupler.
Some people use a hole saw to cut out 3” circles to reach in and repair, others have removed the entire bottom of the tunnel. The latter were replacing or repairing all the tubes in the tunnel.
It’s still not easy any way you choose.
You can try pushing an electricians fish tape in through the rear and with a hook to grab the tape and see how loose it is _________________ Volkswagen!
Turning owners into mechanics since 1938.
“Let he that is without oil throw the first rod”
(Compression 8.7:1) |
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glassbuggy Samba Member
Joined: June 02, 2005 Posts: 897
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Posted: Wed Dec 21, 2022 4:00 pm Post subject: Re: Clutch tube help |
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May 2000 HVWs has a clutch tube repair article
October 2001 VW Trends also did an article
Both are on eBay if you search for them. basically, without looking, you have to locate the spot welds and reattach the bracket(s) where they came loose. I can't remember if there is a tack weld at the brace inside the tunnel aft of the clutch hook. Also, there is a bend in the tube within the tunnel that acts much like the Bowden tube outside. When the bracket within the cavity comes loose in the e brake area it plays havoc with shifting. One of those articles discusses that |
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glassbuggy Samba Member
Joined: June 02, 2005 Posts: 897
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Posted: Wed Dec 21, 2022 4:09 pm Post subject: Re: Clutch tube help |
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I think the last one I repaired I was able to tack the tube up front through the pedal hole - I had the pan on sawhorses though. Perhaps I cut a small hole to get the mig head in there and looked through the pedal hole to weld it. (been awhile)You don't need to make a big hack job on this procedure if you think smart. The one by the e brake I drilled a hole where the bracket came loose ( the spot weld indent ) and pushed it up to the hole and plug welded it in place. You will know it when you see it. feel for the tube bracket that is crimped on the tube in there.The spot weld will be on the outside of the tunnel and you will see it with some sand paper. The aft spot the tube is welded at
is under the shifter plate and is the easy one to get at but that is rarely broke loose there it has a bead of weld from the factory. |
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