Clutch Cable Too Short? Help!

[piscator]

For my 1979 SC Targa, I purchased two GEM brand (made in Germany) clutch cables from our host. Both are identical but do have different part numbers, 424 681 05 19 and 424 681 47 18 – I suspect the last digits are a manufacturing date.

The rubber (Beldin) sleeve on the new cables are about 8mm LONGER than the previously functioning GEM cable that came out of the car – made in Poland, part number 424 427 4 513 – also purchased from our host. Here’s the problem:

As you’ll see in the photos, even though the rubber sleeves on the new cables are 8mm longer, the threaded end doesn’t reach the aluminum bracket on the transmission, where you make the adjustments. There’s 18mm (3/4”) from where the cable sits in the bracket to the FIRST thread on the cable. And almost 50mm (2”) to the center of the cable’s threaded section.

The firewall end of the clutch cable is seated correctly, as far over the tube as it can go.

I should mention that I’m in the process of reinstalling this engine. It went up pretty easily with no particular problems. I had to fiddle a bit with the rear mounting bolts, but they are in place, waiting to be torqued to spec. The transmission is currently supported with a floor jack.

The only thing I can think of is that the engine is not far enough forward in the compartment, even though the rear mount bolts are in. That doesn’t really makes sense to me. And if you look at the last picture, you’ll see that there’s only 11.5 mm (.45”) between the back of the transmission and the torsion bar tube.

I don’t remember how much clearance there was behind the engine before I dropped it, but even if I could figure out how to push the engine forward, closing that 11.5 mm gap between the transmission and the torsion bar tube is not enough distance to bring the clutch cable to where it belongs.

So I’m baffled! How could the car have operated happily for years with a clutch cable that’s shorter than then new one? There must be something I’m doing wrong, but I just can’t see it.

All help greatly appreciated on this last leg of my journey!

[1987 Porsche]

Make sure the clutch pedal isnt pushed to the floor. I just installed my engine about two weeks ago and when putting the clutch cable on I thought my cable was short but the pedal was to the floor. Once I pulled the pedal up off the floor the cable length was correct. Hope that's it.

Lou

[piscator]

Greetings Lou,

Thanks for your suggestion, much appreciated!

Unfortunately, I don't think that's the answer. At the moment, the pedal end of the cable is not connected to anything. The inner cable, that slides, is not too short. The sleeve that runs from the firewall to the bracket (that the inner cable slides through) is what is too short.

I'm at the point of thinking I'll need to make an extension tube to lengthen the farrel at the firewall end of the rubber sleeve. But that's an abnormality and I found nothing like it in my forum searches. Hopefully someone will shout out the answer before I do that.

[pete3799]

So you're saying that even if you put the old cable in it would be too short?

[yelcab1]

That "Bowden" tube does not look too short to me compared to the old one. Something is off with the installation.

[3rd_gear_Ted]

When researching both country of origin Gemo P/N's, My wrench guy knew there was a dash# associated with each cable assy. Must get this specified correct when ordering.
Variation is in the overall cable assy. length, cable size, threaded end length and size of threads used. maybe other aspects too. Proper bowden tube curvature is critical for clutch feel.
I found I could use a larger size cable and threaded end for my 80 SC 3.6 conversion. Originally used for 930 tranny.

[pmax]

Zimmermann said then the "Made in W Germany" in white print cables are junk and recommended the OEM. It looks like you have the current day equivalent "Made in the EU".

How about ordering the OEM cable and comparing the length with the two(!) GEMO cables to resolve this once and for all ?

[piscator]

Thanks very much for your responses, gentlemen!

Pete, yes. You are exactly right. When I try to put the ‘old’ cable back in the car, it’s even shorter than the new ones. Weird!

Yelcab, it didn’t and doesn’t look short to me either, but it doesn’t fit.

I agree that it seems the installation must be off, but I’ve examined it over and over. For the cable sleeve to span the distance, the engine would have to move forward toward the bulkhead. But as I showed in my last photo, another 1/2” and the transmission will be hitting the torsion bar tube!

From working around the engine all day today, attaching vacuum and fuel lines, it certainly ‘feels’ like the engine is where it always was. That’s just sorta based on remembering how much of my hand I can get behind the fuel distributor, etc.

Another ‘data-point:’ When I put the bolts through the rear mounts I needed to flex the mounts (on both sides) slightly (1/4”?) forward to get the holes to line up. That suggested to me that the engine is slightly forward of where it once was.

Ted & Pmax, I’m beginning to think it could be a combination of my install being slightly off but mostly that I have the wrong cable.

The main reason I say that is that the rearward nut on the adjustment section of the older Gem cable was on the very first thread. I noticed that when I took it off. I’d think it should have been somewhere in the middle. So however it was jacked into place, it looks like it was too short to begin with.

So how do I locate the correct ‘dash#’ cable for my car? I wouldn’t mind ordering the Porsche factory part if I knew it was going to fit. But I’m not sure I want to order it just for the exercise.

I’ll definitely start doing more research into cables and if anyone can help with further information, I’d sincerely appreciate hearing about it!

[yelcab1]

Some more stupid questions:

1. What all did you do to the engine / gearbox?
2. Did you remove / replace that cable mounting bracket that goes under the gearbox?
3. Is it put back in correctly? Could it have been turned around? Is there only one way it could fit?
4. Could the transmission mounting bracket be turned around? Is that even possible?

It's been 6 years since I had my SC so I cannot remember it all.

[yelcab1]

I just found a picture in the Clutch section of the 1984 Carrera manual. yes, you got that little bracket backward.

[piscator]

For everyone's edification, this is what I found on the PET for 1978 - 1983

Part Number Description Quantity Model

930 423 401 0 Clutch cable 1 TURBO
F >>93088 00190
F >>93087 09547

930 423 401 10 Clutch cable 1 TURBO
F >>93088 00190
F >>93087 09547

930 423 401 05 Clutch cable 1
F 93088 00191>>
F 93087 09548>>

930 423 401 09 Clutch cable 1
F 93088 00191>>
F 93087 09548>>

930 423 401 05 Clutch cable 1 SC

930 423 401 09 Clutch cable 1 SC

[rsscotty]

[piscator]

Yelcab, I really appreciate your help!

The offset of that ‘little bracket’ (cable mounting bracket) is about the distance that needs to be made up. So if it’s backwards that would make sense. I’ll certainly check tomorrow!

But that also adds to the puzzle. I’ve never removed that cable mounting bracket. I did send the transmission to the very reputable Dan Jacob’s ‘Hairy Dog Garage’ for rebuilding. Do you need to remove that bracket to do a re build? If so, it’s Dan that got it backwards, which would be rather surprising!

To finish answering your questions (which are not at all stupid):

I believe the holes on the transmission mount are offset, so it can’t be reversed. I haven’t installed the transmission mount, yet, so that’s not impacting the situation.

And lastly, I think you have a d-mn fine memory, considering it’s been 6 years since you owned an SC!! I can’t remember this stuff from one day to the next! :-)

Thanks for checking the manual for me! I’ll let you know what I find.

[piscator]

Thanks for the photo, Scotty!

[yelcab1]

Yes, the picture above shows you got that backward. Remove it, turn it 180 degrees and your problem is solved. Don't blame Dan, it's easy to do with the gearbox on the bench and no cable to orient you.

[piscator]

Yelcab, No blame! Just surprise. Thanks again for the help! I'll let you know how it goes.

[proporsche]

just wanted to say your bracket installed inside out.... yellow is quicker

[piscator]

Good Morning Yelcab, Scotty & Ivan,

Yoo hoo hoooo!! Success!! I'm happier than a kid with a peach cobbler. In fact, I'd love a peach cobbler right now!

You guys were certainly right, that bracket was on backwards. However it got that way, it's fixed now! I might have stared at that for months without figuring it out. I really, really, appreciate your help!

[proporsche]

now it is time to drive the beast ,it`s way too clean;-)

Ivan
do not forget to lubricate the omega spring and the little nipple on the black arm where the omega lends on...

[piscator]

Ivan,

Thanks for the reminder about the spring!

We're very close, my friend, to getting this car on the road. Very close! It's been quite a fun journey. I'm not sure what I'll do with myself once it's running! The shop's gonna feel empty!